ENGINE

ELECTRICAL
SYSTEM
GENERAL ............................................................................... EE - 2
STARTER ................................................................................. EE-18
ALTERNATOR .......................................................................... EE-36
VACUUM PUMP ....................................................................... EE-55
PREHEATING SYSTEM ........................................................... EE-56
EE-2 ENGINE ELECTRICAL SYSTEM

GENERAL
SPECIFICATIONS

Model
D4AE, D4AF D4AL D4DA, D4DB
Item
Voltage-polarity 24V-Negative grounding
Starter Type Overhang electromagnetic push-in type reduction starter
Output 24V - 3.2 kW
Alternator Type Built-in IC regulator and silicon-diode rectifier
Output 24V-40A(Truck), 24V-70A(Bus)
Vacuum pump Rotary type with 4 movable vanes, Gear drive vacuum
directly coupled to alternator pump
Pre-heating system Type Air heating type Glow plug type
Capacity 2.0 KW -
Heater relay fuse 95A ←
Type Electroc Coil
Tachometer sensor Out-put voltage VP-P 1.5V or more (Sensor plate rotating : 325rpm)
Resistance 1.4±0.2
Inductance 0.48±0.08H
Insulation resistance 10M or more

SERVICE STANDARDS

Nominal value Corrosionand

Correction and
Description Limit
(Basic diameter [ ]) remarks
remarks
Starter Commutator O.D. 32 31 Replace
Commutator runout on periphery 0.05 or more Correct or replace
Depth of grooves between bars 0.2 or less Correct
Brush length 18 11 Replace
Brush spring pressure 25 to 34 N 20 N Replace
(2.55 to 3.45 kf) (2 kgf)
Pinion shaft thrust gap 0.1 to 0.5 Adjust with washer
Pinion gap 0.5 to 2.0 Adjust with packing
24V No-load Voltage 23 V Check
type characteristic 80A or less
Current
Rotating speed 3,400 rpm or moe
Magnetic switch operating voltage 16V or less Replace
GENERAL EE-3

Alternator Regular voltage 24V

(24V 40A)
Output 40A
Rated speed 5,000rpm
Speed in use 8,000rpm
Adjusting voltage of IC regulator (below 500 rpm, 5A) 28~29V
Characteristic Ampere (A) Speed
of assurance Voltage(V) Cool Hot (rpm)
output
(30) 24 1,500
27V (47) 38 2,500
(-) 45 5,000
Alternator Regular voltage 24V
(24V 70A)
Output 70A
Rated speed 5,000rpm
Speed in use 8,000rpm
Adjusting voltage of IC regulator (below 500 rpm, 5A) 28~29V
Characteristic Ampere (A) Speed
of assurance Voltage(V) Cool Hot (rpm)
output
(38) 33 1,500
27V (56) 55 2,500
- 65 5,000
Vacuum Capacity 120 cc/rev, 90cc/rev(D4DA/DB)
pump Using condition Maximum speed 8,000rpm
Oil SAE 10W.30
Oil pressure 1~3.5kg/cm²
Deliver Speed (after 20 seconds 1,500rpm 3,000rpm
Characteristic with a 10 lit tank load) 550mmHg 600mmHg
700mmHg (at 3,000rpm)
Air heater Heating time Coolant temp. : -5°C 6 seconds
of indicator Coolant temp. : -15°C 10 seconds
Coolant temp. : -20°C 20 seconds
Pre heating Coolant temp. : -5°C 14 seconds
time Coolant temp. : -15°C 18 seconds
Coolant temp. : -20°C 28 seconds
Post heating Coolant temp. : -5°C~10°C 10 seconds
time
Coolant temp. : below -5°C 30 seconds
EE-4 ENGINE ELECTRICAL SYSTEM

Glow plug Regular voltage DC 23V

Temperature increasing (after 30 secnds) 1,050°C ± 80°C
Current (after 30 seconds) 3A
Resistance (at 25°C) 4W
Heater Coil current 2.3A(24V 20°C)
relay
Allowable contact currecnt 200A
Open circuit voltage 5V or less
Closed circuit voltage 16V or less

TIGHTENING TORQUE TABLE

Thread size Tightening torque

Description Nm (kgf·m) Remarks
O.D. x pitch mm
Alternator pulley nut M17 x 1.5 83 to 105 (8.5 to 11)
Alternator bolt M12 x 1.25 91 (9.3)
Alternator adjusting bolt M12 x 1.25 82 (8.4)
GENERAL EE-5

TROUBLESHOOTING

Starter motor operates

but engine does not start.
Yes

Does flywheel speed No Does starter motor No Is the contact point of No Repair or re-
increase? speed increase? magnetic switch OK? place magnetic
Yes Yes Yes switch.

Is there slip in over Repair or replace

runing clutch? faulty parts of starter
Yes motor.

Repair or replace starter

motor or faulty parts.

Is there abnormal noise Starter motor is

heard or vibration No No
Does engine start? normal. Check fuel
observed in starter system and other
motor or parts? parts for malfunction.
Yes

Is starter motor pinion No Repair or replace faulty

worn or damaged? parts of starter motor.
Yes

Repair or replace pinion

and parts.
EE-6 ENGINE ELECTRICAL SYSTEM

Ingition switch is at “START” but

starter motor will not operate

When ignition switch is at

Does “CLICK” sound of No No Inspect and replace ignition
“START”, is voltage of starter
pinion be heard? motor S terminal and starter switch or wiring as necessary.
Yes relay normal?
Yes

Check for continuity between

No
magnetic switch S and M Repair magnetic switch
terminal. Is it continued?
Yes

Faulty starter motor. No open

curcuit between M terminal and
ground.
Yes

Repair or replace

No
Starter motor is chattering? Is holding coil of magnetic Yes
Repair magnetic switch
Yes switch damaged?

Check for magnetic switch

No Repair or replace starter
contact point for melt or wear.
switch
Is it OK?
Yes

Replace magnetic switch

GENERAL EE-7

Battery is overdischarged

Check the following items

• Starter motor rotating
speed
• Head lamp brightness
• Charge warning lamp
operation
Yes

• Is wiring between alternator No

Is fan belt loose No
and BATT normal? Repair or replace
or damaged? • Is fuse connected normally?
Yes
Yes

Correct belt tension

or replace? Measure voltage of B terminal Voltage is high
while increasing engine speed to
1,000~1,200rpm

Battery voltage is
not changed

Connect an ammeter (25A or

more) to alternator output terminal
and operate all electric units.
Start engine, let it idle at 2,300 rpm
or more, and measure the maxi-
mum valve of ammeter.
(an assistant will be helpful)

Rated output at 70% or less Rated output at 70% or

more

Repair or replace alternator

Alternator is normal.
Check battery and electric
unit for abnormality
Continued on next page
EE-8 ENGINE ELECTRICAL SYSTEM

Ground F terminal and measure B terminal

voltage.
(Be careful of sudden increase of voltage :
Slowly run engine while checking voltage) High

Voltage is not
With engine off, does No
increasing. Replace faulty IC regulator
charge warning lamp
illuminate?

Yes
Malfunction of diode trio.
Repair or replace.

High(As much as
With engine off, measure L termi- battery voltage) An open circuit of (+) diode.
nal voltage. Repair or replace.
Low(1V or less)

With engine off, does charge warn- No Bad brush contact or field coil damaged.
ing lamp illuminate? Repair or replace.
Yes

Are L terminal and (+) brush not Yes

Repair or replace.
grounded?
GENERAL EE-9

Battery is overdischarged

Check the following items

• Battery distilled water
• Battery temperature
Yes

Is B terminal voltage stayed When ignition switch is

No No
while increasing idle “OFF”, isn’t brush (-) Replace abnormal IC regulator
gradually? grounded?
Yes Yes

If (-) brush is grounded, IC

regulator doen’t work.
Replace.

With engine operating at Abnormal IC regulator or (-)

No
high speed, is F terminal brush grounded.
voltage higher than at idle? Replace IC regulator repair
Yes ground point.

Inspect regulator voltage

Voltage is high Excessive adjusting voltage
and measure L terminal
: Replace IC regulator
voltage with engine operat-
ing at high speed
Alternator is normal.
Voltage is low : Check battery for
abnormality
EE-10 ENGINE ELECTRICAL SYSTEM

DESCRIPTION
Starter
The starter is a device which rotates the crankshaft through the Magnetic switch

flywheel ring gear to start the engine. Pinion

When the starter is activated by the starter switch, the magnetic
switch operates and meshes the pinion with the outer ring gear of
the flywheel through lever action. The engine is then rotated by the
motor and starts.
When the starter switch is returned to ON after the engine has
started, the pinion release the ring gear and motor revolution stops.
Major parts in the assembly are the motor to generate torque, the Overrunning
clutch
overrunning clutch to transmit power and to prevent starter overrun, Reduction gear
the magnetic switch to turn on/off motor current and mesh the pin-
ion with the ring gear and the internal gear to amplify armature Motor
torque.

D4AF1865

1. Reduction Gear
The tip of the armature is a gear which meshes with the reduc- Armature
tion gear. The turning force is thereby increased by about 3.7
times and transmitted to the pinion.

Pinion Overrunning clutch D4AF0030

2. Overrunning Clutch
The overrunning clutch is of the roller type mounted to the pin- Outer race Spring
Roller
ion shaft assembly.
Inner race
There is a wedge-shaped gap between the outer race and the
inner race (sleeve), which contains rollers held by spring force.
When the starter begins to rotate, the rollers are pressed to the
narrow end of the gap, acting as keys to transmit outer race
revolution to the pinion. When the engine starts and the pinion D4AF0031

is driven by the engine, these rollers compress their springs,

moving towards the wide end of the gaps, thereby preventing
the transmission of power from the pinion to the outer race.
GENERAL EE-11

3. Operation
When the starter switch turns ON, the battery current flows
from the terminal S of the magnetic switch to the pull-in coil (P)
Starter
and holding coil (H). The feebler current then flows from the swtich
terminal M to the motor.
The plunger is attracted by the magnetic force of the pull-in S
P2 P H
and holding coils, pushing out the pinion via the lever. B
M

Reduction gear

Pinion

M Clutch Ring
gear
Fiel coil

Battery

D4AF003A

As the pinion comes into complete mesh with the ring gear, the
contact P, closes allowing a large current to directly flow from
the battery to motor to turn the pinion.
Starter
At the time, no current flows to the pull-in coil (P), the plunger swtich
being retained by the holding coil (H) alone.
S
B P1 P H
M

Reduction gear

Pinion

Clutch Ring
gear
Fiel coil

Battery

D4AF0032
EE-12 ENGINE ELECTRICAL SYSTEM

The moment the starter switch is turned OFF, battery current

flows from the terminal B to the pull-in (P) and holding (H) coils,
cancelling the magnetic fluxes of the plunger. This causes the Starter
swtich
plunger to be returned spring force, opening the contact P1 to
shut off current to the motor.
S
B P1 P H
M

Reductiongear

Pinion
M
Clutch Ring
gear
Field coil

Battery

D4AF003C

Alternator
The alternator is driven by the V-belt, acting to charge the battery
and supply power to other electrical equipment. Rectifier

It mainly consists of a rotor to generate a magnetic field, a stator to

Stator
generate power, a rectifier to rectify the generated current and a
regulator to stabilize the generated voltage.

Regulator

Rotor

D4AF2976

1. Rotor
When the rotor is driven by the pulley rotation, a current flows
Slip ring
from the brushes, through the slip ring, to the rotor coil. The
rotor core tabs then become magnetic poles. Rotor coil

Rotor core

D4AF2702
GENERAL EE-13

2. Stator
Together with the rotor core, the stator core forms the mag-
netic flux path. The magnetic flux lines in the stator core are
affected by the passage of the rotor core field and generate
electricity.

Stator coil Stator core D4AF2703

3. Rectifier
The rectifier mainly consists of 3 diode trios, 6 diodes and 2
heat sinks. It rectifies the AC stator output to DC power.
Each heat sink has the (+) or (-) leads from 3 diodes attached
to it, performing full wave rectification for 3-phase AC.

D4AF2704

<Diode operation> 1
In diagram 1 , a high voltage is generated between I and II, so
1 2 3
current passes through diode 1 to the load and returns through
I
diode 5.

Battery
Load
II
III

4 5 6

D4AF2705

In diagram 2 , high voltage is generated between I and III, so

2
current passes through diode 1 to the load and returns through
1 2 3
diode 6.
I

II
III

4 5 6

D4AF2706
EE-14 ENGINE ELECTRICAL SYSTEM

Following the process sequentially, it can be seen that the current

3
always flows to the load, while each phase passes current to a 1 2 3
I
different pair of diodes for rectification. III II

4 5 6

4 1 2 3
I
III
II
4 5 6

5 1 2 3
I

III II
4 5 6

6 1 2 3
I
III II

4 5 6
D4AF2707

4. Regulator
IC regulator
The regulator is integral with the brush holder. The assembly
combines the IC regulator, the brushes and the brush springs.
The IC regulator alters the strength of the field coil field to sta-
bilize output power which varies with engine speed fluctuations.

Brush spring
Brush D4AF2708

<IC regulator operation>

Battery
When the starter switch is turned on, base current flows from the R2

battery to the power transistor, turning it on. Current then flows to Rectifier
Field Df R1 R3
the field coil, lighting the charge lamp. coil

ZD
Tr1 R4
Stator coil
Tr2

Q8SD006A

When the engine is started and the alternator begins to generate Battery
electricity, the base current is supplied by the alternator itself. The R2

field current comes from the diode trio, exciting the field coil. The Rectifier
Field Df R1 R3
output voltages at B and L terminals are the same, extinguishing coil

the charge lamp. ZD

Tr1 R4
Stator coil
Tr2

Q8SD006A
GENERAL EE-15

When alternator voltage rises, Zener diode Dz is energized, and Battery

supplies a base current to transistor Tr1, turning it on. R2

This causes the base current of power transistor to short to Tr1. The Rectifier
Field Df R1 R3
power transistor is turned off and the current flow stops, lowering coil

alternator output voltage. ZD

When output voltage drops, Zener diode Dz shuts off, turning on the Stator coil Tr1 R4
Tr2
power transistor, and raising the voltage by supplying field current
again. Q8SD006A
Adjustment of the voltage generated by the alternator is thus achieved
by the IC regulator constantly repeating this operating cycle.
Alternator

Charging Circuit
The charging circuit operates as follows:
1. Set the starter switch in ON position. Starter

Battery

↓ ↓
E R L B B
Starter switch Charge lamp ON

↓ ↓ Charge lamp Fusible link

Alternator (R terminal) Alternator (L terminal)

B ACC M ST
↓
LOCK
ACC
Ground ←
O N
Battry
START
Starter switch
D4AF2542

2. Start the engine. Alternator

After engine started, when the alternator starts power genera-

tion and the voltage at alternator B terminal becomes higher
than the battery voltage, current flows as shown below, start-
ing battery charge. Starter

Alternator (B terminal)

↓ ↓
B
Starter switch Battery E R L B

↓ ↓ Fusible link
Charge lamp
Alternator (R terminal) Ground

↓ B ACC M ST
LOCK
Ground ACC
O N
Battry
Thus the charging to battery is started, and the charge lamp START
Starter switch
turns off. D4AF254B
EE-16 ENGINE ELECTRICAL SYSTEM

Vacuum Pump
The vacuum pump is installed on the back of the alternator and has its Rotor
rotor coupled to the alternator shaft for simultaneous rotation with the
alternator.
Within its cylindrical housing, the rotor has three movable blades which
are pressed onto the housing inner wall by centrifugal force generated
as the rotor rotates, thus producing pumping action. The vacuum pres-
Housing
D4AF2750
sure generated by this action evacuates the vacuum tank.

The rotor is positioned eccentrically to the housing cylinder. The

Suction Housing
air from the vacuum tank is sucked through the suction port and
compressed gradually before it is discharged from the discharge
Vane
port. From the suction port, engine oil is also sucked in to keep the
Rotor
housing oil tight and to lubricate and cool the housing. The oil is
discharged from the discharge port and is returned to the oil pan
Compression
with compressed air.

Discharge

D4AF0035

At the suction port, a check valve is provided to prevent air and

Check valve
engine oil from flowing back from the vacuum pump to the vacuum
tank when the engine is stopped.

D4AF0653
GENERAL EE-17

TACHO METER SYSTEM

Tacho meter inputs output pulse corresponding to rotor revolution of tacho meter sensor and indicates two times of rotor
revolution number as an engine revolution number.

(LIGHTING SW.) (LAMP 3W)

TACHO MAIN SW.

METER +
ROTOR SENSOR
(ED LAMP) TACHO
METER

BATT

(ED BZ Output)
(EX. BRAKE SW.)

(PULS) (OVER RUN

BUZZER
Output)

BZ (BUZZER)
EARTH (MAGNET
VALVE)

EEEE001A
EE-18 ENGINE ELECTRICAL SYSTEM

STARTER Rear plate

Removal and Installation

Remove the starter from the rear plate.

CAUTION
Whenever removing electrical parts from the vehicle, be sure
to place the starter switch in OFF position and disconnect the
Starter
negative battery cable from the frame. D4AF1285

Disassembly

14 Rough surface, ridged wear,

or seizure of commutator
17
16 15 4 Turning state
10 Turning 2
state
Bearing 3
wear

8
Wear, damage

11
12
13
22 Wear, damage 7
23 1
21 9
18 19 20 24 6
Wear damage Brush powder deposits,
5
Pole and field coil brush contact condition
mounting state

Disassembly
1. Rear bracket 9. Brush holder 17. Lever
2. Rear bearing 10. Cover bracket 18. Pinion ring
3. Front bearing 11. Center bracket 19. Pinion stopper
4. Armature 12. Washer 20. Pinion
5. Yoke assembly 13. Gear 21. Pinion spring
6. Brush ( side) 14. Magnetic switch 22. Pinion shaft
7. Brush ( side) 15. Spring set 23. Front bearing
8. Brush spring 16. Bushing 24. Front bracket

Do not remove items 2,3 and 23 unless necessary.

D4AF0045
STARTER EE-19

1. Remove the terminal mounting bolt and the two long bolts from
the magnetic switch. Remove the yoke assembly from the front
bracket assembly.
NOTE
The armature is merely inserted into the yoke assembly
brush holder, so be sure not to drop it.
Yoke assembly
D4AF2546

2. Remove the armature and rear bracket from the yoke assembly.
3. Open up brush spring towards the outside of the brush holder
and remove the brush.
Armature

Yoke assembly

Rear bracket

D4AF2548

4. Remove the center bracket from the front bracket by the follow-
ing procedures.
Bush spring

Brush

D4AF2549

1) Remove the cover mounting screws and remove the cover Washer
and washers from the center bracket. Cover
2) Remove the center bracket and gear from the front bracket
assembly.

Center bracket
D4AF2550
EE-20 ENGINE ELECTRICAL SYSTEM

5. Remove the spring set and magnetic switch from the front
Gear
bracket assembly. Front bracket
assembly

Center bracket
D4AF2551

6. Remove the bushing from the front bracket and remove the
lever from the pinion shaft.

Spring set

D4AF2554

7. Remove pinion from the pinion shaft by the following procedures. Lever
1) Hold the front bracket assembly in a vice. Front bracket

Hold so that the pinion overhangs from the front bracket

assembly.

Bushing

Pinion shaft D4AF2556

2) Apply a piece of pipe to the pinion stopper and strike the

Pinion
pipe with a hammer to disengage the ring from the pinion Vise
Front bracket
stopper ring groove. assembly

D4AF2557

Pinion shaft
Ring Pinion
stopper
Pinion

D4AF2558
STARTER EE-21

3) Remove the ring from the pinion shaft ring groove. Ring

Pinion shaft

D4AF2559

4) With the blade of a screwdriver inserted between the pin-

Pinion stopper Pinion shaft
ion and pinion stopper, pry it to remove the pinion stopper
from the pinion shaft.

D4AF2560

5) Remove the pinion and spring from the pinion shaft.

Pinion
Spring

D4AF2561

8. Remove the pinion shaft from the front bracket.

Bearing Pinion shaft

D4AF2562
EE-22 ENGINE ELECTRICAL SYSTEM

Inspection

Coil open circuit test Short circuit testCommutator O.D.

Fused contacts Coil ground test NV 32 mm
Loose contact L 31 mm
Commutator runout Depth of groove
L 0.05 mm or more between bars
L 0.2 mm or less

Brush length
NV 18 mm
L 11 mm
Rotation test
Brush spring pressure Brush holder
NV 25 to 34N insulation test
NV .. Nominal Value Coil ground test (2.55 to 3.45 kgf)
L ... Limit Open circuit test L 20 N (2kgf)
D4AF0045

1. Armature Inspection
1) Coil short circuit test
Place the armature on a growler tester. Hold a piece of
iron in parallel with the armature and slowly turn armature
by hand. If the iron piece is attracted or vibrates, it means
there is a short circuit. Replace the armature.

D4AF7505

2) Coil ground test

Check for continuity across the commutator and shaft (or
core). If there is a continuity, indicating that the coil is
grounded, replace the armature.

D4AF7506

3) Commutator out-of-roundness
Rotate the commutator by hand and measure deflection.
If the measured value is equal to or higher than the limit,
correct it within the limit of O.D. [refer to the following item].
If the OD of the commutator is rough or has step wear,
finish it with #300 to #500 abrasive paper.

D4AF7507
STARTER EE-23

4) Commutator OD
Measure the OD of the commutator, and replace the arma-
ture if the value exceeds the limit.

D4AF7508

5) Inter-segment mica depth Mica depth

Measure the mica depth between the segments.

Replace the armature if the measured value exceeds the
limit.

D4AF7505

Replace the armature if the segments are as shown above.

Segment

Good Faulty

D4AF7509

2. Field Coil Inspection

1) Coil open test
Check continuity between the terminal lead and the brush
+ . If there is no continuity, the coil is opened and the yoke
assembly must be replaced.

D4AF2554

2) Coil ground test

There should not be continuity between the yoke and the
brush + . If there is continuity, the coil is shorted to ground.
Repair the faulty insulation or replace the yoke assembly.

D4AF2565
EE-24 ENGINE ELECTRICAL SYSTEM

3. Brush Inspection
1) Measure the brush length and replace the brush holder
assembly if the length is equal to or below the limit.

D4AF2566

2) If the contact face with the commutator is rough or unevenly

worn, finish the brush surface with #300 to #500 abrasive
paper.
NOTE
When correction the brush contact, finish the brush
surface so that it has the same curvature as the com-
mutator for good contact.
D4AF2567

4. Brush Spring Inspection

Using a new brush, measure the load generated when the brush
spring separates from the brush, as shown above. If the value
is equal to or less than the limit, replace the brush spring.

D4AF7513

1) To remove, withdraw the brush spring from the brush holder.

Brush holder

Brush spring

D4AF2569

2) To insert the brush spring, compress it and snap it into the

brush holder. Brush holder

NOTE
Cover the spring by the hand during insertion to pre- Brush spring

vent injury in the event it suddenly snaps out of the

pliers.

D4AF2570
STARTER EE-25

5. Brush Holder Insulation

Verify there is no continuity between the + and - brush holder
sides. If there is continuity, replace the brush holder assembly.

D4AF2571

6. Overrunning Clutch Inspection

Verify that the pinion shaft rotates smoothly in the drive direc-
tion (clockwise), and locks when it rotates in the opposite
direction.
Otherwise, replace the overrunning clutch.

D4AF7545

7. Front Bracket Bearing Inspection

Replace the bearings as detailed below if they do not rotate
smoothly.
Front bearing

D4AF2572

1) To remove the bearing, apply a bar to the bearing on the

pinion mounting side of the front bracket and strike the bar
with a hammer.

D4AF2573

2) To install the bearing, proceed as follows.

Caulking tool
Using Caulking tool, install the bearing to the front bracket
as illustrated.
Sleeve bearingset

Front bracket D4AF7574

EE-26 ENGINE ELECTRICAL SYSTEM

Using the special tools, Caulking tools A and B combined 29.4 kN

as illustrated above, stake the front bearing. Stake twice at (3,000 kgf)
four positions each or a total of eight positions.
NOTE Caulking tool A
1. The bearing replacement by this method is permit-
Caulking tool B
ted only once.
Sleeve bearing set
2. Stake to a static load of 29.4 kN (3,000 kgf).
3) After installation, check that the bearing can be rotated
(Caulk)
lightly by fingers. If it does not rotate smoothly and lightly, Stake here Front bracket D4AF1876
replace the front bracket assembly.

8. Inspection of Armature Bearing

If the bearing fails to rotate smoothly and lightly, replace it by
the following procedures.

Commutator side bearing

Shaft side bearing

D4AF2575

1) Use a bearing puller to remove the bearing from the arma-

ture.
Bearing puller
2) To install the bearing on the commutator side, pack fully
with grease and strike its inner race with a plastic hammer.

D4AF2576

Pack grease

Inner race

D4AF2577

3) To install the bearing on the shaft side, apply a pipe of di-

ameter matching its inner race and strike the pipe with a
hammer. Inner race

Pipe

D4AF2578
STARTER EE-27

9. Check the pinion shaft thrust gap by the following procedures. Pinion shaft
assembly Gear Washer
1) Fit the gear and washer to the pinion shaft assembly and
install the assembly to the front bracket.

D4AF2579

2) Install the center bracket to the front bracket by mounting Center bracket
bolts.

D4AF2580

3) Fit the washer over the end of the pinion shaft and fix with
the cover mounting screw.

D4AF2581

Set a dial gauge over the pinion shaft end and measure the On the end of the pinion shaft
pinion shaft thrust gap. If the value is out of standard, ad-
just with an adjusting washer.
The adjusting washers are available in two thickness of 0.
2mm and 1.0mm.

D4AF2582

Insert an adjusting washer, if necessary between the gear

and pinion shaft assembly.

Adjusting washer
D4AF2583
EE-28 ENGINE ELECTRICAL SYSTEM

10. Magnetic Switch Inspection

1) Coil open test
Verify that there is continuity between S and M terminals,
and replace the magnetic switch if not.
S terminal

M terminal

D4AF2584

Verify that there is continuity between S terminal and

ground, and replace the magnetic switch if not.

S terminal

Ground

D4AF2585

2) Contact soldering inspection

B terminal

M terminal

D4AF2586

3) Contact operation inspection

Close the contacts of the magnetic switch as shown above.

D4AF2587

In the closed state, verify that there is continuity between B

and M terminals. If not, replace the magnetic switch.

B terminal

M terminal

D4AF2586
STARTER EE-29

Reassembly

Apply grease to contact surfaces

16 24
14 15 17

21 Pinion gap
NV 0.5 to 0.2 mm
8 7 20
1
19

2
Pack grease
18

Apply grease

23
6 5 4 10 11 13 22

3 Pack grease

NV ... Nominal Value

Reassembly sequence

23 → 24 → 22 → 21 → 20 → 19 → 18 → 17 → 16
→ 15 → 14 → 13 → 12 → 11 → 10
↑
6 ↓ 3 ↓
9→8→7→5→4→1
2 ↑

D4AF0050
EE-30 ENGINE ELECTRICAL SYSTEM

1. Install the pinion and pinion shaft to the front bracket by the
Apply gease
following procedures.
1) Apply grease to the illustrated areas of the pinion shaft.

D4AF2589

2) Insert the pinion shaft into the front bracket bearing.

Bearing Pinion shaft

D4AF2562

3) Install the spring and pinion over the pinion shaft.

Install the pinion in the illustrated direction.
Pinion
Pinion shaft side
Spring

D4AF2561

4) Install the pinion stopper to the pinion shaft in the illus-

trated direction, striking with a plastic hammer.

D4AF2590

5) Install the ring in the ring groove of the pinion shaft. Pinion stopper

Pinion shaft

Ring

D4AF2591
STARTER EE-31

6) Pull hard the pinion or pinion stopper to the ring side so

Pinion stopper
that the ring is seated in the ring groove of the pinion stopper. Pinion shaft
Ring

D4AF2592

2. Install the lever over the pinion shaft in the illustrated direction.

Lever
D4AF2593

3. Install the bushing to the lever in the illustrated direction and

Lever
install the assembly to the front bracket.

Bushing

D4AF2594

4. Install the spring set to the front bracket in the illustrated

direction.

D4AF2595

5. Install the magnetic switch to the front bracket by the following S terminal
Apply grease
procedures.
1) Apply grease to illustrated area and install magnetic switch
to the lever, with the S terminal facing up.

D4AF2596
EE-32 ENGINE ELECTRICAL SYSTEM

2) Holding the spring set by magnetic switch mount them to

the front bracket.

Spring set

D4AF2597

6. Install the center bracket to the front bracket by the following

procedures. Adjusting
washer
1) Install the thrust gap adjusting washer over the pinion shaft.

Pinion shaft D4AF2598

2) Apply grease to the needle bearing of the center bracket

and set the center bracket over the pinion shaft. Tighten Apply grease on needle bearing
the center bracket via rubber portion of the spring set onto Spring set
the front bracket using the bolt.

D4AF2599

3) Apply grease to the pinion shaft end and install the washer
and cover using the screws. Apply grease

Cover
Washer

D4AF2600

7. Install the armature to the yoke assembly as follows:

Wooden block
1) Compress the brush spring, and set a wooden block that is
larger than the commutator outer diameter as a support. Brush spring

NOTE
To avoid damaging the brushes, use a wooden block
free of burr.

D4AF2568
STARTER EE-33

2) Insert the armature in the yoke assembly from the commu-

tator side, and remove the wooden block when the com-
Armature commutator
mutator reaches the brushes.
NOTE
The armature is supported entirely by the brush spring
force, so be sure not to drop it.

Yoke assembly D4AF2588

8. Attach the rear bracket to the yoke assembly as detailed below:

1) Pack the rear bracket armature bearing contact portion with
grease.

Pack grease

D4AF2594

2) Fit the O-ring to the yoke assembly.

D4AF2595

3) Using the screw and O-ring, fix the brush holder to the rear
bracket.

Yoke assembly Brush holder Rear bracket

D4AF2596

9. Attach the yoke assembly to the center bracket as detailed

below:
1) Apply grease to the splined portion of the armature.

Apply grease

D4AF2597
EE-34 ENGINE ELECTRICAL SYSTEM

2) Fit the O-ring to the yoke assembly.

D4AF2698

3) Attach the yoke assembly to the center bracket, aligning Align yoke terminal to the
center bracket notch
the terminals on the yoke with the cutout in the center
bracket.

D4AF2700

Inspection and Adjustment after Reassembly Switch K1

1. Pinion Gap Adjustment
Perform testing by the following procedure:
1) Connect test wires to assembled starter as shown in the Battery
S terminal
illustration.
2) Snap out the pinion by turning switches K1 and K2 on. Switch K2
3) Stop pinion rotation by turning switch K2 off.
D4AF0053

4) Now measure the amount of axial pinion movement (pinion Pinion

gap) when the pinion is pushed gently towards the armature. Pinion shaft

Pinion gap(0.5~2.0 mm)

NV ... Nominal Value

D4AF0054

6) If the pinion gap is out of specification, adjust by increasing Washer

Magnetic switch
or decreasing the number of washers on the magnetic
switch mount. Washers come in two types: 0.25 mm thick
and 0.5 mm thick.

D4AF2910
STARTER EE-35

2. Test Switch k

Connect as shown beside and check the no load characteristics.

Ammeter
No-load Voltage 23V
characteristics Current 100A or less Battery Starter
Rotating speed 3,400 rpm or more

Magnetic switch operating voltage 16 V or less Voltmeter

D4AF7533

NOTE
1. For wiring, use as thick wires as possible and tighten
well each terminal.
2. The rotating noise during no-load operation is loud as
the starter has built-in reduction gears.
EE-36 ENGINE ELECTRICAL SYSTEM

ALTERNATOR
Component

Without vacuum pump type

<D4DA, D4DB>

Rotor
Bearing Rotor
Rear Bracket assembly Stator
Bolt
Generator

Generator

Pulley

Nut

Brush
Regulator
Bearing

Brush Spring

Front Bracket
Assembly

With vacuum pump type

<D4AF, D4AE, D4AL>
Rear
Bracket Rotor
Bearing
Generator Rotor

Set Bolt
Vacuum
Pump
Vane Washer
Pump Nut
Rotor
Pulley
Spool

Regulator Bearing

Brush Brush Front Bracket

Spring Assembly

CS27003B/CS27003C
ALTERNATOR EE-37

Removal and Installation

Vacuum hose

82 Nm (8.4 kgf.m)

Oil hose

Vacuum hose
overlap 25
Alternator

91 Nm (9.3 kgf.m)

<Removal steps>
1. Alternator
2. Oil hose
3. Vacuum hose
4. Other parts

D4AF0055
EE-38 ENGINE ELECTRICAL SYSTEM

Disassembly

11

5 14
13
12
2 7 6
9 8
10
3 4

18

19 20
17

21
1

15 16

Disassembly sequence
1. Vacuum pump assembly 12. Cover
2. Pulley and fan 13. Spring
3. Pulley 14. Rear bearing
4. Fan 15. Stator coil
5. Front bracket assembly 16. Rear bracket assembly
6. Cover 17. Rectifier assembly
7. Front bearing 18. Regulator assembly
8. Cover 19. Regulator assembly
9. Packing 20. Brush spring
10. Spacer 21. Oil seal
11. Rotor assembly

Items marked with * are not available separately.

Do not remove items 7 and 14 unless necessary.

D4AF8117
ALTERNATOR EE-39

1. Remove the vacuum pump assembly (Except D4DA, D4DB

engine).
2. Remove the rear bracket assembly by the following procedures.
1) Wind vinyl tape around the shaft splined end to prevent the
oil seal lip from being damaged when the seal is removed.

Shaft splines
D4AF1949

2) Remove the through bolts, and use the tip of a screwdriver

as shown to pry apart the rear bracket from the front bracket,
evenly around the entire circumference.
NOTE
1. The rear bearing is tightly mounted.
Before disassembly, heat the bearing box section Bearing box Through bolt
of the rear bracket to facilitate disassembly.
2. Be sure not to lose the spring in the rear bearing
outer race during removal.
Spring Rear bearing

Front bracket
Rear bracket
D4AF8107

3. Disassemble the front bracket assembly as detailed below:

Do not clamp here
1) Clamp the rotor in a vise as shown.
NOTE
Do not damage the rotor by clamping the rotor at other
positions than shown above.

Rotor D4AF1029
EE-40 ENGINE ELECTRICAL SYSTEM

2) Remove the pulley and fan mounting nut and disassemble

the pulley, the fan, the spacer, the front bracket, the cover
and the rotor in that order.

Front Spacer
Fan Pulley
bracket
Rotor Cover

D4AF8053

4. Unsolder the stator coil lead wires from the rectifier diodes (three
locations) and remove the stator coil from the rear bracket.
NOTE
To prevent overheating, be careful not to use the soldering
iron for more than 5 seconds at a time.

Rectifier diodes

Stator coil lead wires D4AF1031

5. Remove the rectifier assembly as detailed below: B terminal

Rectifier
1) Remove the nut of the B terminal on the back of the rear assembly

bracket and remove one of the rectifier assembly mounting

bolts.

D4AF2713

2) Remove the other rectifier assembly mounting bolt and take

the rectifier assembly out of the rear bracket.

Rectifier
assembly

D4AF2714
ALTERNATOR EE-41

6. Remove the regulator assembly mounting bolt and take the

regulator assembly out of the rear bracket. Rear bracket

Regulator
assembly

D4AF2715

7. Remove the brushes and brush springs as detailed below:

1) Unsolder the regulator assembly at locations shown.
NOTE
To prevent overheating, be careful not to use the sol-
dering iron for more than 5 seconds at a time.

D4AF2716

2) Remove the brushes and brush springs from the regulator

assembly.

Brush spring

Brush
D4AF2717

NOTE
Brush
Be careful not to disconnect the brush leads from the
brushes, as they are easily broken.
Connection

Lead wire

D4AF2738
EE-42 ENGINE ELECTRICAL SYSTEM

Inspection

Slip ring O.D.

NV 33±0.2 mm
L 32.4 mm
Field coil resistance
NV Approx. 10 Ω <25A> Ground test
Approx. 2 to 3 Ω <50A>

Open circuit test

Ground test
Brush length
NV 18.5 mm
L 7 mm
Brush spring pressure
NV 3 to 4.2 N
(0.31 to 0.43 kgf)
L 2.1N (0.21 kgf)

NV ... Nominal Value

Short test
L ... Limit
Open test
D4AF8103

1. Stator Inspection
1) Continuity between lead wires
Check that there is continuity between the lead wires.
If there is no continuity, there is a broken wire in the stator
windings and the stator must be replaced.

D4AF8058

2) Continuity between lead wire and core

Check that there is no continuity between each lead wire
and the core. If there is continuity, the stator windings are
grounded and the stator must be replaced.

D4AF805B

2. Rotor Inspection
1) Continuity between slip ring and core
Check that there is no continuity between the slip rings
and the core. If there is continuity, the rotor is grounded
and must be replaced.

D4AF8130
ALTERNATOR EE-43

2) Field coil resistance

Measure the resistance between slip rings, replace the ro-
tor if the measured value is out of specification.

D4AF8131

3) Slip ring OD
Measure the slip ring OD. If the measured OD is out of
specification, correct by grinding or replace.
Use sand paper or a lathe to finish off slip ring roughness
or uneven wear. Be sure that the OD after finishing is still
within the specified range.

D4AF8132

3. Brush Inspection

Length when new

Wear limit
Check the brush length, and replace if it is worn beyond the
wear limit.

Wear limit D4AF8062

4. Brush Spring Inspection Bushing spring

Fit the brush and its spring to the regulator assembly, com-
press the brush end with a push-pull gauge and measure the
spring tension.
Brush

D4AF2718

5. Rectifier Diode Inspection

Measure the resistance of each diode, first applying the (+)
tester probe to the diode, then the (-) tester probe.
If the resistance is infinite in both cases, the diode open circuit.
If near zero in both case, the diode is short-circuited. Diode trio (3)
Whatever the trouble may be, replace the rectifier.
Diode (6)
For measurement method, see procedures below.
D4AF2719
EE-44 ENGINE ELECTRICAL SYSTEM

1) Heat sink diode measurement (6 locations)

Stator coil
Make measurement between the heat sink and the stator lead wire mount
(3 locations)
coil lead wire.

Heat sink

D4AF2721

2) Diode trio inspection (3 locations)

Make measurement between the regulator connection plate
and the stator coil lead connection.

D4AF2722

6. Bearing Inspection
Front bearing
Replace the bearings if the rotation of the rotor in the front and
rear bearings is not smooth.
Rear bearing

D4AF2723

1) Replace the front bearing as detailed below:

<Removal>
Remove the bearing cover screws.

Cover
Front bracket
D4AF2724
ALTERNATOR EE-45

Set a rod on the spacer from the front bracket side, and pull out the
bearing toward the rear with a hammer.

Rod

Spacer Rod
Spacer

Front
bracket
Front bracket Bearing D4AF2725

Remove the spacer, washer and packing from the front bracket Spacer
side.

Packing
Washer

D4AF2726

<Installation>
Install the packing and washer to the front bracket, positioning the
Front
washer with the thrust side forward.

Packing
Washer
D4AF2727

Lightly apply engine oil to the bearing outer circumference and in- Apply engine oil
stall the bearing from the inside of the front bracket, gently and
evenly tapping the outer circumference with a soft hammer. Insert
until the end is flush with the bearing cover mounting surface.

Bearing Cover

Front bracket

D4AF3109
EE-46 ENGINE ELECTRICAL SYSTEM

Attach the bearing cover with its screws.

Cover
Front bracket
D4AF2724

Insert the spacer from the front face of the front bracket, and tap
with a soft hammer to verify that the bearing and bearing cover are
in contact. If not, tap the spacer.

Spacer
Front bracket Bearing

D4AF2730

2) Replace the rear bearing as detailed below:

<Removal>
Use a bearing puller to remove the rear bearing.
NOTE
Be careful not to damage the slip rings with the bearings puller.

<Installation>
D4AF2731

Apply engine oil lightly to the inside of the bearing inner race.
Hold the bearing with the spring groove side towards the slip rings,
and tap in the bearing with a soft hammer evenly on the entire
inner race circumference.
NOTE
Tapping the outer race would damage the bearing. Be careful Apply engine oil
to tap the inner race only.

Spring
groove

D4AF2732
ALTERNATOR EE-47

Attach the spring so that the spring bulge is over the deepest part Minimize
of the spring groove. Spring spring bulge

Bulge

D4AF8099

7. Inspection of oil seal

Bar
Replace the oil seal by the following procedures if it is faulty as
indicated such as by traces of engine oil on the oil seal leaked
from the vacuum pump.

<Removal>
Apply a bar to the oil seal on the vacuum pump mounting side of
the rear bracket and strike it to remove the oil seal. D4AF2733

<Installation>
Apply grease to the lip of the oil seal and applying a bar and hitting
it, install the oil seal in the rear bracket from the rear bearing mount-
ing side.

Apply grease

D4AF2734
EE-48 ENGINE ELECTRICAL SYSTEM

Reassembly
1. Insert the brush springs into the regulator assembly. Bushing spring

Regulator
assembly
D4AF2735

2. Attach the brush to the regulator assembly as detailed below:

1) Align the brush lead wires with the notches in the regulator
assembly and insert the brushes into the regulator assem-
bly by compressing the springs.

Regulaor assembly
notches

D4AF2736

2) Insert a pin through the hole in the brush and solder the Soldering
lead wire to the regulator assembly.
Remove the pin after soldering.

Pin Brush D4AF2737

NOTE
Brush
When removing the pin, hold the brush down by hand,
and release the brush springs gradually. Removing the
pin from the spring suddenly may cause the lead wire Connection
connection to be broken.

Lead wire

D4AF2738

3. Attach the regulator assembly to the rear bracket with one screw.
The other screw to tighten the assembly is also used to tighten
the plate of the rectifier assembly, and will be installed later.
Regulator
assembly

D4AF2739
ALTERNATOR EE-49

4. Install the rectifier assembly to the rear bracket as detailed

below:
1) Attach the rectifier assembly to the rear bracket with the
screws.
Rectifier
assembly

D4AF2740

2) Attach the nut to the B terminal of the rear bracket. B terminal

Install the plate onto the regulator, insert the screw and Rectifier assembly
tighten. Plate

Regulator

D4AF2713

5. Attach the stator to the rear bracket detailed below:

1) Solder the stator coil lead wires to the rectifier diodes.
NOTE
To prevent overheating, be careful not to use the sol-
dering iron for more than 5 seconds at a time.

Rectifier diode

Stater coil lead wire D4AF1301

2) Assemble the stator to the rear bracket being sure to align

it.

D4AF2742

6. Assemble the front bracket assembly as detailed below: Do not clamp here
1) Hold the rotor in a vise as shown.
NOTE
To avoid damage to the rotor, be sure that it is clamped
in the vise as shown.

D4AF1029
EE-50 ENGINE ELECTRICAL SYSTEM

2) Apply engine oil lightly to the front bearing mounting sur- Apply engne oil
face of the rotor.

D4AF102M

3) Install the cover, the front bracket, the spacer, the fan and
130 to 160 Nm
the pulley in that order, on the rotor. (13.5 to 16.5 kgf·m)
Tighten pulley mounting nut to the specified torque.

Front Spacer Fan Pulley

Cover bracket
Rotor

D4AF805D

7. Assemble the front and rear bracket assembles together as

detailed below:
1) Wind vinyl tape around the rotor splined shaft end to pre-
vent the oil seal lip from being damaged by the rotor when
the seal is installed in the rear bracket.

D4AF2743

2) Apply grease to the rotor bearing outer race.

Grease

Rear bearing
D4AF2744
ALTERNATOR EE-51

3) Hold down the brushes by hand, insert a pin from the rear
of the rear bracket into the hole provided in the brush to
Pin
secure the brush.

Brush
D4AF2745

4) Align the rotor rear bearing with its mounting portion of the Front bracket assembly Rear bearing
rear bracket and insert the rear bearing.

Rear bracket assembly

D4AF2746

5) Insert the through bolts from the front bracket side and
tighten.

Through bolt
D4AF1949

6) After assembly, remove the pin holding the brushes.

7) Install the vacuum pump.

D4AF2747

Tests
1. Handling Precautions
Observe the following precautions when testing the alternator.
1) Be sure the battery polarity is correct. If reversed, the large
current flowing from the battery will destroy the diodes and
the IC regulator.

D4AF8072
EE-52 ENGINE ELECTRICAL SYSTEM

2) Do not remove the battery terminal while the engine is

rotating, as this will cause a surge voltage which adversely
affects the sevice life of the diodes and the IC regulator.

D4AF8073

3) Do not use meggers or high voltage tester, as this will de-

stroy the diodes and IC regulator.

D4AF8074

4) Be sure the alternator does not get wet, as this will cause
shorting and damage.

D4AF8075

5) Do not operate the altenator with B and L terminals shorted,

as this will cause damaged to the diode trio.

D4AF8076

6) When rapid charging the battery, disconnect the battery

terminals, otherwise the diodes and the regulator may be
destroyed.

D4AF8077
ALTERNATOR EE-53

2. Performance Testing Ammeter

+ -
A
1) Testing on test bench
B
Test by the test circuit shown above. Switch K1 Switch
R + K2
Set at maximum load resistnce (almost no load current Alternator V oltmenter
V
flowing) and close the switches K1 and K2. -
Battery
While increasing the alternator speed gradually, decrease E

the load resistance and measure the current value at speci-

fied terminal voltage ans specified speed. If the value is D4AF8068

out of standard, check the alternator.

Nominal value (when the alternator is cool)

<40A type unit>

Terminal valtage 27V 27V
Current 24A or more 38A or more
Rotating speed 1,500 rpm 2,500 rpm

<70A type unit>

Terminal valtage 27V 27V
Current 33A or more 55A or more
Rotating speed 1,500 rpm 2,500 rpm

2) On-vehicle testing Ammeter

+ -
A
Referring to Section Alternator, install the alternator to the
B
vehicle. Provide a voltmenter, an ammeter and a switch on Switch
+
the harnesses leading to the alternator B teminal. V Voltmenter
Alternator -
NOTE
Battery
Connect with switch open E

Close the switch and verify that voltmenter indicates bat-

D4AF8069
tery voltage.
Start the engine and turn on all witches for lamps and other
electrical equipment, raise engine rpm and read maximum
current when alternator speed is 5,000 rpm (engine speed
is about 2,410 rpm).
If the current reading is 70% or more of the nominal output,
the alternator may be considered normal.
NOTE
1. When measuring with the engine rotating, be careful of
moving engine parts.
2. The on-vehicle testing is merely a simple inspection
method. Precision testing of the alternator must be done
on a test bench, i.e. after removal from the vehicle.
EE-54 ENGINE ELECTRICAL SYSTEM

3. Regulator Inspection Ammeter

+ -
A
1) Inspection on test bench
B
Using the circuit as shown above, check the regulated volt- R
L Switch
age by the following procedures. +
Alternator V voltmenter
Use a fully charged battery and close the switch. -
Increase the alternator speed gradually and check that the Battery
E
current value is 5 A or less when the speed is 5,000 rpm
D4AF8070
(engine speed about 2,410 rpm).
If the voltage value (regulator voltage) when the alternator
speed is 5,000 rpm is as specified, the IC regulator is oper-
ating normally. If out of standard, replace the regulator
assembly.

Nominal value.....................................................28 to 29V

2) Inspection on vehicle
NOTE B Switch
Make connection with the switch open L +
Alternator A Ammeter
+
Close the switch and check that indicated voltage is 0. If V -
Voltmenter
the voltmeter needle moves, either the wiring or the alter- E - Battery
nator is faulty.
Short the ammeter terminals to prevent the stater current
D4AF8071
from flowing through it, and start the engine.
If the charging current is 5 A or less when the engine speed
is about 2,410 rpm, read the regulated voltage. If 5 A or
more, either let the system charge for a while, or replace
with a fully charged battery. Alternately, place a 0.25(25W)
resistor in series with the battery to restrict the charging
current.
If the regulated voltage exceeds the specification, replace
the regulator assembly

Nominal value ....................................................28 to 29V

VACUUM PUMP EE-55

VACUUM PUMP
Disassembly, Inspection and Reassembly

Replace seal set.

Apply all grease
in cluded in seal
setto lips.
4 2 Wear in splines

3 Wear, damage

For reassembly, reverse the order of disassembly. Disassembly sequence

NOTE 1. Vacuum housing
When reassembling the vacuum pump, make sure that 2. Rotor
the housing nd rotor are free from metal particles and 3. Vane
other contaminants.
4. Plate
Vacuum pump is not applied to D4DA engine
D4AF8551

Test 10 lit. tank

Engine oil
Vacuum pump performance standards
Maximum attainable Vacuum 91kPa (680mmHg) or more
vacuum Rotating 3,000 rpm
Vacuum
speed Alternator pump

Deliver At low Vacuum 67kPa (500mmHg) or more

characteristics speed Rotating 1,500 rpm D4AF8552

after 20 sec.
speed
(with 10lit. tank)
At high Vacuum 80kPa(600mmHg) or more
speed Rotating 3,000 rpm
speed

If the performance is below standards, check hose joints for tight-

ness and the amount of oil supplied.
Then, recheck. If the poor performance is still persistent, check
vanes for chips; housing, rotor, and rear bracket mating surfaces
for scratches; and, oil seals and check valves. Replace parts if
defective.
EE-56 ENGINE ELECTRICAL SYSTEM

PREHEATING SYSTEM
AIR HEATER DEVICE
Removal and Installation.
Remove the heater harness, air heater assembly and heater relay.

CS27001A

Heater
relay

Starter CS27001B

Inspection of Air Heater Assembly

1. Looseness of air heater terminal
2. Heater element damage
3. Over clearance or interference between glass cases.

CS27001C

Inspection of heater relay

1. When the heater is glowing, check the continuity between ter-
minal B and terminal C. “C”
2. If the fuse of relay is blown, check the cause and replace the
fuse (fuse capacity is marked on fuse)

“D”

CS27001D
PREHEATING SYSTEM EE-57

GLOW PLUG
CONPONENT

2 0.10~0.15 kgf·m

1.5~2.0 kgf·m 1

Removal step
1. Connector
2. Glow plug plate
3. Glow plug

Removal of glow plug

The glow plug is apt to drop, so remove the glow plug by hand as
not completely loosen using tool.

Inspection.
1. Check for rust of glow plug plate
2. Check for damage of glow plug.

Caution
Do not use the glow plug dropped at 10cm higher.
3. Check the reistance of each glow plug.

Standard value ............................................................. 4Ω

NOTE
Because the resistance is very low, clean the oil before
checking the resistance.

Installation of glow plug CS27002B

Glow plug is apt to break, completely tighten it by using tool after

one turning by hand.