TR & WR TR ST R SYSTM TTS RUT... 2 RUTS... 2 Supplemental Restraint System (SRS) "R " and "ST T R-TSR"...2 recaution for ower eneration Variable Voltage ontrol System...2 RRT... 3 RRT... 3 Special Service Tool...3 ommercial Service Tool...3 S ST... 4 SS RR WRW... 4 Work low...4 UT SS... 5 R SYSTM... 5 System iagram...5 System escription...5 omponent escription...5 WR RT VT VR- TR SYSTM... 6 System iagram...6 System escription...6 omponent escription...6 MT SS... 7 R SYSTM RMRY - ST... 7 nspection rocedure...7 WR RT VT VR- TR SYSTM RT - ST... 8 nspection rocedure... 8 TRM RUT...10 escription...10 iagnosis rocedure...10 TRM RUT...11 escription...11 iagnosis rocedure...11 S TRM RUT...12 escription...12 iagnosis rocedure...12 R SYSTM...13 Wiring iagram...13 SYMTM SS...18 R SYSTM...18 Symptom Table...18 -V RR...19 RTR...19 xploded View...19 Removal and nstallation...19 SRV T STS (SS)...21 SRV T STS (SS)...21 enerator...21-1
< RUT > RUT RUTS RUTS Supplemental Restraint System (SRS) "R " and "ST T R-TS- R" :0000000004095194 The Supplemental Restraint System such as R and ST T R-TSR, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. nformation necessary to service the system safely is included in the SR and S section of this Service Manual. WR: To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized SS/T dealer. mproper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. or removal of Spiral able and ir ag Module, see the SR section. o not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. recaution for ower eneration Variable Voltage ontrol System :0000000004095195 UT: or this model, the battery current sensor that is installed to the negative battery cable measures the charging/discharging current of the battery and performs various engine controls. f an electrical component is connected directly to the negative battery terminal, the current flowing through that component will not be measured by the battery current sensor. This condition may cause a malfunction of the engine control system and battery discharge may occur. o not connect an electrical component or ground wire directly to the battery terminal. -2
< RRT > RRT RRT RRT Special Service Tool :0000000004095196 Tool number (ent-moore o.) Tool name escription ( ) Model R-8 Multitasking attery iagnostic Station Tests batteries, starting and charging systems. or operating instructions, refer to diagnostic station instruction manual. ommercial Service Tool @V @0128YY :0000000004095197 Tool name escription ower tool oosening bolts, nuts and screws 03/ 6-3
< S ST > SS RR WRW S ST SS RR WRW Work low :0000000004095198 VR SQU @V @0031-4
< UT SS > UT SS R SYSTM System iagram R SYSTM :0000000004095199 @ @/ 1/6 System escription :0000000004095200 The generator provides voltage to operate the vehicle's electrical system and to keep the battery charged. The voltage output is controlled by the regulator. omponent escription enerator omponent part Terminal 1 Terminal 2 Terminal 3 Terminal 4 ombination meter (harge warning lamp) M /R Refer to -10, "escription". Refer to -11, "escription". Refer to -12, "escription". escription :0000000004095201 Used for the power generation voltage variable control system. Refer to -6, "System escription". The regulator warning function activates to illuminate the charge warning lamp if any of the following symptoms occur while generator is operating: xcessive voltage is produced. o voltage is produced. Used for the power generation voltage variable control system. Refer to -6, "System escription". -5
WR RT VT VR TR SYSTM < UT SS > WR RT VT VR TR SYSTM System iagram :0000000004095202 @ @/ /46 System escription :0000000004095203 ower generation variable voltage control system has been adopted. y varying the voltage to the generator, engine load due to power generation of the generator is reduced and fuel consumption is decreased. T: When any malfunction is detected in the power generation variable voltage control system, power generation is performed according to the characteristic of the regulator in the generator. omponent escription :0000000004095204 omponent part attery current sensor M M /R enerator ( regulator) escription The battery current sensor is installed on the battery cable at the negative terminal. The battery current sensor detects the charging/discharging current of the battery and sends a voltage signal to the M according to the current value detected. The battery current sensor detects the charging/discharging current of the battery. The M judges the battery condition based on this signal. The M judges whether to request more output via the power generation voltage variable control according to the battery condition. When performing the power generation voltage variable control, the M calculates the target power generation voltage according to the battery condition and sends the calculated value as the power generation command value to the M /R. The M /R converts the received power generation command value into a pulse width modulated (WM) command signal and sends it to the regulator. The regulator controls the power generation voltage by the target power generation voltage based on the received WM command signal. When there is no WM command signal, the generator performs the normal power generation according to the characteristic of the regulator. -6
< MT SS > R SYSTM RMRY ST MT SS R SYSTM RMRY ST nspection rocedure 1. TTRY TRMS T heck if battery terminals are clean and tight. s the inspection result normal? YS >> T 2 >> Repair battery terminals connection. 2. US heck for blown fuse and fusible link. :0000000004095205 Unit ower source (ower supply terminals) use or usible ink attery (terminal 3) use 30 enerator attery (terminal 1) usible ink ombination meter gnition switch (terminal 2) use 14 s the inspection result normal? YS >> T 3 >> e sure to eliminate cause of malfunction before installing new fuse or fusible link. 3. RTR RU TRM T Verify connector 209 terminal 5 (generator ground harness) is clean and tight. s the inspection result normal? YS >> T 4 >> Repair connection. 4. RV T TS heck drive belt tension. Refer to M-12, "hecking rive elts". s the inspection result normal? YS >> nspection nd. >> Repair as needed. -7
WR RT VT VR TR SYSTM RT ST < MT SS > WR RT VT VR TR SYSTM R- T ST nspection rocedure :0000000004095206 UT: When performing this inspection, always use a charged battery that has completed the battery inspection. (When the charging rate of the battery is low, the response speed of the voltage change will become slow. This can cause an incorrect inspection.) 1. M (SUT-) erform M self-diagnosis with SUT-. Refer to -67, "SUT- unction ()". Self-diagnostic results content o malfunction detected>> T 2 Malfunction detected>> heck applicable parts, and repair or replace corresponding parts. 2. RT WR RT VT VR TR SYSTM 1. onnect SUT- and start the engine. 2. The selector lever is in or position and all of the electric loads and /, etc. are turned. 3. Select TRTR UTY in ctive Test of, and then check the value of TTRY VT monitor when UTY value of TRTR UTY is set to 40.0 %. TTRY VT 2 seconds after setting the UTY value of TR- TR UTY to 40.0 % : 12-13.6 V 4. heck the value of TTRY VT monitor when UTY value of TRTR UTY is set to 80.0%. TTRY VT 20 seconds after setting the UTY value of TR- TR UTY to 80.0 % : +0.5 V or more against the value of TTRY VT monitor when UTY value is 40.0 % s the measurement value within specification? YS >> nspection nd. >> T 3 3. M /R (SUT-) erform M /R self-diagnosis with SUT-. Refer to -67, "SUT- unction ()". Self-diagnostic results content o malfunction detected>> T 4 Malfunction detected>> heck applicable parts, and repair or replace corresponding parts. 4. RSS TW RTR M /R 1. Turn ignition switch. 2. isconnect generator connector 205 and M /R connector 122. 3. heck continuity between generator harness connector 205 () terminal 4 and M /R harness connector 122 () terminal 37. ontinuity onnector Terminal onnector Terminal 205 4 122 37 Yes -8 @ @/ 085YY
WR RT VT VR TR SYSTM RT ST < MT SS > 4. heck continuity between generator harness connector 205 () terminal 4 and ground. onnector Terminal ontinuity 205 4 round o re the continuity test results as specified? YS >> Replace M /R. Refer to S-34, "Removal and nstallation of M /R". >> Repair harness or connector between M /R and generator. -9
< MT SS > TRM RUT escription TRM RUT :0000000004095207 The terminal 1 () circuit supplies power to charge the battery and operate the vehicles electrical system. iagnosis rocedure :0000000004095208 1. TRM 1 T 1. Turn ignition switch. 2. Verify terminal 1 is clean and tight. s the inspection result normal? YS >> T 2 >> Repair terminal 1 connection. onfirm repair by performing complete Starting/harging system test. Refer to diagnostic station instruction manual. 2. TRM 1 RUT heck voltage between generator connector 206 terminal 1 and ground. (+) onnector Terminal (-) Voltage 206 1 round attery voltage s voltage reading as specified? YS >> T 3. >> heck harness for open between generator and fusible link. 3. TRM 1 T (VT R TST) 1. Start engine, then engine running at idle and warm. 2. heck voltage between battery positive terminal and generator connector 206 terminal 1. @ @/ 086YY (+) onnector Terminal (-) Voltage 206 1 attery positive terminal ess than 0.2V s the voltage reading as specified? YS >> Terminal 1 circuit is normal. Refer to -4, "Work low". >> heck harness between battery and generator for high resistance. @ @/ 087YY -10
< MT SS > TRM RUT escription TRM RUT :0000000004095209 The terminal 2 () circuit controls the charge warning lamp. The charge warning lamp illuminates when the ignition switch is set to or STRT. When the generator is providing sufficient voltage with the engine running, the charge warning lamp will go off. f the charge warning lamp illuminates with the engine running, a malfunction is indicated. iagnosis rocedure :0000000004095210 1. R WR M RUT T Verify generator connector 205 terminal 2 is clean and tight. s the connection secure? YS >> T 2 >> Repair the connection. onfirm repair by performing complete Starting/harging system test. Refer to diagnostic station instruction manual. 2. R WR M RUT 1. isconnect generator connector 205. 2. pply ground to generator harness connector 205 terminal 2 with the ignition switch in the position. harge lamp should illuminate oes the charge lamp illuminate? YS >> heck generator function. Refer to -4, "Work low". >> T 3 3. RSS TUTY 1. Turn ignition switch. 2. isconnect the combination meter connector M24. 3. heck continuity between generator harness connector 205 () terminal 2 and combination meter harness connector M24 () terminal 2. Terminal Terminal ontinuity onnector Terminal onnector Terminal 205 2 M24 2 Yes 4. heck continuity between generator harness connector 205 () terminal 2 and ground. @ @/ 1//YY @V @/ 388YY Terminal onnector Terminal ontinuity 205 2 round o re the continuity results as specified? YS >> Replace the combination meter. Refer to -11, "Removal and nstallation". >> Repair the harness or connector. -11
< MT SS > S TRM RUT escription S TRM RUT :0000000004095211 The output voltage of the generator is controlled by the regulator at terminal 3 (S) detecting the input voltage. Terminal 3 circuit detects the battery voltage to adjust the generator output voltage with the regulator. iagnosis rocedure :0000000004095212 1. VT RUTR RUT T heck to see if connector 205 terminal 3 is clean and tight. s the inspection result normal? YS >> T 2 >> Repair terminal connection. onfirm repair by performing complete Starting/harging system test. Refer to diagnostic station instruction manual. 2. VT RUTR RUT heck voltage between generator harness connector 205 terminal 3 and ground. 3 - ground attery voltage oes battery voltage exist? YS >> Refer to -4, "Work low". >> heck harness for open between generator and fuse. @ @/ 1/0YY -12
< MT SS > R SYSTM Wiring iagram R SYSTM :0000000004095213 @ V @/ 027-13
< MT SS > R SYSTM @ @/ 275-14
< MT SS > R SYSTM @ @/ 276-15
< MT SS > R SYSTM @ @/ 277-16
< MT SS > R SYSTM @ @/ 278-17
< SYMTM SS > SYMTM SS R SYSTM Symptom Table R SYSTM :0000000004095214 attery discharged Symptom The charge warning lamp does not illuminate when the ignition switch is set to. The charge warning lamp does not turn after the engine starts. The charging warning lamp turns when increasing the engine speed. Refer to -4, "Work low". Reference -18
< -V RR > -V RR RTR xploded View RTR :0000000004095215 V@2080 1. enerator 2. ngine block 3. enerator stay Removal and nstallation RMV 1. isconnect the negative battery terminal. 2. Remove the fan shroud. Refer to -15, "xploded View". 3. Remove the drive belt. Refer to M-12, "Removal and nstallation". 4. Remove the generator stay, using power tools. 5. Remove the generator upper bolt, using power tools. 6. isconnect the generator harness connectors. 7. Remove the generator. RTR UY ST erform the following. Make sure that the generator pulley does not rattle. Make sure that the generator pulley nut is properly tightened. enerator pulley nut : 118 m (12.0 kg-m, 87 ft-lb) STT nstallation is in the reverse order of removal. nstall the generator and check tension of drive belt. Refer to M-12, "hecking rive elts". :0000000004095216-19
< -V RR > RTR Terminal "1" nut : 10.8 m (1.1 kg-m, 8 ft-lb) UT: Tighten terminal "1" nut carefully. or this model, the power generation variable voltage control system that controls the power generation voltage of the generator has been adopted. Therefore, the power generation variable voltage control system inspection should be performed after replacing the generator in order to ensure that the system operates normally. Refer to -8, "nspection rocedure". -20
SRV T STS (SS) < SRV T STS (SS) SRV T STS (SS) SRV T STS (SS) enerator :0000000004095217 Type ngine ominal rating round polarity Minimum revolution under no-load T15S147 Valeo VQ40 14V-130 egative 1,200 rpm More than 52/1,500 rpm More than 82/1,800 rpm ot output current (When 13.5 volts is applied) More than 115/2,500 rpm More than 130/5,000 rpm Regulated output voltage 13.5V @ 5,000 rpm @ 20 djustment range of power generation variable 11.4-15.6V voltage control -21