K ELECTRICAL

Special Service Tool

How to Handle Battery

CAUTION:

• If jump-starting is necessary, use a 12-volt booster battery.
• Ensure battery cables are tightly clamped to battery terminals for good contact after connection.
• Never add distilled water through the specific gravity check hole.

METHODS OF PREVENTING OVER-DISCHARGE

To prevent battery over-discharge:

• Keep the battery surface (especially the top) clean and dry.
• Ensure terminal connections are clean and tight.
• Check the electrolyte level during routine maintenance, even for "low maintenance" and "maintenance-free" batteries.
• When the vehicle will be unused for an extended period, disconnect the negative battery terminal (or turn off the extended storage switch if equipped).

Periodically check the battery's charge condition and the electrolyte's specific gravity to prevent over-discharge.

CHECKING ELECTROLYTE LEVEL

WARNING: Battery fluid is corrosive. Avoid contact with skin, eyes, fabrics, or painted surfaces. If contact occurs, wash hands thoroughly before touching eyes. Flush affected areas with water for 15 minutes and seek medical attention.

Remove the cell plug using a suitable tool. Add distilled water up to the MAX level.

Sulphation

A battery left unattended for a long time may become completely discharged (specific gravity below 1.100), potentially leading to sulphation on the cell plates. Sulphated batteries may show lower charging current and higher voltage during initial charging. Some sulphated batteries can be restored with a long, slow charge (12+ hours) followed by a capacity test.

SPECIFIC GRAVITY CHECK

1. Read hydrometer and thermometer indications at eye level.
2. Use the chart below to correct the hydrometer reading based on electrolyte temperature.

Corrected specific gravity indicates approximate charge condition:

CHARGING THE BATTERY

CAUTION:

• Do not "quick charge" a fully discharged battery.
• Keep the battery away from open flame while charging.
• Connect charger leads first, then turn on the charger. Avoid turning on the charger first to prevent sparks.
• If battery electrolyte temperature exceeds 60°C (140°F), stop charging. Always charge below 60°C (140°F).

Charging Rates

Do not charge at more than 50 ampere rate.

NOTE: The ammeter on the charger decreases as the battery charges, indicating increasing voltage. The charging amps listed are for initial charge rate.

If the specific gravity of any two cells varies by more than .050 after charging, the battery should be replaced.

Trouble Diagnoses with Battery/Starting/Charging System Tester

CAUTION: Always wear appropriate eye protection when working with batteries.

NOTE: Perform battery, starter, and generator tests as a complete set.

• If battery surface charge is detected, turn on headlights to remove it as prompted by the tester.
• The tester may ask to select battery temperature (above or below 0°C / 32°F). Use arrow buttons and ENTER to make the selection.

DIAGNOSTIC RESULT ITEM CHART

System Description

KA24DE M/T MODELS

Power is supplied at all times:

• Through 40A fusible link (e) to ignition switch terminal B.

With the ignition switch in START position, power is supplied:

• Through ignition switch terminal ST
• To clutch interlock relay terminal 5.

With the ignition switch in ON or START position, power is supplied:

• Through 10A fuse [No. 11, (J/B)]
• To clutch interlock relay terminal 2.

Ground is supplied:

• To clutch interlock relay terminal 1
• Through clutch interlock switch terminal 1
• Through clutch interlock switch terminal 2
• Through body grounds M14 and M68.

The clutch interlock relay is energized, supplying power:

• Through clutch interlock relay terminal 3
• To starter motor windings terminal S.

The starter motor plunger closes, completing the circuit between the battery and starter motor. The starter motor is grounded to the cylinder block. With power and ground, the starter motor operates.

KA24DE A/T MODELS

Power is supplied at all times:

• Through 40A fusible link (e) to ignition switch terminal B.

With the ignition switch in START position, power is supplied:

• Through ignition switch terminal ST
• To park/neutral position (PNP) relay terminal 5.

With the ignition switch in ON or START position, power is supplied:

• Through 10A fuse [No. 11, (J/B)]
• To PNP switch terminal 1.

With the selector lever in P or N position, power is supplied:

• Through PNP switch terminal 2
• To PNP relay terminal 2.

Ground is supplied:

• To PNP relay terminal 1
• Through body grounds E12 and E54.

The PNP relay is energized, supplying power:

• Through PNP relay terminal 3
• To starter motor windings terminal S.

The starter motor plunger closes, completing the circuit between the battery and starter motor. The starter motor is grounded to the cylinder block. With power and ground, the starter motor operates.

VG33E AND VG33ER M/T MODELS

Power is supplied at all times:

• Through 40A fusible link (e) to ignition switch terminal B.

With the ignition switch in START position, power is supplied:

• Through ignition switch terminal ST
• To clutch interlock relay terminal 5.

With the ignition switch in ON or START position, power is supplied:

• Through 10A fuse [No. 11, (J/B)]
• To clutch interlock relay terminal 2, and
• Through 10A fuse [No. 5, (J/B)]
• To vehicle security relay terminal 2 (if equipped).

If the vehicle security system is not activated and the clutch pedal is depressed, ground is supplied:

• To clutch interlock relay terminal 1
• Through vehicle security relay terminals 3, 4 (if equipped)
• Through clutch interlock switch terminal 1
• Through clutch interlock switch terminal 2
• Through body grounds M14 and M68.

The clutch interlock relay is energized, supplying power:

• Through clutch interlock relay terminal 3
• To starter motor windings terminal S.

The starter motor plunger closes, completing the circuit between the battery and starter motor. The starter motor is grounded to the cylinder block. With power and ground supplied, the starter motor operates. If the vehicle security system is activated, ground is supplied to vehicle security relay terminal 1 via smart entrance control unit terminal 40, disengaging the clutch interlock relay and preventing starter motor operation.

VG33E AND VG33ER A/T MODELS

Power is supplied at all times:

• Through 40A fusible link (e) to ignition switch terminal B.

With the ignition switch in START position, power is supplied:

• Through ignition switch terminal ST
• To park/neutral position (PNP) relay terminal 5.

With the ignition switch in ON or START position, power is supplied:

• Through 7.5A fuse [No. 12, (J/B)]
• To PNP switch terminal 1 and
• Through 10A fuse [No. 5, (J/B)]
• To vehicle security relay terminal 2 (if equipped).

With the selector lever in P or N position, power is supplied:

• Through PNP switch terminal 2
• To PNP relay terminal 2.

If the vehicle security system is not activated, ground is supplied:

• To PNP relay terminal 1
• Through body grounds E12 and E54 (VG33E without security system), or
• Through body grounds M14 and M68 (VG33ER without security system), or
• Through vehicle security relay terminals 3, 4 (if equipped) and
• Through body grounds M14 and M68.

The PNP relay is energized, supplying power:

• Through PNP relay terminal 3
• To starter motor windings terminal S.

The starter motor plunger closes, completing the circuit between the battery and starter motor. The starter motor is grounded to the cylinder block. With power and ground supplied, the starter motor operates. If the vehicle security system is activated, ground is supplied to vehicle security relay terminal 1 via smart entrance control unit terminal 40, disengaging the PNP relay and preventing starter motor operation.

Wiring Diagram -- START --

KA24DE M/T MODELS

Wiring Diagram - START - KA24DE M/T MODELS: This diagram illustrates the electrical connections for the starting system, showing the battery, ignition switch, clutch interlock relay, clutch interlock switch, and starter motor, along with associated fuses and grounds. It details the power flow from the battery through various switches and relays to the starter motor.

KA24DE A/T MODELS

Wiring Diagram - START - KA24DE A/T MODELS: This diagram illustrates the electrical connections for the starting system in automatic transmission vehicles, showing the battery, ignition switch, park/neutral position (PNP) relay, PNP switch, and starter motor, along with associated fuses and grounds. It details the power flow, including the role of the PNP switch and relay.

VG33E AND VG33ER M/T MODELS

Wiring Diagram - START - VG33E and VG33ER M/T MODELS: This diagram shows the starting system wiring for manual transmission vehicles with VG33E/VG33ER engines. It includes the battery, ignition switch, clutch interlock relay, vehicle security relay (if equipped), smart entrance control unit, clutch interlock switch, and starter motor, detailing power and ground paths.

VG33E AND VG33ER A/T MODELS

Wiring Diagram - START - VG33E and VG33ER A/T MODELS: This diagram illustrates the starting system wiring for automatic transmission vehicles with VG33E/VG33ER engines. It features the battery, ignition switch, park/neutral position (PNP) relay, vehicle security relay (if equipped), smart entrance control unit, PNP switch, and starter motor, outlining power and ground connections.

Trouble Diagnoses with Battery/Starting/Charging System Tester

NOTE: Perform battery, starter, and generator tests as a complete set.

• Turn off all loads on the vehicle electrical system.
• Perform battery and starting system test with the Battery/Starting/Charging system tester.
• Press "ENTER" to begin the starting system test.
• Start the engine.
• Diagnosis results are displayed on the tester. Refer to SC-8, "DIAGNOSTIC RESULT ITEM CHART".

NOTE:

• If the starter operates normally but the engine does not start, perform engine diagnosis.
• For intermittent "NO CRANK" or "NO STARTER OPERATION" issues, refer to SC-21, "DIAGNOSTIC PROCEDURE 2".

DIAGNOSTIC RESULT ITEM CHART

WORK FLOW

Work Flow for Starting System Diagnosis: This flowchart guides troubleshooting based on engine cranking status (normal or low voltage). It directs checks for starter operation, engine start, and specific circuit tests (B terminal, S terminal) leading to potential repairs or component replacement.

DIAGNOSTIC PROCEDURE 1

Check "B" Terminal Circuit

1. CHECK POWER SUPPLY FOR STARTER MOTOR "B" TERMINAL
   1. Remove the fuel pump fuse.
   2. Crank or start the engine (if possible) until fuel pressure is released.
   3. Turn the ignition switch OFF.
   4. Check that the starter motor terminal "B" [E210, (B/Y) for KA24DE models or E203, (B/L) for VG33E and VG33ER models] connection is clean and tight.
   5. Check voltage between starter motor terminal "B" [E210, (B/Y) for KA24DE models or E203, (B/L) for VG33E and VG33ER models] and ground using a digital circuit tester. The tester screen shows a diagram of the starter motor terminal B connected to a voltmeter and ground, indicating "Battery voltage should exist."
   OK or NG
   • OK: GO TO 2.
   • NG: Check harness between the battery and the starter motor for open circuit.
2. CHECK BATTERY CABLE CONNECTION QUALITY (VOLTAGE DROP TEST)
   1. Check voltage between starter motor terminal "B" [E210, (B/Y) for KA24DE models or E203, (B/L) for VG33E and VG33ER models] and battery positive terminal using a digital circuit tester. The tester screen shows a diagram of the starter motor terminal B connected to a voltmeter and battery positive terminal, indicating "When the ignition switch is in START position, Voltage: Less than 0.5V".
   OK or NG
   • OK: GO TO 3.
   • NG: Check harness between the battery and the starter motor for poor continuity.
3. CHECK STARTER MOTOR GROUND CIRCUIT (VOLTAGE DROP TEST)
   1. Check voltage between starter motor case and battery negative terminal using a digital circuit tester. The tester screen shows a diagram of the starter motor case and battery negative terminal connected to a voltmeter, indicating "When the ignition switch is in START position, Voltage: Less than 0.2V".
   OK or NG
   • OK: Starter motor "B" terminal circuit is OK. Further inspection necessary. Refer to SC-18, "WORK FLOW".
   • NG: Check the starter motor case and ground for poor continuity.

DIAGNOSTIC PROCEDURE 2

Check "S" Terminal Circuit

1. CHECK POWER SUPPLY FOR STARTER MOTOR "S" TERMINAL
   1. Remove the fuel pump fuse.
   2. Crank or start the engine (if possible) until fuel pressure is released.
   3. Turn the ignition OFF.
   4. Disconnect starter motor terminal "S" [E209 (B/R) for KA24DE models or E202 (B/R) for VG33E and VG33ER models] connector.
   5. Check voltage between starter motor terminal "S" [E209, (B/R) for KA24DE models or E202, (B/R) for VG33E and VG33ER models] and ground using a digital circuit tester. The tester screen shows a diagram of the starter motor connector with terminal S connected to a voltmeter and ground, indicating "When the ignition switch is in START position, Battery voltage should exist."
   OK or NG
   • OK: GO TO 2.
   • NG: Check the following:
     • 40A fusible link (e)
     • Clutch interlock relay (M/T)
     • Park/neutral position relay (A/T)
     • Harness for open or short.
2. CHECK "S" TERMINAL CONNECTION QUALITY (VOLTAGE DROP TEST)
   1. Connect starter motor terminal "S" [E209, (B/R) for KA24DE models or E202, (B/R) for VG33E and VG33ER models] connector.
   2. Check voltage between starter motor terminal "S" [E209, (B/R) for KA24DE models or E202, (B/R) for VG33E and VG33ER models] and battery positive terminal using a digital tester. The tester screen shows a diagram of the starter motor connector with terminal S connected to a voltmeter and battery positive terminal, indicating "When the ignition switch is in START position, Voltage: Less than 1V".
   OK or NG
   • OK: Starter motor "S" terminal circuit is OK. Further inspection necessary. Refer to SC-18, "WORK FLOW".
   • NG: Check harness between the battery and the starter motor "S" terminal for poor continuity.

MINIMUM SPECIFICATION OF CRANKING VOLTAGE REFERENCING COOLANT TEMPERATURE

Construction

KA24DE MODELS

Exploded view diagram of the starter motor for KA24DE models, showing components such as the gear case, shift lever, magnetic switch assembly, pinion assembly, planetary gear, and armature, with numbered parts and torque specifications.

VG33E AND VG33ER MODELS

Exploded view diagram of the starter motor for VG33E and VG33ER models, showing components such as the gear case, shift lever, magnetic switch assembly, pinion assembly, planetary gear, and armature, with numbered parts and torque specifications.

Removal and Installation

KA24DE MODELS

Removal

1. Remove engine undercover.
2. Remove two bolts and starter.

Diagram shows the starter motor mounted to the engine, with torque specifications indicated for mounting bolts (30.4-36.3 N·m / 3.1-3.7 kg-m, 22-27 ft-lb).

Installation

To install, reverse the removal procedure.

VG33E AND VG33ER MODELS

Removal

1. Remove engine undercover.
2. Remove two bolts and starter.

Diagram shows the starter motor mounted to the engine, with torque specifications indicated for mounting bolts (30.4-36.3 N·m / 3.1-3.7 kg-m, 22-27 ft-lb).

Installation

To install, reverse the removal procedure.

Pinion/Clutch Check

1. Inspect pinion teeth. Replace pinion if worn or damaged. Check ring gear teeth condition.
2. Inspect reduction gear teeth. Replace reduction gear if worn or damaged. Check armature shaft gear teeth.
3. Check if the pinion locks in one direction and rotates smoothly in the opposite direction. If it locks or rotates in both directions, or shows unusual resistance, replace it.

System Description

The generator provides DC voltage to operate the vehicle's electrical system and charge the battery, controlled by an IC regulator. Power is supplied to generator terminal S via an 80A (KA24DE) or 120A (VG33E/VG33ER) fusible link and a 7.5A fuse. Generator terminal B supplies power to the battery and electrical system. Ground is supplied to generator terminal E via body ground E203 (KA24DE) or A1 (VG33E/VG33ER). With the ignition switch ON or START, power is supplied via a 10A fuse to the combination meter terminal 32 for the charge warning lamp. Ground is supplied to combination meter terminal 22 through generator terminal L. The charge warning lamp illuminates when the ignition is ON and goes off when the generator provides sufficient voltage while the engine is running. If the lamp stays on with the engine running, a fault is indicated.

Wiring Diagram -- CHARGE --

KA24DE MODELS

Wiring Diagram - CHARGE - KA24DE MODELS: This diagram illustrates the electrical connections for the charging system, showing the battery, ignition switch, fuse block, combination meter, and generator, along with associated fuses and grounds. It details the power flow from the battery to the generator and the warning lamp circuit.

VG33E AND VG33ER MODELS

Wiring Diagram - CHARGE - VG33E and VG33ER MODELS: This diagram illustrates the electrical connections for the charging system in VG33E/VG33ER models, showing the battery, ignition switch, fuse block, combination meter, and generator, along with associated fuses and grounds. It details the power flow and warning lamp circuit.

Trouble Diagnoses with Battery/Starting/Charging System Tester

NOTE: Perform battery, starter, and generator tests as a complete set.

1. Turn off all loads on the vehicle electrical system.
2. Perform battery and starting system test with the Battery/Starting/Charging system tester.
3. Press "ENTER" to begin the charging system test.
4. Start engine.
5. Press "ENTER" until "LOADS OFF REV ENGINE 5 SEC" is displayed.
6. Raise and hold engine speed at 1,500 to 2,000 rpm for 5 seconds, then return to idle. Press "ENTER" to continue.

NOTE: If engine idle speed increase is not detected within 30 seconds, "RPM NOT DETECTED" will display. Continue testing; final results are not affected.

7. The tester checks the engine at idle and performs the DIODE/RIPPLE check.
8. When complete, turn on the following electrical loads:
   • Heater fan (highest speed). Do not use A/C or windshield defroster.
   • Headlamp high beam.
   • Rear window defogger.
   NOTE: Do not run windshield wipers or other cyclical loads.
9. Press "ENTER" to continue.
10. Raise and hold engine speed at 1,500 to 2,000 rpm for 5 seconds, then return to idle. Press "ENTER" to continue.

NOTE: If engine idle speed increase is not detected within 30 seconds, "RPM NOT DETECTED" will display. Press "ENTER" to restart the test.

11. Diagnostic result is displayed on the tester. Refer to SC-30, "DIAGNOSTIC RESULT ITEM CHART".
12. Press "ENTER" to display the test output code. Record it on the repair order.
13. Toggle back to the "DIAGNOSTIC SCREEN" for test results.

DIAGNOSTIC RESULT ITEM CHART

WORK FLOW

Work Flow for Charging System Diagnosis: This flowchart guides troubleshooting based on charging voltage and diode ripple results. It directs checks for the 'L', 'B', and 'S' terminals and the generator drive belt tension, leading to potential repairs or generator replacement.

DIAGNOSTIC PROCEDURE 1

Check "L" Terminal Circuit

1. CHECK "L" TERMINAL CONNECTION Check if "L" terminal is clean and tight. OK or NG
   • OK: GO TO 2.
   • NG: Repair "L" terminal connection. Confirm repair by performing a complete Battery/Starting/Charging system test.
2. CHECK "L" TERMINAL CIRCUIT
   1. Disconnect E207 (KA24DE) or A8 (VG33E/VG33ER) connector from the generator.
   2. Apply ground to terminal "L" [E207, (Y/B) for KA24DE or A8, (Y/B) for VG33E/VG33ER] with the ignition switch ON. The diagram shows the generator connector with terminal L connected to ground, indicating "CHARGE lamp should light up."
   OK or NG
   • OK: Replace the generator. Confirm repair by performing a complete Battery/Starting/Charging system test.
   • NG: Check the following:
     • 10A fuse [No. 11, (J/B)]
     • CHARGE lamp
     • Harness for open or short between combination meter and fuse.
     • Harness for open or short between combination meter and generator.

DIAGNOSTIC PROCEDURE 2

Check "B" Terminal Circuit

1. CHECK "B" TERMINAL CONNECTION Check if "B" terminal is clean and tight. OK or NG
   • OK: GO TO 2. Confirm repair by performing a complete Battery/Starting/Charging system test.
   • NG: Repair "B" terminal connection.
2. CHECK GENERATOR "B" TERMINAL CIRCUIT Check voltage between generator terminal "B" [E208, (W) for KA24DE or A6, (W) for VG33E/VG33ER] and ground using a digital circuit tester. The diagram shows the generator connector with terminal B connected to a voltmeter and ground, indicating "Battery voltage should exist."

• OK: GO TO 3.
• NG: Check the following:
  • 80A fusible link (a) for KA24DE models.
  • 120A fusible link (a) for VG33E or VG33ER models.
  • Harness for open or short between generator and fusible link.

3. CHECK "B" TERMINAL CONNECTION QUALITY (VOLTAGE DROP TEST) Check voltage between generator terminal "B" [E208, (W) for KA24DE or A6, (W) for VG33E/VG33ER] and battery positive terminal using a digital tester. The diagram shows the generator connector with terminal B connected to a voltmeter and battery positive terminal, indicating "With the engine running at idle and warm, Voltage: Less than 0.2V".

• OK: Replace the generator. Confirm repair by performing a complete Battery/Starting/Charging system test.
• NG: Check harness between the battery and the generator for poor continuity.

DIAGNOSTIC PROCEDURE 3

Check "S" Terminal Circuit

1. CHECK "S" TERMINAL CONNECTION Check if "S" terminal is clean and tight. OK or NG
   • OK: GO TO 2.
   • NG: Repair "S" terminal connection. Confirm repair by performing a complete Battery/Starting/Charging system test.
2. CHECK GENERATOR "S" TERMINAL CIRCUIT Check voltage between generator terminal "S" [E207, (G/B) for KA24DE or A8, (G/B) for VG33E/VG33ER] and ground using a digital circuit tester. The diagram shows the generator connector with terminal S connected to a voltmeter and ground, indicating "Battery voltage should exist."

• OK: GO TO 3.
• NG: Check the following:
  • 7.5A fuse (No. 36).
  • Harness for open or short between generator and fuse.

3. CHECK "S" TERMINAL CONNECTION QUALITY (VOLTAGE DROP TEST) Check voltage between generator terminal "S" [E207, (G/B) for KA24DE or A8, (G/B) for VG33E/VG33ER] and battery positive terminal using a digital tester. The diagram shows the generator connector with terminal S connected to a voltmeter and battery positive terminal, indicating "With the engine running at idle and warm, Voltage: Less than 0.2V".

• OK: Replace the generator. Confirm repair by performing a complete Battery/Starting/Charging system test.
• NG: Check harness between the battery and the generator for poor continuity.

MALFUNCTION INDICATOR

The IC regulator warning function illuminates the "CHARGE" warning lamp if the generator is operating and any of the following symptoms occur:

• Excessive voltage is produced.
• No voltage is produced.

Construction

KA24DE MODELS

Exploded view diagram of the generator for KA24DE models, showing components such as the pulley assembly, front cover, rotor, stator, IC regulator assembly, and diode assembly, with numbered parts and torque specifications.

Removal and Installation

KA24DE MODELS

Removal

1. Remove engine undercover.
2. Remove RH side splash shield.
3. Disconnect harness connectors.
4. Loosen adjustment bolt and remove belt.
5. Remove two generator bolts and generator.

Diagram shows the generator mounted to the engine, with torque specifications indicated for mounting bolts (15.7-18.6 N·m / 1.6-1.9 kg-m, 12-14 ft-lb for bracket; 44.1-52.0 N·m / 4.5-5.3 kg-m, 32.5-38.3 ft-lb for mounting bolts).

Installation

To install, reverse the removal procedure.

VG33E AND VG33ER MODELS

Removal

1. Disconnect harness connectors.
2. Remove engine undercover.
3. Loosen adjustment bolt and remove belt.
4. Remove three generator bolts and generator.

Diagram shows the generator mounted to the engine, with torque specifications indicated for mounting bolts (21.6-29.4 N·m / 2.2-3.0 kg-m, 15.9-21.7 ft-lb; 15.7-18.6 N·m / 1.6-1.9 kg-m, 12-14 ft-lb).

Installation

To install, reverse the removal procedure.

Battery

Starter

Generator