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CHARGING SYSTEM
GENERAL INFORMATION 16100010228
Voltage OPERATION
Rotation of the excited field coil generates AC voltage in
the stator.
This alternating current is rectified through diodes to DC
voltage having a waveform shown in the illustration at left.
Approx. 14.4 V The average output voltage fluctuates slightly with the
alternator load condition.
Time
When the ignition switch is turned on, current flows of approx. 14.4 V, the field current is cut off. When
in the field coil and initial excitation of the field the battery voltage drops below the regulated
coil occurs. voltage, the voltage regulator regulates the output
When the stator coil begins to generate power after voltage to a constant level by controlling the field
the engine is started, the field coil is excited by current.
the output current of the stator coil. In addition, when the field current is constant, the
The alternator output voltage rises as the field alternator output voltage rises as the engine speed
current increases and it falls as the field current increases.
decreases. When the battery voltage (alternator
S terminal voltage) reaches a regulated voltage
SYSTEM DIAGRAM
Stator coil
Charging
warning lamp Ignition
switch
Field coil
Voltage
regulator
Battery
ENGINE ELECTRICAL – Charging System 16-3
ALTERNATOR SPECIFICATIONS
Items 4G63, 4G64 4D56
NOTE
*: Vehicles with over fender
SERVICE SPECIFICATIONS 16100030149
Ammeter
Alternator
Voltmeter
Battery
B-terminal
This test determines whether the wiring from the output wire. (Connect the (+) lead of the
alternator “B” terminal to the battery (+) terminal ammeter to the “B” terminal, and then connect
(including the fusible line) is in a good condition the (–) lead of the ammeter to the disconnected
or not. output wire.)
(1) Always be sure to check the following before NOTE
the test. An inductive-type ammeter which enables
D Alternator installation measurements to be taken without
D Alternator drive belt tension (Refer to disconnecting the alternator output wire should
GROUP 11 – On-vehicle Service.) be recommended. Using this equipment will
D Fusible link lessen the possibility of a voltage drop caused
D Abnormal noise from the alternator while by a loose “B” terminal connection.
the engine is running
(2) Turn the ignition switch off. (5) Connect a digital-type voltmeter between the
(3) Disconnect the negative battery cable. alternator “B” terminal and the battery (+)
(4) Disconnect the alternator output wire from the terminal. (Connect the (+) lead of the voltmeter
alternator “B” terminal and connect a DC test to the “B” terminal and the connect the (–) lead
ammeter with a range of 0–100 A in series of the voltmeter to the battery (+) cable.)
between the “B” terminal and the disconnected
ENGINE ELECTRICAL – Charging System 16-5
(6) Connect a tachometer. (Refer to GROUP 11 (11)If the value displayed on the voltmeter is above
– On-vehicle Service.) the limit value, there is probably a malfunction
(7) Reconnect the negative battery cable. in the alternator output wire, so check the wiring
(8) Leave the hood open. between the alternator “B” terminal and the
(9) Start the engine. battery (+) terminal (including fusible link).
(10)With the engine running at 2,500 r/min, turn If a terminal is not sufficiently tight or if the
the headlamps and other lamps on and off harness has become discolored due to
to adjust the alternator load so that the value overheating, repair and then test again.
displayed on the ammeter is slightly above 30 (12)After the test, run the engine at idle.
A. (13)Turn off all lamps and the ignition switch.
Adjust the engine speed by gradually (14)Remove the tachometer.
decreasing it until the value displayed on the (15)Disconnect the negative batter cable.
ammeter is 30 A. Take a reading of the value (16)Disconnect the ammeter and voltmeter.
displayed on the voltmeter at this time. (17)Connect the alternator output wire to the
Limit: max. 0.3 V alternator “B” terminal.
(18)Connect the negative battery cable.
NOTE
When the alternator output is high and the value
displayed on the ammeter does not decrease
until 30 A, set the value to 40 A. Read the
value displayed on the voltmeter at this time.
When the value range is 40 A, the limit is max.
0.4 V.
Ignition
switch L
B
Alternator relay S
Voltmeter
Ammeter
Battery
16-6 ENGINE ELECTRICAL – Charging System
This test determines whether the alternator output (10)Turn the light switch on to turn on headlamps
current is normal. and then start the engine.
(1) Before the test, always be sure to check the (11)Immediately after setting the headlamps to high
following. beam and turning the heater blower switch to
D Alternator installation the high revolution position, increase the engine
D Battery (Refer to GROUP 54 – Battery.) speed to 2,500 r/min and read the maximum
NOTE current output value displayed on the ammeter.
The battery should be slightly discharged. Limit: 70% of normal current output
The load needed by a fully-charged battery NOTE
is insufficient for an accurate test. D For the nominal current output, refer to the
D Alternator drive belt tension (Refer to Alternator Specifications.
GROUP 11 – On-vehicle Service.) D Because the current from the battery will
D Fusible link soon drop after the engine is started, the
D Abnormal noise from the alternator while above step should be carried out as quickly
the engine is running. as possible in order to obtain the maximum
(2) Turn the ignition switch off. current output value.
(3) Disconnect the negative battery cable. D The current output value will depend on
(4) Disconnect the alternator output wire from the the electrical load and the temperature of
alternator “B” terminal. Connect a DC test the alternator body.
ammeter with a range of 0–100 A in series D If the electrical load is small while testing,
between the “B” terminal and the disconnected the specified level of current may not be
output wire. (Connect the (+) lead of the output even though the alternator is normal.
ammeter to the “B” terminal. Connect the (–) In such cases, increase the electrical load
lead of the ammeter to the disconnected output by leaving the headlamps turned on for
wire.) some time to discharge the battery or by
Caution using the lighting system in another vehicle,
Never use clips but tighten bolts and nuts and then test again.
to connect the line. Otherwise loose D The specified level of current also may not
connections (e.g. using clips) will lead to be output if the temperature of the alternator
a serious accident because of high current. body or the ambient temperature is too
NOTE high. In such cases, cool the alternator and
An inductive-type ammeter which enables then test again.
measurements to be taken without (12)The reading on the ammeter should be above
disconnecting the alternator output wire should the limit value. If the reading is below the limit
be recommended. value and the alternator output wire is normal,
remove the alternator from the engine and
(5) Connect a voltmeter with a range of 0–20 V check the alternator.
between the alternator “B” terminal and the (13)Run the engine at idle after the test.
earth. (Connect the (+) lead of the voltmeter (14)Turn the ignition switch off.
to the “B” terminal, and then connect the (–) (15)Remove the tachometer.
lead of the voltmeter to the earth.) (16)Disconnect the negative battery cable.
(6) Connect the negative battery cable. (17)Disconnect the ammeter and voltmeter.
(7) Connect a tachometer. (Refer to GROUP 11 (18)Connect the alternator output wire to the
– On-vehicle Service.) alternator “B” terminal.
(8) Leave the hood open. (19)Connect the negative battery cable.
(9) Check that the reading on the voltmeter is equal
to the battery voltage.
NOTE
If the voltage is 0 V, the cause is probably
an open circuit in the wire or fusible link between
the alternator “B” terminal and the battery (+)
terminal.
ENGINE ELECTRICAL – Charging System 16-7
REGULATED VOLTAGE TEST 16100110195
Load
Ignition Charging warning
switch lamp MD998467 Alternator
L
Alternator relay
S B
Ammeter
Voltmeter
Battery
Yellow
This test determines whether the voltage regulator (6) Connect a DC test ammeter with a range of
is correctly controlling the alternator output voltage. 0–100 A in series between the “B” terminal
(1) Always be sure to check the following before and the disconnected output wire. (Connect
the test. the (+) lead of the ammeter to the “B” terminal.
D Alternator installation Connect the (–) lead of the ammeter to the
D Check that the battery installed in the disconnected output wire.)
vehicle is fully charged. (Refer to GROUP (7) Reconnect the negative battery cable.
54 – Battery.) (8) Connect a tachometer or the MUT-II. (Refer
D Alternator drive belt tension (Refer to to GROUP 11 – On-vehicle Service.)
GROUP 11 – On-vehicle Service.) (9) Turn the ignition switch to the ON position and
D Fusible link check that the reading on the voltmeter is equal
D Abnormal noise from the alternator while to the battery voltage.
the engine is running NOTE
(2) Turn the ignition switch to the OFF position. If the voltage is 0 V, the cause is probably
(3) Disconnect the negative battery cable. an open circuit in the wire or fusible link between
(4) Use the special tool to connect a digital the alternator “S” terminal and the battery (+)
voltmeter between the alternator S terminal and terminal.
earth. (Connect the (+) lead of the voltmeter
to the “S” terminal, and then connect the (–) (10)Turn all lamps and accessories off.
lead of the voltmeter to a secure earth or to (11)Start the engine.
the battery (–) terminal.) (12)Increase the engine speed to 2,500 r/min.
(5) Disconnect the alternator output wire from the (13)Read the value displayed on the voltmeter when
alternator “B” terminal. the alternator output current alternator
becomes 10 A or less.
16-8 ENGINE ELECTRICAL – Charging System
(14)If the voltage reading conforms to the value (17)Remove the tachometer.
in the voltage regulation, then the voltage (18)Disconnect the negative battery cable.
regulator is operating normally. (19)Disconnect the ammeter and voltmeter.
If the voltage is not within the standard value, (20)Connect the alternator output wire to the
there is a malfunction of the voltage regulator alternator “B” terminal.
or of the alternator. (21)Remove the special tool, and return the
(15)After the test, lower the engine speed to the connector to the original condition.
idle speed. (22)Connect the negative battery cable.
(16)Turn the ignition switch off.
20 13.9 – 14.9
60 13.4 – 14.6
80 13.1 – 14.5
ENGINE ELECTRICAL – Charging System 16-9
Special WAVEFORM CHECK USING AN ANALYZER
patterns Analyzer
Alternator 16100120143
pickup
MEASUREMENT METHOD
Connect the analyzer special patterns pick-up to the alternator
B terminal.
B terminal
STANDARD WAVEFORM
Observation Conditions
FUNCTION SPECIAL PATTERNS
0.4
0.2
Voltage at
alternator 0
B terminal
– 0.2
– 0.4
Time
NOTE
The voltage waveform of the alternator B terminal can undulate
as shown at left. This waveform is produced when the regulator
operates according to fluctuations in the alternator load
(current), and is normal for the alternator.
In addition, when the voltage waveform reaches an
excessively high value (approx. 2 V or higher at idle), it often
indicates an open circuit due to a brown fuse between
alternator B terminal and battery, but not a defective alternator.
16-10 ENGINE ELECTRICAL – Charging System
<4G6>
8 14 Nm
9.8 Nm
20 – 25 Nm
12 – 15
Nm 7
2 20 – 25 Nm
1 3
<4D56>
8
14 Nm 9.8 Nm
6
3 7 12 – 15
Nm
2
4
44 Nm 17 Nm
5
1
Removal steps
1. Drive bolt (for A/C) 5. Oil return hose connection
2. Drive belt (for power steering) 6. Vacuum hose connection
3. Drive belt (for alternator) 7. Alternator
4. Oil pipe connection 8. Alternator brace assembly
16-12 ENGINE ELECTRICAL – Charging System
<4G6>
1 4
3
5
6
7
12
10
9
8 14
13
11
Disassembly steps
AA" 1. Front bracket assembly AC" 8. Stator
AB" 2. Pulley 9. Plate
"BA 3. Rotor AC" "AA 10. Regulator assembly
4. Rear bearing 11. Brush
5. Bearing retainer 12. Slinger
6. Front bearing 13. Rectifier assembly
7. Front bracket 14. Rear bracket
ENGINE ELECTRICAL – Charging System 16-13
DISASSEMBLY AND REASSEMBLY
<4D56>
12
9
11
13
14
15
10
22
16
21 1
20
2
18
17 19 3
4
5
6
7
Disassembly steps
1. Check valve 12. Rear bearing
2. Nipple 13. Bearing retainer
3. Vacuum pump housing 14. Front bearing
4. O-ring 15. Front bracket
"CA 5. Vane AC" 16. Stator
"CA 6. Rotor 17. Plate
7. Vacuum pump plate AC" "AA 18. Regulator assembly
8. O-ring 19. Brush
AA" 9. Front bracket assembly 20. Slinger
AB" 10. Pulley 21. Rectifier assembly
"BA 11. Rotor 22. Rear bracket
16-14 ENGINE ELECTRICAL – Charging System
Rear bracket
Brush
Wire
Wire
INSPECTION 16100170162
ROTOR
1. Check rotor coil for continuity. Check that there is no
continuity between slip rings. If resistance is too small,
it means that there is a short circuit. If there is no continuity
or if there is a short circuit, replace rotor assembly.
Resistance value: Approx. 2 – 5 Ω
STATOR
1. Make continuity test on stator coil. Check that there is
continuity between coil leads. If there is no continuity,
replace stator assembly.
RECTIFIERS
1. Check for continuity between positive rectifier and stator
coil lead connection terminal with an ohmmeter. If there
is continuity in both directions, diode is shorted. Replace
rectifier assembly.
ENGINE ELECTRICAL – Charging System 16-17
2. Check for continuity between negative rectifier and stator
coil lead connection terminal. If there is continuity in both
directions, diode is shorted, and rectifier assembly must
be replaced.
BRUSH
1. Replace the brush if its protrusion length is less than
the limit.
Protrusion Limit: min. 2 mm
length
VACUUM PUMP
Check the following and replace if defective.
Rotor 1. Check the rotor ends for streaks or damage.
Housing
2. Check the housing surface in contact with the rotor for
streaks or damage.
3. Check the vanes for damage or breaks.
Vane
O-ring
16-18 ENGINE ELECTRICAL – Starting System
GENERAL INFORMATION
If the ignition switch is turned to the “START” and M terminal to conduct. Thus, current flows to
position, current flows in the pull-in and holding engage the starter motor.
provided inside magnetic switch, attracting the When the ignition switch is returned to the ”ON”
plunger. When the plunger is attracted, the lever position after starting the engine, the starter clutch
connected to the plunger is actuated to engage is disengaged from the ring gear.
the starter clutch. An overrunning clutch is provided between the
On the other hand, attracting the plunger will turn pinion and the armature shaft, to prevent damage
on the magnetic switch, allowing the B terminal to the starter.
SYSTEM DIAGRAM
Holding coil Plunger
Pull-in coil Lever
Over-running clutch
Pinion shaft
Ignition switch
Armature
Battery
Brush
Yoke
Field coil (4G63-Standard and M/T, 4D56)
<4D56>
Items Standard and M/T Cold climate zone and A/T
Type Reduction drive with planetary gear Reduction drive with planetary gear
Rated output kw/V 2.0 2.2
No. of pinion teeth 10 10
ENGINE ELECTRICAL – Starting System 16-19
SERVICE SPECIFICATIONS
Items Standard value Limit
Pinion gap mm 0.5 – 2.0 –
Commutator outer diameter mm 32.0 31.0
Commutator runout mm 0.05 0.1
Commutator undercut mm 0.5 –
B
INSPECTION
PINION GAP ADJUSTMENT
S
M 1. Disconnect field coil wire from M-terminal of magnetic
Battery switch.
2. Connect a 12V battery between S-terminal and
Field coil wire M-terminal.
3. Set switch to “ON”, and pinion will move out.
Caution
This test must be performed quickly (in less than
10 seconds) to prevent coil from burning.
Stopper
Pinion gap
Pinion
3
4
12
15
13
17
5 11
16
14
7
8
9
10
Disassembly steps
1. Screw 9. Brush holder assembly
AA" 2. Magnetic switch 10. Yoke assembly
3. Packing 11. Armature
4. Plate 12. Lever
5. Screw 13. Washer
6. Through bolt AC" "AA 14. Snap ring
7. Rear bracket AC" "AA 15. Stop ring
8. Rear bearing 16. Overrunning clutch
17. Front bracket
ENGINE ELECTRICAL – Starting System 16-23
DISASSEMBLY AND REASSEMBLY <REDUCTION DRIVE TYPE – 4G6>
12
13
14
16
11
15
1
21
20
19
18 4
17 3
22
8 5
10
Disassembly steps
1. Screw 12. Packing A
AA" 2. Magnetic switch 13. Packing B
3. Screw 14. Plate
4. Screw 15. Planetary gear
5. Rear bracket 16. Lever
6. Brush holder AC" "AA 17. Snap ring
7. Brush AC" "AA 18. Stop ring
8. Rear bearing 19. Overrunning clutch
AA" 9. Armature 20. Internal gear
10. Yoke assembly 21. Planetary gear holder
AA" 11. Ball 22. Front bracket
16-24 ENGINE ELECTRICAL – Starting System
14
12
13
16
11
15 4
1
22
3
21 8
20
19
18
17
23
5
6
10 7
Disassembly steps
1. Screw 13. Plate
AA" 2. Magnetic switch AB" 14. Ball
3. Screw 15. Planetary gear
4. Screw 16. Lever
5. Rear bracket AC" "AA 17. Snap ring
6. Brush holder AC" "AA 18. Stop ring
7. Yoke assembly 19. Overrunning clutch
8. Brush 20. Internal gear
AB" 9. Armature 21. Washer
10. Bearing 22. Planetary gear holder
11. Packing A 23. Front bracket
12. Packing B
ENGINE ELECTRICAL – Starting System 16-25
Magnetic switch “S” terminal DISASSEMBLY SERVICE POINTS
AA" MAGNETIC SWITCH REMOVAL
“B” terminal Disconnect field coil wire from “M” terminal of magnetic switch.
“M” terminal
Field coil wire
Socket
AC" SNAP RING/STOP RING REMOVAL
1. Press stop ring off snap ring with a suitable socket.
Stop ring
Pinion gear
Overrunning
clutch
Armature
2. Remove snap ring with snap ring pliers and then remove
Snap ring stop ring and overrunning clutch.
Snap ring
Pinion gear pliers
Overrun-
ning
clutch
Armature
Snap ring
INSPECTION 16200130194
COMMUTATOR CHECK
1. Place the armature in a pair of “V” blocks and check
the runout with a dial indicator.
Standard value: 0.05 mm
Limit: 0.1 mm
Yoke
GENERAL INFORMATION
When the primary current stops suddenly in the timing.
ignition coil, high voltage appears in the secondary The engine-ECU detects the crankshaft position
side of the coil. The distributor supplies the high by the crank angle sensor incorporated in the
voltage to the applicable spark plug. The engine distributor to provide ignition at the most appropriate
firing order is 1-3-4-2 cylinders. timing for the engine operating condition.
The high voltage ignites the compressed air fuel When the engine is cold or operated at a high
mixture in the combustion chamber through the altitude, the ignition timing is slightly advanced to
spark plugs. provide optimum performance to the operating
The engine-ECU makes and breaks the primary condition.
current of the ignition coil to regulate the ignition
SYSTEM DIAGRAM
Ignition switch
Battery
Ignition coil
Ignition switch-ST
Spark plugs
16-30 ENGINE ELECTRICAL – Ignition System
DISTRIBUTOR SPECIFICATIONS
Items Specifications
NGK BKR5E-11
LUBRICANT
Items Specified lubricant Quantity
NOTE
An analogue-type circuit tester should be used.
Voltage: 1.5V Terminal No.
1 2 3
Applied
Ignition coil
Power transistor
Not applied
+ – Replace the power transistor if there is a malfunction.
1.5V
– +
MEASUREMENT METHOD
1. Clamp the high-tension cable with the secondary pickup.
2. Clamp the spark plug cable with the trigger pickup.
(Basically, clamp the spark plug cable of the No.1 cylinder.)
NOTE
The waveform of the cylinder clamped to the trigger pickup
appears at the left edge of the screen.
STANDARD WAVEFORM
Observation Conditions
FUNCTION SECONDARY
PATTERN HEIGHT HIGH (or LOW)
PATTERN SELECTOR RASTER
Engine Speed Curb idle speed
kV Spark line
(Point A)
Ignition
voltage
(Point D)
Vibration damping
section (Point B)
Dwell
section
Ignition
secondary
voltage
waveform
(Point C)
Time
16-34 ENGINE ELECTRICAL – Ignition System
Spark line Plug gap Condition of Compression Concentration of Ignition timing Spark plug
electrode force air mixture cable
Point B: Number of vibration in reduction vibration section (Refer to abnormal waveform example 5)
Point C: Number of vibrations at beginning of dwell section (Refer to abnormal waveform example 5)
5 – 6 or higher Normal
Point D: Ignition voltage height (distribution per each cylinder) shows the following trends.
Ignition Plug gap Condition of Compression Concentration of Ignition timing Spark plug cable
voltage electrode force air mixture
Example 1 Spark line is high and short. Spark plug gap is too large.
01P0215
Example 2 Spark line is low and long, and is Spark plug gap is too small.
sloping.
Also, the second half of the spark line
is distorted. This could be a result of
misfiring.
Example 3 Spark line is low and long, and is Spark plug gap is fouled.
sloping. However, there is almost no
spark line distortion.
Example 4 Spark line is high and short. Spark plug cable is nearly falling off.
Difficult to distinguish between this (Causing a dual ignition)
and abnormal waveform example 1.
Ignition coil
Power transistor
(V)
Zener voltage
(Point C)
Spark line
100 (Approx. 40×10V) (Point A)
Vibration damping
section (Point B)
Dwell
section
Ignition
primary
voltage 0
waveform
Time
Observation conditions
(Only the pattern selector shown below changes from the previous conditions)
(V)
100
Centre
section
Ignition
primary
voltage 0
waveform
Time
16-38 ENGINE ELECTRICAL – Ignition System
Spark line Plug gap Condition of Compression Concentration of Ignition timing High tension
electrode force air mixture cable
3 or higher Normal
Example 1 Spark line is high and short. Spark plug gap is too large.
Example 2 Spark line is low and long, and is Spark plug gap is too small.
sloping.
Also, the second half of the spark line
is distorted. This could be a result of
misfiring.
Example 3 Spark line is low and long, and is Spark plug gap is fouled.
sloping. However, there is almost no
spark line distortion.
Example 4 Spark line is high and short. Spark plug cable is nearly falling off.
(Causing a dual ignition)
DISTRIBUTOR 16300200140
6 9 8
10 – 12 Nm
3
1 4
10 Nm
24 Nm
9
13 Nm
6 7
5 8
Removal steps
1. Timing belt upper cover 5. Ignition coil connector
2. Spark plug cable and high tension "CA 6. Distributor assembly
cable 7. Distributor bracket
3. Distributor connector "BA 8. Camshaft sprocket spacer
4. Power transistor connector "AA 9. Oil seal
Mating
marks
Timing mark
Disassembly steps
1. Distributor cap
2. Rotor
3. Cover
4. Distributor housing
ENGINE ELECTRICAL – Glow System 16-43
GENERAL INFORMATION
SELF-REGULATING GLOW SYSTEM
The self-regulating glow system reduces the time also the glow indicator lamp illumination time in
required for starting at low temperatures to provide accordance with the engine coolant temperature.
a degree of starting and operation that is identical The resistances of the heating coils which are built
to petrol-engine vehicles by preheating the glow into the glow plugs increase as the glow plug
plugs at super-quick speed. temperatures become higher. As a result of this,
The glow control unit controls both the time during the flow of current gradually decreases, thus
which current is supplied to the glow plugs after stabilizing the glow plug temperature at the
the ignition switch is turned to the ON position and specified temperature.
Glow plugs ON
ST
Ignition switch
Starter motor
Alternator
Battery
16-44 ENGINE ELECTRICAL – Glow System
Resistance between glow plug plate and glow plug body 0.10 – 0.15
(parallel resistance for 4 glow plugs) (at 20 _C) Ω
Voltage between glow plug plate and Immediately after igni- 9 – 11 (Drops to 0 V after 4 – 8 seconds have passed)
glow plug body V tion switch is turned to
ON (without starting
the engine)
SEALANT 16400050021
Engine coolant temperature sensor 3M Nut Locking Part No.4171 or equivalent Drying sealant
ENGINE ELECTRICAL – Glow System 16-45
ON-VEHICLE SERVICE 16400100023
<Reference>
Glow Plug Energization Timing Chart
START
Ignition ON
switch
OFF
Glow ON
indicator lamp
OFF
Glow plug ON
relay OFF
Alternator H
L terminal L
NOTE
After glow time T3 becomes longer as the engine coolant temperature drops.
10 Earth – –
(–)
ENGINE ELECTRICAL – Glow System 16-49
Engine coolant temperature gauge unit ENGINE COOLANT TEMPERATURE SENSOR
(engine coolant temperature sensor) CHECK 16400280031
1.8 Nm 2 1
18 Nm
Removal steps
1. Connector connection
2. Glow plug plate
AA" 3. Glow plug
INSPECTION 16400190044
ENGINE
ELECTRICAL
CONTENTS
IGNITION SYSTEM
GENERAL
OUTLINE OF CHANGE
The following service procedures have been ignition system. Other procedures are the same
established to correspond to the change of the as before.
GENERAL INFORMATION
This system is provided with two ignition coils (A The engine-ECU controls the two power transistors
and B) and two power transistors (A and B) for (A and B) to turn them alternately ON and OFF.
the No. 1 and No. 4 cylinders, and No. 2 and No. This causes the primary currents in the ignition
3 cylinders respectively. coils (A and B) to be alternately interrupted and
Interruption of the primary current flowing in the allowed to flow to fire the cylinders in the order
primary side of ignition coil A generates a high 1-3-4-2.
voltage in the secondary side of ignition coil A. The engine-ECU determines which ignition coil
The high voltage thus generated is applied to the should be controlled by means of the signals from
spark plugs of No. 1 and No. 4 cylinders to generate the camshaft position sensor which is incorporated
sparks. At the time that the sparks are generated in the camshaft and from the crank angle sensor
at both spark plugs, if one cylinder is at the which is incorporated in the crankshaft. It also
compression stroke, the other cylinder is at the detects the crankshaft position in order to provide
exhaust stroke, so that ignition of the compressed ignition at the most appropriate timing in response
air/fuel mixture occurs only for the cylinder which to the engine operation conditions.
is at the compression stroke. When the engine is cold or operated at high
In the same way, when the primary current flowing altitudes, the ignition timing is slightly advanced
in ignition coil B is interrupted, the high voltage to provide optimum performance.
thus generated is applied to the spark plugs of Furthermore, if knocking occurs, the ignition timing
No. 2 and No. 3 cylinders. is gradually retarded until knocking ceases.
Spark plug
Cylinder No. 3 2 4 1
ENGINE ELECTRICAL – Ignition System 16-3
ON-VEHICLE SERVICE
IGNITION COIL CHECK
1. Measurement of the primary coil resistance
Measure the resistance between (+) terminal and (–)
terminal.
Standard value: 0.74 – 0.90 Ω
2. Measurement of secondary coil resistance
Measure the resistance between the high-voltage
terminals and (+) terminal.
Standard value: 20.1 – 27.3 kΩ
–
POWER TRANSISTOR CONTINUITY CHECK
+
1.5 V NOTE
An analogue-type circuit tester should be used.
No. 1 – No. 4 cylinder side
Voltage:
g 1.5V Terminal No.
3 7 8
Applied
Not applied
– +
1.5 V No. 2 – No. 3 cylinder side
Voltage:
g 1.5V Terminal No.
1 2 3
Applied
Not applied
Replace the power transistor if there is a malfunction.
16-4 ENGINE ELECTRICAL – Ignition System
Function Secondary
Ignition voltage
(point D)
Wave damping
reduction section
(point B)
Dwell
section
Secondary
ignition
voltage
waveform
Point C
Time
Observation Condition (The only change from above condition is the pattern selector.)
kV
Secondary
ignition Time
voltage
waveform 0
2 Neutral section
16-6 ENGINE ELECTRICAL – Ignition System
Spark line Plug gap Condition of Compression Concentration of Ignition timing Spark plug
electrode force air mixture cable
Point B: Number of vibration in reduction vibration section (Refer to abnormal waveform example 5)
Point C: Number of vibrations at beginning of dwell section (Refer to abnormal waveform example 5)
Point D: Ignition voltage height (distribution per each cylinder) shows the following trends.
Ignition Plug gap Condition of Compression Concentration of Ignition timing Spark plug cable
voltage electrode force air mixture
Example 1 Spark line is high and short. Spark plug gap is too large.
01P0215
Example 2 Spark line is low and long, and is Spark plug gap is too small.
sloping.
Also, the second half of the spark line
is distorted. This could be a result of
misfiring.
Example 3 Spark line is low and long, and is Spark plug gap is fouled.
sloping. However, there is almost no
spark line distortion.
Example 4 Spark line is high and short. Spark plug cable is nearly falling off.
Difficult to distinguish between this (Causing a dual ignition)
and abnormal waveform example 1.
(V)
Zener voltage
(Point C)
Dwell
section
Primary
ignition
voltage
waveform
Time
ENGINE ELECTRICAL – Ignition System 16-9
Observation Conditions (The only change from above condition is the pattern selector.)
Pattern selector Display
(V)
100
Ignition
primary
voltage
wave Time
pattern 0
Neutral section
Spark line Plug gap Condition of Compression Concentration Ignition High tension
electrode force of air mixture timing cable
Height High Large Large wear High Lean Retarded High resistance
Point B: Number of vibrations in reduction vibration section (Refer to abnormal waveform example 5)
Number of vibrations Coil, condenser
3 or higher Except above
Normal Abnormal
Example 1 Spark line is high and short. Spark plug gap is too large.
Example 2 Spark line is low, long, and sloping. Spark plug gap is too small.
Also, the second half of the spark line
is distorted. This could be a result of
misfiring.
Example 3 Spark line is low, long, and sloping. Spark plug gap is fouled.
However, there is almost no spark line
distortion.
Example 4 Spark line is high and short. Spark plug cable is not properly
connected, creating more than one
spark from the plug.
10 ± 2 N·m
<4G6>
35 ± 6 N·m
3 <4D56-Step III>
2
Removal steps
1. Idler pulley <4G6> 3. Crank angle sensor
2. Timing indicator bracket <4G6>
ENGINE ELECTRICAL – Ignition System/Glow System 16-13
CAMSHAFT POSITION SENSOR <4G6>
REMOVAL AND INSTALLATION
GLOW SYSTEM
GENERAL
OUTLINE OF CHANGE
Due to the introduction of the electronic-controlled injection system, the engine-ECU controls the glow
system. As for the ECU terminal voltage measurement, refer to GROUP 13I – Troubleshooting.
NOTES