Beruflich Dokumente
Kultur Dokumente
SYSTEM
EL
SECTION
CONTENTS
STARTINGSYSTEM
STARTINGSYSTEM- Starter- ...
CHARGINGSYSTEM
CHARGINGSYSTEM* AlternatorCOMBINATION
SWITCH ....
HEADLAMP- Without DaytimeLight Systemand Dim-dipLamp System
HEADLAMP- DaytimeLight SystemHEADLAMP- Dim-dipLampSystemHEADLAMP- HeadlampAimingControl
HEADLAMP
EXTERIOR
L A M P. . . . . . . . . . . .
tNTER|OR
1 A M P. . . . . . . . . . . .
M E T E RA N D G A U G E S
WARNINGLAMPS AND BUZZER
WIPERAND WASHER
HORN,CIGARETTELIGHTERAND CLOCK
REARWINDOWDEFOGGER
LOCATIONOF ELECTRICAL
UNITS
H A R N E S SL A Y O U T. . . , . . . . . . . .
( S . M . J . .). . . . . . . . .
S U P E RM U L T I P L E
JUNCTION
EL- 2
EL- 3
EL- 6
EL- 11
EL. 18
EL.20
EL- 28
EL- 30
EL-
EL-
CI
EL- 64
EL.
OO
ELELELEL-
73
80
88
89
I::L-
J Z
EL- 95
EL-101
E L -1 2 9
URING DIAGRAMREFERENCECHART
ENGINEROOM FAN
E.C.C.S.
A/T CONTROL
ANTFLOCKBRAKINGSYSTEM
POWERWINDOU POWEROOOB LOCK, HEATEDSEAT.
SAT BELT. SUN ROOF.OOORMIRROB
HEATERANO AIB CONDITIONER
J/
EL. 39
EL- 40
EL- 42
EL. 44
EL- 49
LC SCTION
EF & EC SECTION
AT SECTION
BR SECTION
BF SECNON
HA SECNON
HARNESSCONNECTOR
Description
HARNESS CONNECTOR
o All harnessconneclorshave been modifiedto preventaccidenlalloosenessor disconneclion.
o The connectorcan be disconnected
by pushingor liftingthe lockingsection.
CAUTION:
Do not pull the harness when disconnecting the connector.
IExample]
PUSH
( Fo. combinrtbn mri..l
EL-2
RELAY
STANDARDIZED
Description
NORMALOPEN,NORMALCLOSEDAND MIXEDTYPE RELAYS
Relayscan mainlybe dividedintothreetypes:normalopen,normalclosedand mixedtyperelays.
s1!r
eatriq,
5M
BATTERY
s r i YI
z
o
3
sEL881t-l
TYPEOF STANDARDIZED
RELAYS
... 1 t\,4ake
1L4
2M
. . . . . . . . . . . . . .2. . t. 4. .a k e
'
1
N
i
l
l Transler
| 18.............1
. .M
. . .a k e1
1T
EL.3
RELAY
STANDARDIZED
Description(Cont'd)
Tvpe
Outa? Yicw
Circuit
Connector iymbol
and connction
Caa colo.
IT
BLACK
IM
BLUE
or
G REEN
2M
8 ROWN
GRAY
IM,IB
EL4
REALY
STANDARDIZED
NOTE
EL.5
POWERSUPPLYROUTING
WiringDiagram
FOB CENTRALEUBOPE
'a'
/:\
-:
: GNi !N
R:LAY-2
ACC:!SORY
FE!i'
I
4'r
LAl+
Nfl*
:)'ts+
s!\
ne
rode
mrJ.
s
Toae
\!:-
:!ceDt
5F2al:
er'.
f--
a:l'
:!c3pa
lalb:l:
e.E
r.A r.ce
..i
:!aep:-12J
-l
t,'t
mode :
e",9:.e
en,e -e
Ll2l
,:;.
;;',ER *a;;*
Si2 !UE
CA16!'lE e.9
e-a.e
ila.i,
n:.JF
!.r: -
n,J.le
riale
R a I O F: ' s - E | ]
P O W E RD O O RL O C K
SYSTEf
L I G r l T I N GS w i I O f l
b
.IDIT:I
-l11
EN
5!
iGNirlOii Sv!ITCH
.|-r,rrTi
-r---
tuL! r
t.ldFF:TTnxTtf
:
_ ao
2
a)
rD
r ri:
.TTI
ast,rage
[T--r--To]
40
ET TT
TOI
IDT} w L
tr
6ln
lil5
-Tre'I
I3\IT:!\:YS-EII
:f;...cl
iAD I AT!'rR
-.i\:;iE,
F_ : : t s _ : L : \ (
A\: ;-:: 3OX
Arr,l
CD
al!i;altr_j:vsTEll
i5A E4
illtr
- f;;;
. r.i
\ot usedO
:!0A E)
Nct
Jsed
t:A ai
zse6
F!Sl BLE
LIN(
a---
-lREtR
Fin-rl.rp
E]
'f
AATTERY
MELTOSB]
EL-6
POWERSUPPLYROUTING
WiringDiagram(Cont'd)
FTl
eQ Eo
BOD\ GR!UND
ACCESSORY
2
:GNII]'N
RELAY'L
'etffi
I R O Ff i l T I - : A F ' R I E A T E R ,
! T ] C R 1 1R
R E A R ' \ l P E R A : . 1 , 1f r ! 5 t s : F
(i;\
-.--
o\-I-t.\to-
8/n-1 1)
r-
lB
w/6@
EE
BR +
f.
..
frlEg
L-r
- --l
E\Grf= CCTTFC;5.5TEfr
;3ffi
",^-m
. *
^.."
IC;A";l':l',.?EiiJ...oo
I AIL, C.EARAN'E IND
L I CE\CE LAIIP5
T A I L , C L : A R A N C E.,I C E N C E
I L L L | l I N A TI O N L A i P s ,
W A R NN
I G BUZZER,
tsEADLAI'O
AIIJING LONTROL
SIART SI GNAL,
E N G IN E C O N T R O L S Y S T E I ]
I C
Z A R OW A F N N
R/\1+ffi
l! cr
'
Lr']P
R @R/L
rl.
i2
E N C IN E i J O T F A N 5 I 3 --E, I ] , C L O C K ,
A . ] D IO , ' : .
LE!EL I]NI
SYS:Eir
l - - L r N i N A TI O N C O N T R a I L
F u s E8 - 0 c K
ref
|ue
"'.-'-.L--_
20A ts,
t0i tE)
R E A R ! \ I N D O WD E F O G ' E t
L,p
REAR ELOW:P
I]ITOII
E A C K C C O RL I C K
r3
fn
MELTOSA
EL.7
POWERSUPPLYROUTING
WiringDiagram(Cont'd)
EXCEPTFOR CENTRALEUROPE
aa
S R 2 O D Ee n g l n e m o d eL s
(6\
G A1 6 D E e n g l n e m o d e l s
(6\
C I R C UT
I
AREAKER
IGNITION
RELAY.2
S R 2 0 O Ee n g i n e m o d el s
E x c e p t G A 1 6 O Ee n g i n e m o d el s
G;\
@
@
Fo.
Nonth
Except
fo.
-JJt
...rT-H
(file)ltrEl
t-t
A C C E-S S O R
R E L A Y3
II
GDr#r
T TI
0118
- t )TH
)i
Euaope fiode s
POWERVYINDOVY
SYSTEI1
SUN ROOFSYSTEI1
Europe models
North
rrr)l
t.ql
l--lJ I
R H . D . m o d el s
\T/
.a-\
f,ceo!
e.g'.c
R J.O Todc
E.o Foocls
5a20DL
s 6 ti
w tr -D20 e^g'.c
a-
e,..pt 6
@,
t n D m o d es w l t h L D 2 o c n g l n e
@,
r o n N o r t h E u r o p e n o d e s v / i t h G A 1 6 D Ee n
@,
r-ooon mooes
@,
5-ooor mooes
@,
engln.
r x c e p t L H . O .m o d e s w l t h S R 2 O O E
g/.1-
, L . H . o . m o d ct s
trFml@
r+n @
"+-
wl
--T-T-l @
./t--
EI]]
lal
Jat-
-gt
]+
r2r3rFE-t
frEl
I G N I T I O N S W IT C I - ]
S T A R II N G S ' S I E r I
I G N IT I O N 5 . jS T E T
F U S IB L E L I N K
AND FUSE BOX
A 6tl
QtD2s2)
6l
l
\i
,jF
*6
4sa @
*6
L 0 0 A@
5oAQ&@
25A ) & q-)
5 o Aq & O
2sA (-l)
rl0
G L O V VS Y S T E I 1
LINK
FIR'!V,?39"cl
C H A R GN
I G 5Y5TEI1
R+l
ABSO
TTE
MEL709B1
EL
POWERSUPPLYROUTING
WiringDiagram(Cont'd)
oR+@
o"re*@
ACCESSORR
Y E L A Y I G N IT I O N
-2
-1
RELAY-I
T-t
r:t
T-t
lan
ll /rn
l/rnll
ftlt
lt-rjl I
D O O RI l I R R O R W I T H I I I R R O RH E A T E R ,
REAR WIPER AND WASIIER
R A D IA T O R F A N R E L A Y ,
REAR HEAIER SYSIEN, REAR A,zC
ilo6fE
S9i'ff;o'.'"'n
TAIL, CLEARANCE
L I, C E N C E A N D
I L L U I l I N A TI O N L A I 1 P S ,
i Y A R NN
I G BUZZER
SIARI SI GNAL,
E N G IN E C O N T R O LS Y S T E I l
G+M
G/B+m
",**ffi
BR+m
I l E T E R A N O G A U G E SW
, ARNIIG LAI1PS,
SIJISTF
iISEI
3}3IEX
HF
E N G I N E R O O t l F A N S Y S T E I l ,C L O C K ,
A U D IO , C I L L E V E L U N IT ,
I L L U I l I N A T I O N C O N T R O LS Y S I E I I
r
airD
'J
FUSE BLOCK
"l P.dP,
t" P.dP,
*L
2 0 AO
L 0 A6
I O A D
L s A@
r0AO&)
L s A@
L 0 A@
lsA @
EL.9
POWERSUPPLYROUTING
Fuse
a. It fuse is blown, be sure to eliminatecause of problem
new fuse.
beforeinstalling
b. Use fuse of specifiedrating.Neveruse fuse of more than
specifiedrating.
c. Do not installfuse in obliquedirection;
alwaysinsertit into
luse holderproperly.
d. Removefuse lor clock if vehicleis not used for a lono
periodof time.
FusibleLink
A meltedfusiblelinkcan be detectedby visualinspection.
lf its
conditionis questionable,
use circuittesteror test lamp.
CAUTION:
a. ll lusible link should melt, it is possible that critical circuit
(power supply or large current carrying circuit) is shorted.
In such a case, carefully check and eliminate cause of
problem.
b. Never wrap periphery of fusible link with vinyl tape.
Extreme care should be taken with this link to ensure that
it does not come into contact with any other wiring harness
or vinyl or rubber pans.
EL-l0
BATTERY
CAUTION:
a. lf it becomesneoessaryto start the enginewith a booster
batteryand jumpercables,use a 12-voltboosterbattery.
b. Afterconnec-ting
batterycables,ensurethatthey aretightly
clampedto batleryterminalslor good contact.
How to HandleBattery
METHODS OF PREVENTINGOVER-DISCHARGE
The followingprecaulionsmust be taken to preventoverdischarginga battery.
o The batterysurface(particularlyils top) should always be
keptcleanand dry.
lf the top surface of a battery is wet wilh electrolyteor
water, leakagecurrentwill cause the batteryto discharge.
Always keep the batteryclean and dry.
Whenthe vehicleis not goingto be usedovera longperiod
ol time, disconnectthe negativebatteryterminal.(ll the
vehiclehas an extendedstorageswitch,turn it off.)
t
)
,r/
"
s E L1 9 1
EL-11
BATTERY
How to HandleBattery(Cont'd)
No.mal batia.y
____- S{rloharadb.riarv
Chrti't|
volrrt
"_j:=
Ch.rginf
Yolt.g.
Chartingcsr..nr
Ch|rgin' curr.nl
Ogr.rion ol ch.rt
SULPHATION
When a bafteryhas been left unattendedfor a long period of
time and has a specificgravity ot less than 1.100, it will be
completely discharged, resulting in sulphation on the cell
plates.
Comparedwith a batterydischargedunder normalconditions,
the current flow in a "sulphated" battery is not as smooth
althoughits voltageis high duringthe initialstage of charging,
as shown in the figureat the left.
SPECIFIC
GRAV]TYCHECK
Th6rmornt6a
Hydro.n t.r
e
U
,-a
,rt a
Thsmoniatea
t.$
|.2t
r.2t
t.2a
l.z,
1.20
r.ta
t.ta
t.ta
a t.t2
r.ro
||al
t32t
t50]
tat|
Elactrolvta latnoaratura
tr]
'C
fF,
SEL197P
EL.l2
BATTERY
BatteryTest and ChargingChart
V ISUAL INSPECTION
.Chcct batary cata lor crack! or bat'tdt
. Chack ballary t.rmrnalt tor ctnagc
.|lthcditf.rlnc.b.tw.cnth.maxrndmlh.G|!ct.o|ytc|.*||nct||t'rwnhinl0mm(o-39inl.
r t r sO . K
o.K
R.9l.cr
bfiarY.
C H E C KI N G S P E C I FI C G R A V I T Y
'Sp.cilic Gr.v(y Ch.ck"
Rrl.. ro
SLOWCXARGE
R.l.r to 'Ar slow
Ch.rg.'.
STANOARO CHARGE
R.l.r to "B: St.ndard
.
c,r.rF
CAPACITYTST
R.lcr to "Chart ll
CAPACITY TEST
R.{.. io "Ch..l ll
N.G
o.K.
N,G
Radv
lor ura
CAPACITY TST
'
R.l.r to "Ch.rl ll
O U I C KC H A R G
Ft.l.r lo 'C Ou|ck
Ch..ga".
o.K. N,G.
Rcady tot ura
. Mount batlary .earn
a.id ch.ck loot lar'
mrnalt. Alao, chack
orhar r.latad o.curlt
Ra9l.c.
battary.
C H C KI N G S P C C I FI C G R A V I T Y
R.l.r to "sgacilic GravilY Ch'ck"
RECHARGE
'Cr Ourcl Ch.tg. .
Rclcr to
'dC
-cvt
ri. tt btna.Y |rtFa.aol?t
clr'{'
Alt.v.
t rad F l, rrog dr4i.r..
i. b'lot
in |.|rF?atuna
b.rtaw th-r
8dC fiadFl.
CAPACITYTEST
R.t.r to "Ch.n ll
N.G.
R..dy
tor uat
. 'STAIIDARO
CHABOE" la ..conmandad
R.pl.E.
br(arv
EL.13
ch"g|ng'
O U I C KC H A R G E
Rrl.. !o "C: Ouicl
Chrrta"
ta6 tri|r.
. tiir tlu-td:
CAPACITYTEST
n.1.. ro "Ch..r ll
o.K
R.-v
N.G,
Rtlact
BATTERY
BatteryTestand ChargingChart(Cont'd)
F i g .1 O I S C H A R G I N G
CURRENT
(Lo.d re5t6r)
Tatr ul|ng load taata.
cuiienr (A)
28819R
Follow mrnut.crur!r'r
inrtrudion. io chck and
d.t.rmr^Grl ba[ary il
R..dy
tor u..
Go to nlri
ittp
EL-14
90
46824A
55D23R
180
80D268
195
95D31R
244
I15D31R
244
BATTERY
BatteryTestand ChargingChart(Cont'd)
A
SLOW CHARGE
F 1 9 .2 l N l T l A L C H A R G I N G C U R R E N T S T T | N G l s t o w c h . r g . ,
\8ATTERY
TYPE
\
coN-\
VERTEO\
SPEC|FtC \
GRAVITY \
t2 ro l5 voltr
tr
cc
cc
cc
(D
7.0
{A'
8.0
tAt
4.0
tA)
Bdow I .l0O
. C h a . g cb r t . r y .
. C h . c k c h . r g a n 9v o l t . g . 3 0 m r n u r c r a l t c r
rra.tinq tha batla.y chrrgc
c!
t!
5.0
{a)
lo.0
(At
ft
14.O
r 150 1 200
C H E C K I N GS P E C I FI C G R A V I T Y
R a l c r t o " S o a c r l r cG r a v r t v C h a c t '
Go Io
',CAPACIIY
TEST,'
G o t o , , C A P A C I T YT E S T ,
CAUTION:
a. Set charging current to value specified in Fig. 2. lf charger
is not capable of producing specified current value, set its
charging current as close to that value as possible.
b. Keep battery away lrom open flame while it is being
charged.
c, When connecting charger, connect leads first, then turn on
charger. Do not turn on charger first, as this may cause a
spark.
d. lf battery temperaturerises above 60"C (140'F),stop charging. Always charge battery when its temperature is below
60"c (140"R.
EL-15
BATTERY
BatteryTest and ChargingChart(Cont'd)
SETTING
F i s . 4 l N t T l A LC H A R G I N GC U R R E N T
lst.nd.rd ch.rerl
A. STANOAROCHARGE
\BATTERY
TYPE
\
coN. \
Cha.g. b.ttrry
VRTEO\
S P E C | F T\C
GRAVITY \
9.O(a)
8.0 (A) l r . o t a l
r . 1 6 0- 1 . 1 $
lor S hou13
1 3 . Ot A l
7.0(Al LO {A)
Coruct
Fq
addrt|onal
charg?.3
cu.r.nr rrint
th. i.bl.
Pcr
5, it nccgrary
F r 9 .5 A O D I I I O N A L
Go ro "CAPACITY TEST
'
r 150 I 200
C h a r g ct o r 3 . 5 h o u r s
e l r n r t i a lc h a r g , n g
G o I o . , c A P A c I T YT E S T ' '
CAUTION:
a. Do not use standard charge method on a battery whose specific gravity is less than 1.100.
b. Set chargingcurrentto value specifiedin Fig.4. It chargeris not capabteof producingspecified
currentvalue,set its chargingcurrentas closeto that valueas possible.
c. Keep bdtery away from open flame while it is being charged.
d. Whenconnectingcharger,connecileadslirst, then tum on charger.Do not turn on chargerfirst, as
this may causea spark.
e. lf batterytemperaturerises above 6O"C(lril)"D, stop charging.Always chargebattery when its temperatureis below60"C(140"D.
EL.l6
BATTERY
BatteryTest and ChargingChart(Cont'd)
C
OUICK CHAFGE
F r s .6 l N t T l A L C H A R G I N G
C U R R E N T S E T T I NAGN o
CHARGI G TIME lorick chrrg.)
1
\\
O a a r r h i n a r ^ r t . l c h a r g r n gc u r r ! . 1 l a t t r n 9 a n d
c h r r g r n gr r m c l r o m t p . c r f i c g . a v r l y , r l t l r r r n g
ro Frg 6
BATTERY
TYPE
c!
\\-cuR\
\
coN. \ RENr
V E R T E D\ A I
SPECTFTC
\
GRAVITY
1 0t A l
(!
iIC!
_t
cD
oo
3?
15lA)
20 (A)
30 (a)
1 1 0 0- 1 . 1 3 0
2.5 hour3
r .r 3 0. 1 .t 6 0
2.Ohour3
40 (a)
1 . 1 6 0- r . 1 9 0
1 . 1 9 0- 1 . 2 2 0
O.75 houri (45 mi^.)
Above 1.220
G o r o " C A P A C I T YT E S T "
C h . c k b a r t e r y t y p a n d d e t c r m r n ? t h s p e c i l j e dc u r r e n t u t r n g t h e l a b l e
a l r e r r r a r r ' n 9 c h a . g r h 9 ,a d t u r i h ? . t o l c h a r g r n gc u r r ^ l r 3 n o r n a c a r g f v
CAUTION:
a. Oo not use quick charge method on a bdtery whose specific gravity is les.sthan 1.10O.
b. st initial charging curent to valr.p specified in Fig. 6. lf charger is not capable of producing spe
cified current value, set its charging current as close to that value as possible.
c. Keep battery away from open llame while it is being charged.
d. When connecting charger, connect leads tirst, then tum on charger. Do not turn on charger tirst, as
this may caus a spark.
ServiceDataand Specifications(S.D.S.)
Destination
ForNorthEurope
Engine
SR2ODE
GA16DE
LD20tl
Type
46824R
28819R
1245
12-30
95D31R
'12-80
CapacityV-AH
EL.17
SR2ODE
GA16DE
LD20rl
80D26R
't245
55D23R
11 5 D 3 R
1
12-60
12-aO
SYSTEM
STARTING
WiringDiagram
clreor
e'..pt
fi)
e n g i n e m o c J es
@
I
@;
615)o
(cl0)[r
n
[-r]
/:;,\
!.&_r ! tr
1l
Ll
@
.:^r
ii
ad)
6i
{pT
.)-li
!@.,
UNJ
_]
5TAFI:Ii
|]c r0R
AND/.i \,
!::]-/
EL-18
STARTINGSYSTEM
Trouble-shooting
lf any abnormality is found, immediately disconnect battery negativeterminal.
-
s3
lo
!
h
96
6
E
E
q
I
g>
6 3+
-E
a 39
9:
ih
::
H:
F
d b;
o(Ig
;r;
b
q-_
;-9:
qi"
:;
55;
Ee
io
Eis.E:
E5 s =3 s
Coo.
eB
EO
L'l;ct
!
>E
69
. EEE
6
9
1 e =F
;9
9
I
!.
iq
=2
.p6.
e!;9.
;> ;i
i;
Oo
O9
E
99dgP
E
2
E
qF;
9;
6
E
o
-9
E
I
q
cr
d
O 5(!
-9
o
2
og
o-
EL-l9
STARTINGSYSTEM- StarterConstruction(Mitsubishimake)
M1T6681(SR2oDEengine)
O
O
O
O
@
@
O
Rear cover
Metal rear cover
Brushspring
Brush
Brushholder
Fieldcoil
Armature
O
@
@
@
@
@
Pack
Magneticswitch
Shittlever
Gearcase
Stopperprnion
Pinionshalt
EL-20
@ Gear
'rt Hrnron
@ Bearing
@ Housing
(} Startermotorassembly
(t Gear case metal
STARTINGSYSTEM- StaderConstruction(Cont'd)(BOSCHmake)
9q)0.3.31424 (LlI2Ollengine)
w$
FF.-,
wk
I@----.
@ /K:b@;-"
O
O
O
O
@
O
Bearing
Gearcass
Bushing
Pinionassmbty
wheelcrown
Plate
O
@
@
@
O
@
Armatureassembly
Armaturelrame
Solenoid
shitt tever
Pinionshatt
Brush
EL.21
@
@
@
@
O
Dust cap
Rear cover
Fieldcoil
Brushspring
Brushspring guide
STARTINGSYSTEM_ StArtEr_
Bemovaland Installation
SR2ODEENGINE
ENGINE
GA16DE
N m 1 r s - mh . r u 1 y(
LD2OIIENGINE
Dismantling(SR20DE,
GA16DE)
REMOVINGTHE MAGNETIC SWITCH
the feed wire irom the solenoidterminalaf .
o Disconnect
Removethe screws if , securingthe switchto the end hous.
ing O
o Liftthe frontend of the solenoidto disengagethe plunger
from the engagemenllever.Removethe solenoid.
EL-22
STARTINGSYSTEM_ Starter_
Dismantling(SR20DE,
GA16DE)(Cont'd)
REMOVE THE BRUSH PLATE
o By meansof a pliers,move the end @ of the brushsprings
Irom the rearlo the left side of the brush.This is to release
the brushesfrom pressure.
Repeatthe same operationfor the rest of brushes.
o Take out the brush plate assembly.
REMOVING
THEFIELDCOILANDTHEARMATURE
o
(SMODE engine)
Take care not to lose the ball located inside the planeting
assembly.This ball is for bearingthe armatureend.
SR20DEengine
Dismantlinggearcase
EL-23
STARTINGSYSTEM_ Starter_
MagneticSwitchCheck
Beforestartingto check,disconneclbatterygroundcable.
Disconnect"M" terminalof startermotor.
Continuitvtest.
Continuilybetween
Continurty
Action
Yes
o.K.
No
Replace
Yes
o.K.
No
Replace
Pinion/Clutch
Check
1. Inspectpinionteeth.
o Replacepinion if teeth are worn or damaged.(Also check
conditionof ring gear teeth.)
2. Check to see if pinion locks in one directionand rotates
smoothlyin the oppositedirection.
o lf it locksor rotalesin both directions,or unusualresistance
is evident.... Reolace.
REDUCTIONGEAR TYPE
3. Inspectreductiongear teeth.
o Replacereductiongear it teeth are worn or damaged.(Also
check conditionof armalureshaft gear teeth.)
EL.24
STARTINGSYSTEM_ Starter_
BrushCheck
BRUSH
Checkwearof brush.
Wearlimit length:
Referto S.D.S.
wear...Replace.
o Excessive
BRUSHSPRINGPRESSURE
Checkbrushspringpressurewithbrushspringdetachedfrom
brush.
Springpressure(with new brush):
Referto S.D.S.
o Notwithinthespecified
values...Replace.
S r u s hs p r i n g
BRUSHHOLDER
1. Performinsulation
testbetweenbrushholder(positive
side)
Negative
brush
rsolat
Positivebrush
ArmatureCheck
1. Continuitytest (betweentwo segmentsside by side).
o No continuiw...Reolace.
EL-25
STARTINGSYSTEM_ StaTteT_
ArmatureCheck(Cont'd)
2. Insulatrontest (betweeneach commutatorbar and shafl).
exrsts.... Replace.
o Continuity
3. Check commutatorsurface.
o Rough... Sand lightlywith No.500 - 600 sandpaper.
Undercutprocedures
Round
-->-
O.
IO.O2O.
^/
r{\\ilrr,
\\\\r'////
Correc!
Sr
F ,t e
rF:=
E1.26
STARTINGSYSTEM- StarterAssembly
greaseto lubricatethe bearing,gears
Apply h igh-temperature
and frictionalsurfacewhen assemblingthe starter.
Care{ullyobservethe followinginslructions.
Assemblyat next order:
Gear case
.
Pinionassemblyand shiftlever,musl be mountedtogether.
Ringand pinionshaft.
.
(sR20DE)Put the ball in its hole.
.
o Fieldcoil and armatureframe,must be mountedtogether.
Don'tlockthe holesof screws.
o Armaturef rame.
o Brushholder.
Checkthe correctalignmentof holesof screws.
o Rear cover.
Magneticswitch.
.
(S.D.S.)
ServiceDataand Specifications
M TSUBISHI
Type
t\.rf
1T6 058 I
SR20DE
Engineapplied
Systemvoltage
BOSCH
M002T25481 9000.3
31424
GA16DE
LD20rl
12
No load
Terrnrnavoltage
t1
115
Current
[ra.x 88
50
[,,lorelhan 150
tulorethan
3 000
5.600
Less than
4,500
288
28 8 (1 134)
2 8 . 9( 1 . 1 3 8 )
12.0
1 20 ( 4 . 4 7 2 )
7 (0 028)
Bevolubon
Brushspringtenson
EL.27
rpm
N (kg, lb)
13.7 25.5
(1.4 26
3 . 1- 5 7 )
137
( 1. 4 - 2 . 6
3.1
16.5 32.0
( 1 . 7- 3 . 3
3.7- 7.3)
CHARGING
SYSTEM
WiringDiagram
ffi
dd
'HEE
.<
-Fr
Fl-1
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t44
E
o
t-.t-.]
-H
t-f1
t-t-1
H
t:]-
c
rr,
F;
ll
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8sF
r?r r
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9t I
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o
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o
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frt6
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EL.28
.9
!F
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6 i, ofo)to6
F 9
n
HHI'::IP:
ooo(,
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it:
urr!
@@@@@@ec
CHARGING
SYSTEM
Troubleshooting
Beforeconductingan alternatortest, make sure that the batteryis fullycharged.A 3o-voltvoltmeterand
suitabletest probesare necessaryfor the test. The alternatorcan be checkedeasilyby relerringto the
InsoectionTable.
Betore starting troubleshooting, inspec,t the fusible link.
WITH IC REGULATOR
l/Vrrh.lt.rn.to. iid. L r.rm;nel
g r o u n d a d , I n t c r n a l 3 h o 7 to c c u r i
whln + diod. ri 3hoit-crrcurtod.
|;;;;-l
I burb Repl.ceI
Proceed I
I end
- -l'."r-"
' S G e4 l l o r g r o u n d i n g F t e r m r n e l .
\--6;;"*;l
,/
( H I T A C HI
lRepleco.
I
I
) F"-"r"""c;:l
E."*;;I
- -lo, a.c.c
- F;"d"-l
_-l
--F*
-@
D-|;;;d'cnc'l
/
Morethan 15.5V
I
__l
---l;*
lR6elacs.
1 3r o l 5 V
EL-29
CHARGING
SYSTEM_ Alternator_
Removaland lnstallation
SR2ODEENGINE
pl
ro :r t.6-p1 12 i,,i
."-"'-E
Z|o! as. so
( 4 . 6, 6 . 1
33 - 44)
fq:
r?)
N m { K om . t l - l b )
GA16DEENGINE
--'-.!
t)
N m r r . t j ma , b )
r e - z r t 16
f)
EL-30
21 1p,i5t
//
rz so(38 s r 27 37r
EEL0]3
SYSTEM_ Alternator_
CHARGING
Removaland Installation(Cont'd)
EL-31
CHARGING
SYSTEM- AlternatorConstruction
SF2ODEENGINE _ LR.19O-719
GA16DE ENGINE_ LR-18G735
*>d0
(n
.eu'r6
,"d
@shM*
(v\
. \
" .\ Y
.'
.i,
,9
O
O
(D
@
pump
Vacuum
Rotor
Frontcover
Fan
.9 Pulley
O stator
O Diodeplateassy.
EL.32
@ Rearcover
O Voltageregulator
f,Q Brush
CHARGING
SYSTEM- AlternatorDisassembly
BEAR COVER REMOVAL
CAUTION:
Rear cover may be hard to remove because a ring is used to
lock outer race of rear bearing. To facilitate removal of rear
cover, heat iust bearing box section with a 2oGwatt soldering
iron.
Do not use a heat gun, as it can damage diode assembly.
S o l d e r i n ga r o n
{200W capacirv,
RotorSlip RingCheck
1. Continuity
test
o No continuity...Replacerotor.
Ohmmeter
2 mm (0.O8in)
2. Insulatortest
exists... Replacerotor.
. Continuity
3. Checkslip ringfor wear.
Slip ring minimum outer diameter:
Referto S.D.S.
BrushCheck
EL.33
CHARGING
SYSTEM- AlternatorStatorCheck
To test the stator or diode, separatethem by unsolderingthe
connectingwires.
CAUTION:
Useonly as much heatas requiredto melt solder.Otherwise,
diodeswill be damagedby excessiveheat.
1. Continuity
test
o No continuity...
Replace
stator.
2. Groundtest
o Continuity
exists...Replace
stator.
MAINDIODES
r
o
NegativeO
Diodeterminals
Continuity
Yes
Diodelerminals
Positivediode plate
No
Negalivediode plate
Oiodeterminals
No
Oiodeterminals
Negativediode plate
Yes
EL-34
- AltematorCHARGING
SYSTEM
StatorCheck(Gont'd)
SUB-DIODES
o
o
Assembly
Carefullyobservethe followinginstructions.
eachstatorcoilleadwireto diodeassemo Whensoldering
bly terminal,carryoul lhe operationas fastas possible.
Crolin
REARCOVERINSTALLATION
.nia|| ,Dod.l
1. Beforeinstalling
frontcoverwithpulleyand rotorwith rear
cover,push brush up with lingersand retainbrush by
insertingbrushliftwireintobrushlift holelrom outside.
pull out
2. After installingfront and rear sidesof alternator,
brushlift wire.
EL5
SYSTEM- AlternatorCHARGING
(S.D.S.)
ServiceDataand Specifications
ALTERNATOR
LR190-719
Type
1 R 1 8 0 - 7 3 5 I 120.335.000
HITACHI
Engine
Nomina rating
V-A
SR2ODE
GAl6DE
LD20rl
12-90
12- 80
12-90
Groundpolarity
Negalrve
l\,4inimum
revolutionunderno-load
(When13 5 voltsis applred) rpm
Hotoutputcurrent
Regulatedoulpulvollage
A./rpm
Brushspringpressure N (9,oz)
E1.36
10500
234300
63/2500
87/5000
BOSCH
mm (1n)
2311300
63/2500
77l5000
16.5/1300
68.5/2500
B3/5000
1 4 . 1 14.7
6 0 (0 236)
t 010.276)
1.0003.432 1.8633.040
(102 350,
( 1 S 0- 3 1 0 ,
3 . 6 0- 1 2 . 3 4 ) 6 7 0 - 1 0 . 9 3 )
26.0
( 10 2 4 )
306 (1.20s)
1 00 { 0 . 3 9 )
1 . 9( 1 9 4 ,
6 84)
1 s . 3( 0 6 0 2 )
COMBINATION
SWITCH
CombinationSwitch/Check
REARWIPER
AND WASHER
-wrpEa
o"fr
TURN
a; --r
WASH& WIPE
OFF
Lf
INT
1ST
in,A
tl {
t\
-r-\
OFF
LIGHT
;*-a
\\1t
\-:=///
o
ll
F
LO
Ht
a-Lj
F N O N TW I P E R
AND WASHEF
a]
tq-Tfll
til
.td
Iii ,6iGT,
l-l
l , L 6 l eL , r tIr
L r g h t r n ga n d
rurn srgnal
FRONTWIPERAND
WASHERSWITCH
REARWIPERAND
WASHERSWITCH
PER
\ OFF I NT
WIPE O F F WIPE
I]I GH
LIGHTING SWITCH
HORN SWITCH
TURN
SIGNAL
swtTcH
NmNn
llo
ol
f2TdTm
ETT r0l
l-1
tGt
INTERMITTENT
wlPEF VOLUME
EL-37
COMBINATION
SWTCH
Replacement
o
SEL39OL
EL.38
ttf
ffi
T.-l
m
G
ffii
ff-l
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L
t=
t-:J!.ll=
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o
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rf
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)
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+
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;\
fI Ii f f
EL.39
ur
\ll,
'\-,--l
,/
- DaytimeLight SystemHEADLAMP
Operation
After startingthe engine with lhe lightingswitch in the "OFF"
position,the headlamplow beam and clearance,tail, license
and instrumenlillumination
lampsautomatically
turn on. Lighting switch operationsother than the above are the same as
conventionallight systems.
Engine
Wjth enginestopped
OFF
Lightingswitch
Wrthenginerunning
2ND
1ST
c
o
High beam
LOWDeam
x
o
o
o
Licenseand instrument
illumination
lamp
Headlamp
OFF
c
o
o
o
1ST
o
o
c
o
o
o
2ND
c
o
O: Lamp"ON"
X: Lamp"OFF"
El: Added functions
Schematic
] GNI TI ON SWI ICIl
ON o. START
BATTERY
L]GNTING SW]TCH
tt
)?
3
OAYIIIlE L] GII
C O NI R O L U N ] T
HEAO.
H] GH AEAM
] NDI CAIOR
Rf.
ALIERNAIOR
LO20 ensine
mode s
Exccpt
eng ine
LDz0
node
MEL675A
EL4O
- DaytimeLightSystemHEADLAMP
WiringDiagram
t
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iY
i
Y
-u \Y/
ea^an. e
amF+
-..
ir F
ril trTT
FE rq
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ffi
tTt
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To.
ffi
q
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o
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t,t -F
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trTl
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FF ffi
H fl
-T-t F?r
Tt l
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:
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.a .a
ttr
fT_
-T-
G ra , -
6lr6
-----1
c
o
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al E
t, til
- /:\
3- rR."i
t
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/:\
=l
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rldadd
n o
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F:u
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.4
trT-l
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h:i
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/a a.n
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rEl
5
6),
Frl
t-,
reJc
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+so
=
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I
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ffi'
fl
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t-*,-'
t!.4E16744
EL.41
ON
OFF or ACC
OFF
Lighting switch
1ST
2ND
High beam
c
o
Low beam
Dimp-dip
(Low bam)
Licenseand instrument
illumination
lamp
Headlamp
c
o
2ND
1ST
OFF
(.
o
o
O: Lamo "ON"
X: Lamo "OFF"
Cl Added functions
Schematic
I G N JI ] O N S W JI C H
0N o. START
AAITERY
L ] G I l T ] N G S W JT C H
To c a.ance,
ta i I
I iccnse
amps
O]I1'O]P LJGHT
C O NI R O L U N I I
9
?
it
]?
HI GH 8EAI1
JN O ]C A I O R
MEL6/78
EL42
6,3
r_re'jt =
Tr]
Tr"l
rn
ffi
\y
T5-1
!'t-
-T-.1-.1|
E
LG,S_
F. s -Gll
H +fm
:J^-r
LZ
OO
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tq
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u or----f-t-l-t-t-
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a66l
ol :l:9dc9{,!
i - -
-L _-
-;:+H++++H+a
-----6-d-:',P
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/ax\ I
Lti19
bl tr<<:ir"li(7
dc rrrrrlrrri
co
f$a
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\9
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II
MEL676A
- Headlamp
HEADLAMP
AimingControlDescription
The verticaldirectionof the headlampprolection
can be adjustedlrom insidethe vehicleto prevent
lhe headlightbeam axis from facingupwarddue to a changein the numberof occupantsand load
conditionsin the vehicle.
Battot^y
R c v cn a I n 9
t cIlv
Fon /ard
.e lay
No cont Inu lty
(Whltc po.t I or,
ContInu lty
Almlno
gw I tc6
S E N S O R( R o t E t I n a
por-t I od
Thoi. trto.
AI I1ING I1OTORUNI T (R. I-t )
Rcve.aIno
rc l!y
Contlnu lty
EL-44
EnI a.ocd
gont l6n A
- Headlamp
HEADLAMP
AimingControlDescription(Cont'd)
l J p a n d d o w n a d j u s t r n gs c r e w
A r m r n gm o t o r u n t t
CIRCUIT
OPERATION
IExample]
Aimingswitch"0"
o
0
l
2
3
Aimingswitch"1" - "0"
o
EL-rts
- HeadlampAimingControlHEADLAMP
EL.45
- HeadlampAimingControlHEADLAMP
WiringDiagram
/:\
6
o *#l
e -{-rl
---t^/A
c
E^
f oc
,a\I*'Ha
)'+t'I
\?
n l
.
a
:
Lrn
-Ll
6
i;
L-l
o
zu
tr
o
EL47
- Headlamp
HEADLAMP
AimingControlA
Troublediagnoses
5rCil
Lightingswrlch lsl
ts
EI
'H)
P O W E RS U P P L YC I R C U I T
CHECK(For aimingswitch)
Check if 12 voltsexistbetween
t e r m i n a l sO a n d a O .
A I M I N GS W I T C HC H E C K
Checkcontinuitybetweenterminals at each switchposition.
mtri
mti
G R O U N DC I R C U I TC H E C K
F O RA I M I N GM O T O R
Checkcontinuitybetweenterminals rj) and body grround.
Continuity exists ... O.K.
Bepairharnessbetweenaiming
motorand body ground.
P O W E RS U P P L YC I R C U I T
CHECK
(For aimingmotor unit)
Check il 12 volts existbetween
t e r m i n a t s' O , @ , @ , @ a n d
Check harnessbetweenaimjng
switchand aimingmotor unit.
Voltmeter
Voltage [V]
termina
o
.;\
Approx.12
o
Approx1
.2
o
o
Aiming
switch
posrtron
"0"
"0"
"1"
"1"
Approx.12
0
A p p r o x .1 2
0
EL.48
,.3,,
"3"
HEADLAMP
Bulb Replacement
PUSHIo
_@.
PUSH
lo
AimingAdjustment
headlampaimingadjustment,
use an aiming
When performing
machine,aimingwall screenor headlamplester. For operating
instructionsof any aimer,it shouldbe in good repair,calibrated
and used accordingto respectiveoperationmanualssupplied
with the unit.
lf any aimeris not available,
aimingadjustment
can be doneas
Iollows:
For details, reter to the regulations in your own country.
CAUTION:
a. Keep all tires inflated to correcl pressures.
b. Place vehicle and tester on one and same flat surfacec. Seethat there is noload in vehicle (coolant,engine oil filled
up to correct level and tull tuel tank) other than the driver
(or equivalent weight placed in driver's position).
lF-bl
l3 2 I 0l
,n
L,\_-! Sl l
CAUTION:
Be sure aiming switch is set to "0" when performing aiming
adiustment on vehicles equipped with headlamp aiming control.
[)
\/
EL-49
HEADLAMP
AimingAdjustment(Cont'd)
LOWBEAM
1. Turn headlamplow beam on.
2. Use adjustingscrewslo performaiming adjustment.
o First tighten the adiusting screw all the way and then make
adiustment by loosening the screw.
Heighr ol -
q$ = acceenerenrruce
EL-50