C Engine Electrical: To Index
C Engine Electrical: To Index
C Engine Electrical: To Index
C ENGINE ELECTRICAL
1KR-FE --------------------------------------------- C - 1
ARTICLES TO BE PREPARED ----------- C - 1
STARTER ------------------------------------------ C - 1
CIRCUIT DIAGRAM-------------------------- C - 1
UNIT CHECK ---------------------------------- C - 2
DISASSEMBLING AND
ASSEMBLING --------------------------------- C - 3
DISASSEMBLING AND
ASSEMBLING --------------------------------- C - 8
ALTERNATOR ---------------------------------- C - 21
DISASSEMBLING AND
ASSEMBLING ------------------------------- C - 21
CIRCUIT DIAGRAM ------------------------ C - 22
C–1
1 1KR-FE
1-1 ARTICLES TO BE PREPARED
1-1-1 ARTICLES TO BE PREPARED LIST
SST
Shape Part No. Part name
Tool
Soldering iron
Instrument
Torque wrench,Spring separates ,Dial gauge,Vernier calipers,Voltage tester,V-shaped blocks
Lubricant,adhesive,others
High-temperature grease
2 STARTER
2-1 CIRCUIT DIAGRAM
IG SW(ST)
AM2
(30A)
30 50
Battery
Starter
T11E8507ES20
Starter performance
Rated output (kW) 0.7 1
Non-loaded characteristics 50 A or less [at time of 11.5 V] 90 A or less [at time of 11.5 V]
6000 rpm or more 3000 rpm or more
Number of pinion teeth 9 9
Rotating direction Clockwise as viewed from pinion side Clockwise as viewed from pinion side
Weight (kg) 3.25 3.15
C–2
2-2 UNIT CHECK
CAUTION
• Each check should be performed within a short length of time (3-5 seconds).
2-2-1 CHECK
(1) Pull-in check
1.Apply the battery voltage to the terminal ö. Connect the
earth wire to the terminal C and the starter body. Ensure
that the pinion gear jumps out.
CAUTION Cterminal
• This test should be carried out with the lead wire of the %0terminal
magnet switch disconnected.
T01E9501ET10
Cterminal
T01E9502ET10
T01E9503ET10
a T:9.8&0.2 {100&20}
k
T:8.3&2.5 {85&25} i ~l
h
m
c
k b
d
f T:5.9&1.5 {60&15}
j
e
T11E9053S20
Unit: N;m{kgf;cm}
~: Non-reusable parts
(2) Disassembling and assembling procedure
1 a Switch Ay, magnet 8 h Armature Ay, starter
2 b Bolt, through 9 i Lever, starter drive pinion
3 c frame Ay, starter commutator end 10 j Housing Ay, starter drive
4 d Insulator 11 k Nut, pinion stop
5 e Brush, spring 12 l Ring, snap
6 f Brush, holder 13 m Clutch S/A, starter
7 g York Ay, starter
T01E9507T10
T01E9508T10
T01E9509T10
T01E9510T10
T01E9512T10
C–5
2.Check the continuity between the yoke and the field coil
side brush.
SPECIFIED VALUE: Continuity exists
T01E9511T10
T11E9054ET10
T01E9551T10
T01E9517ET10
T01E9518T10
T01E9519T10
2.Pass the pinion stop nut at the rear side of the starter clutch S/A to the shaft of the starter armature.
(2) Ring,snap
1.Fit the snap ring into the shaft groove section of the starter
armature, using circlip pliers or the like.
T01E9520T10
C–7
2.While holding the outer periphery of the clutch S/A, lightly
tap the forward edge of the rear side shaft of the starter Front side
armature, using a plastic hammer so that the snap ring
may be fitted into the inner groove of the pinion stop nut. Rear side
T11E9055ET10
3.Pass the pinion stop nut at the front side to the starter Apply heat-resistant
armature. grease.
CAUTION Front side nut,pinion Rear side nut,pinion
stop stop
• Install the pinion stop nut to the shaft section of the
Pinion
starter armature, while confirming the correct direction
of the pinion stop nut.
(If the pinion stop nut should be installed in the oppo-
site direction, it would cause abnormal noise.) Ring,snap
Armature shaft
T11E9056ET10
T01E9521T10
T01E9522T10
T11E9057ET10
C–8
2-4 DISASSEMBLING AND ASSEMBLING
2-4-1 DISASSEMBLING AND ASSEMBLING PROCEDURE(1.0 KW TYPE)
(1) Components
p
T:8.8&1.0 {90&9}
T:9.8&2.0 {100&20}
a
T:8.3&2.5 {85&25}
q T:5.9&1.5 {60&15}
j
~o
i
b T:1.5&0.3 {15&3}
h
~m
n
f e
k
g d
l
c
T11E9052S25
Unit: N;m{kgf;cm}
~: Non-reusable parts
(2) Disassembling and assembling procedure
1 a Switch S/A, magnet 10 j Lever, pinion drive
2 b Bolts, through 11 k Housing Ay, starter drive
3 c Yoke Ay, starter 12 l Gear, starter planetary
4 d Frame S/A, commutator end 13 m Ring, snap
5 e Holder S/A, starter brush 14 n Nut, pinion stop
6 f Spring, starter brush 15 o Ring, snap
7 g Armature Ay, starter 16 p Shaft S/A, starter planet
8 h Clutch S/A, starter 17 q Gear, starter internal
9 i Bearing S/A, center
T11E9058ET10
C–9
(2) Yoke Ay, starter Through bolt
1.Remove the two through bolts. Remove the yoke Ay and
Yoke Ay
commutator end frame Ay as a set.
Frame S/A
T11E9059ET10
Starter brush
spring
Yoke Ay
T11E9061ET10
Housing Ay
T11E9062ET10
Planet gear
T11E9063ET10
C–10
(7) Ring, snap
1.As shown in the right figure, remove the snap ring and pin- Snap ring
ion stop nut so as to separate the starter clutch S/A.
Pinion snap nuts Clutch S/A
T11E9064ET10
T11E9065ET10
Concave part
Convex part
T11E9066ET10
2-4-3 CHECK
Armature core
(1) Check of starter armature Ay
Commutator
1.Check the insulation between the commutator and the
armature core.
SPECIFIED VALUE: No continuity exists
T11E9082ET10
T11E9083ET10
C–11
3.Check the commutator for runout.
ALLOWABLE LIMIT: 0.05 mm Dial gauge
Vee block
Commutator
T11E9084ET10
T01E9537T10
Mica Segment
T01E9538ET10
T01E9539T10
T01E9540T10
C–12
(3) Check the insulation between the brush and yoke.
SPECIFIED VALUE: No continuity exists
Yoke
T01E9541ET10
2.Check of brush
(1) Check the roughness of the contact surface and brush
length.
ALLOWABLE LIMIT: 9 mm
14mm
9mm
T01E9542T10
T11E9067ET10
T01E9544ET10
CAUTION
• Grind the area of the brush holder unit. as indicated in
the right figure. Since the section to be ground is very
A-B cutting
narrow, care must be exercised not to scratch the field
A B
coil. Cut
Terminal at Terminal at
yoke side yoke side
Section to
be removed
Section to be removed
T01E9545ET10
C–13
3.Overlap the plate section of the replacement brush onto
the lead wire fusing side and press-fit the section with pli-
ers.
CAUTION Welding side of
lead wire
• Make sure not to make a mistake concerning the
removal direction of the brush lead wire.
T01E9546ET10
Brush
T01E9548ET10
^terminal
T01E9549ET10
T01E9550ET10
C–14
(7) Check of magnet switch
1.When the plunger is pushed in and released, ensure that
the plunger returns quickly to the original position.
T01E9551T10
T01E9517ET10
T01E9516ET10
T01E9554T10
SST
T01E9557T10
NOTE
• The SST is handled by Denso. "95208(10090"
Bearing
CAUTION S/A
• When installing the bearing, be sure to install it starting
from the outside. 0.5mm
• Drive the bearing into place in such a way that the Oil less or less
center bearing.
T11E9068ET10
Specified value
22.04(22.36mm
T01E9561ET16
2.Assemble the SST, as indicated in the right figure. Turn the SST
SST slightly so that it may engage with the shock
absorber.
NOTE
• The SST is handled by Denso. "95208(10100"
Bearing S/A
T11E9072ET10
T01E9564ET10
C–17
4.As indicated in the right figure, using a torque wrench, Torque rench
apply torque through the SST. Observe a sliding torque
reading at the moment when the rotation starts.
When the reading is deviated from the allowable limit, the
replacement should be made together with the bearing
S/A.
SST
SPECIFIED VALUE: 29.4&3.9 N;m {300&40 kgf;cm}
ALLOWABLE LIMIT: 21.6 N;m {220kgf;cm}
CAUTION T01E9565ET10
• Never disassemble or wash the shock absorber sec-
tion. If it has been disassemble or washed, do not
reuse it.
NOTE
• The SST is handled by Denso. "95208(10100"
(12) Check of planetary brush oil clearance. Planet gear
Planet carrier shaft
1.Calculate the clearance, based on the planetary diameter
(b) press-fitted to the planetary carrier shaft and the plan-
etary bush inner diameter (a).
If the limit is exceeded, replace the planetary gear or the b
planetary carrier shaft. a
SPECIFIED VALUE: 0.03 mm
SPECIFIED VALUE: 0.10 mm Planet pin
Planet bush T11E9073ET10
Plate washer
Turbine oil
T11E9075ET10
C–18
(3) Ring, snap
1.Install a new ring. Snap ring
CAUTION
• Never reuse the ring.
• Ensure that the plate washer has been installed.
Washer
T11E9077ET10
(3) Fit the snap ring into the shaft S/A groove section,
using circlip pliers or the like.
(4) While holding the outer periphery of the clutch S/A,
lightly tap the starter planet gear, using a plastic
hammer so that the snap ring may be fitted into the
inner groove of the pinion stop nut.
T01E9571T10
Housing Ay
Drive lever
T11E9080ET10
C–19
(7) Bearing S/A, center Bearing S/A Mating mark
1.Install the starter drive housing Ay and bearing S/A with
the respective mating marks aligned, as indicated in the
right figure.
Housing Ay T11E9081ET10
Hunger
T01E9575ET10
Lead wire
T01E9576ET10
T01E9577ET10
Mating mark
T01E9578ET10
C–20
(11) Switch S/A, magnet
1.Hang the stud bolt of the switch S/A from the upper side of
the pinion drive lever. Install and secure it with the two
nuts.
TIGHTENING TORQUE: 8.3&2.5 N;m{85&25 kgf;cm}
2.Furthermore, install the terminal C of the switch S/A and
lead wire.
TIGHTENING TORQUE: 9.8&2.0 N;m{100&20 kgf;cm}
T01E9579T10
C–21
3 ALTERNATOR
3-1 DISASSEMBLING AND ASSEMBLING
3-1-1 ARTICLES TO BE PREPARED
SST
Shape Part No. Part name
Instrument
Torque wrench,Vernier calipers,Voltage tester
C–22
3-2 CIRCUIT DIAGRAM
IG
ALT B
AM2
(30A)
E
F
I IG SW
F/L (IG2)
E
C B
U ECU IG2
(7.5A) P
Battery F
L L IC
Battery charge
indicator lamp
E
E
Alternator
T11E8506ES20
Alternator performance
Engine type
1KR-FE
ITEM
Rated voltage ( Rated output (V(A) 12(65
Output characteristics [13.5V(5000rpm] (A) 67 or more
Permissible max. revolution speed (rpm) 18,000
Regulator regulating voltage Hi:14.2-14.8
[5,000rpm(10A(25] (V) Lo:12.5-13.1
Rotational direction Clockwise as viewed from pulley side
Pulley ratio [Crankshaft/alternator] 139.0/52.5
Weight (kg) 3.30
C–23
3-2-1 ALTERNATOR DISASSEMBLING & ASSEMBLING
(1) Components
i
f
T:110.3&17.0 {1124&173} T:3.7&0.7 {38&7}
T:4.1&0.8 {42&8}
c
a
T:4.5&0.8 {46&8}
h
b
T:2.6&0.5 {26&5}
d
e
T:2.0&0.35 {20&4}
T11E9076S25
3-2-2 DISASSEMBLING
(1) Cover S/A, end, RR
1.Remove the washer terminal insulator.
2.Remove the cover S/A.
T01E9582T10
C–24
(2) Regulator Ay, generator
1.Remove the alternator brush holder Ay.
2.Remove the generator regulator Ay.
T01E9583T10
T11E9085ET10
2.Clamp the SST in a vice. Under the state above, set the
SST.
SST: 09820-87201-000 [09820-87202-000]
SST
T01E9586T10
T01E9587T10
C–25
4.Turn the SST B in the arrowheaded direction so as to
remove the SST B from the alternator.
5.Remove the alternator pulley.
T01E9588T10
T01E9589T10
T01E9590ET10
3-2-3 INSPECTION
(1) Resistance check of alternator rotor Ay
1.Measure the resistance between the two slip rings.
SPECIFIED VALUE: 2.3+
T01E9591T10
T01E9592T10
C–26
(3) Slip ring check
1.Check the slip ring for damage.
If the slip ring exhibits damage, rectify it, using an abra-
sive paper (#400).
2.Measure the outer diameter of the slip ring.
SPECIFIED VALUE: 14.2(14.4mm
ALLOWABLE LIMIT: 12.8mm
T01E9593T10
T01E9595T10
T01E9596T10
C–27
(7) Check of regulator Ay, generator
1.Conduct the continuity test for the diode between the ter-
minal B and the terminal F, using the k+ range of the
tester.
SPECIFIED VALUE: There should be continuity in one
direction, while there should be no
continuity in the opposite direction.
T01E9597T10
3-2-4 REPLACEMENT
(1) Replacement of bearing (Rotor Ay, alternator rear
side)
SST
1.Remove the bearing, using the SST.
SST: 09820-00021-000
T01E9598T10
T01E9599T10
3-2-5 ASSEMBLING
(1) Rotor Ay, alternator
1.Attach the rotor assembly to the drive end frame assembly.
(2) Frame Ay, rectifier
1.Press the rectifier end frame assembly, using a 29 mm Socket
socket wrench in combination with a press.
T01E9600ET10
C–28
(3) Pulley, alternator
1.Install the pulley to the shaft section of the rotor. Tighten
the pulley lock nut temporarily.
SSTA
2.Tighten the SSTB to the specified torque so that the
SSTA may be attached to the pulley shaft. SSTB
T01E9602T10
T01E9603T10
T01E9604T10