STARTING/CHARGING SYSTEMS(H4DO)
SC(H4DO)

STARTING/CHARGING SYSTEMS(H4DO) > General Description
SPECIFICATION

Item | Specifications
Starter | Type | Reduction type
Model | M000TF1171
Manufacturer | Mitsubishi Electric
Voltage and output | 12 V — 1.4 kW
Direction of rotation | Counterclockwise (when observed from pinion)
Number of pinion teeth | 12
No-load characteristics | Voltage | 11 V
Current | 90 A or less
Generator | Type | Rotating-field three-phase type, voltage regulator built-in type, each with load response control system
Model | A5TV0881 or A5TV1281
Manufacturer | Mitsubishi Electric
Voltage and output | 12 V — 150 A
Polarity on ground side | Negative
Direction of rotation | Clockwise (when observed from pulley side)
Stator connection | 3-phase type
Output current | 1,500 r/min — 44 A or more [13.5 V] 2,500 r/min — 121 A or more [13.5 V] 5,000 r/min — 148 A or more [13.5 V]
Regulated voltage | 14.0 — 14.6 V [20°C (68°F)]
Rotor slip ring outer diameter | Standard | 22.7 mm (0.894 in)
Limit | 22.1 mm (0.870 in)
Battery | Type | Q‐85
Nominal capacity | 5 HR: 51 Ah, 20HR: 62 Ah [25°C (77°F)]
Nominal voltage | 12 V
CCA | 620 A
BCI group number∗ | N/A

∗: Use the information about the battery size as a reference. This information shall not be guaranteed by SUBARU CORPORATION.

STARTING/CHARGING SYSTEMS(H4DO) > General Description
COMPONENT
1. STARTER

(1) | Cable stay | (2) | Starter | Tightening torque: N·m (kgf-m, ft-lb)
|  |  |  | T1: | 10 (1.0, 7.4)
|  |  |  | T2: | 11 (1.1, 8.1)
|  |  |  | T3: | 50 (5.1, 36.9)

2. GENERATOR

(1) | Rotor & stator ASSY | (5) | Terminal B | Tightening torque: N·m (kgf-m, ft-lb)
(2) | IC regulator | (6) | Cover | T1: | 2 (0.2, 1.5)
(3) | Brush holder | (7) | Collector cover bracket | T2: | 3.9 (0.4, 2.9)
(4) | Rear cover | (8) | Cushion | T3: | 6.4 (0.7, 4.7)
| T4: | 8.9 (0.9, 6.6)
|  |  |  | T5: | 15.5 (1.6, 11.4)
| T6: | STARTING/CHARGING SYSTEMS(H4DO)>Generator>INSTALLATION

3. BATTERY CABLE ASSEMBLY

(1) | Battery cable ASSY |  |  | Tightening torque: N·m (kgf-m, ft-lb)
|  |  |  | T1: | 7.5 (0.8, 5.5)
|  |  |  | T2: | 11 (1.1, 8.1)
|  |  |  | T3: | 13 (1.3, 9.6)
|  |  |  | T4: | 14 (1.4, 10.3)
|  |  |  | T5: | 15.5 (1.6, 11.4)

4. BATTERY SENSOR

(1) | Battery sensor |  |  | Tightening torque: N·m (kgf-m, ft-lb)
|  |  |  | T1: | 3.4 (0.3, 2.5)
|  |  |  | T2: | 7.5 (0.8, 5.5)

STARTING/CHARGING SYSTEMS(H4DO) > General Description
CAUTION

- When performing service operation, refer to “Repair Contents” in “General Description”. REPAIR CONTENTS>Repair Contents

- Prior to starting work, pay special attention to the following:

  1. Always wear work clothes, a work cap, and protective shoes. Additionally, wear a helmet, protective goggles, etc. if necessary.

  2. Protect the vehicle using a seat cover, fender cover, etc.

  3. Prepare the service tools, clean cloth, containers to catch grease and oil, etc.

- Prevent scattering of grease and oil. If it scatters, wipe it off immediately to prevent it from penetrating the floor or flowing out, to protect the environmental.

- If the grease and oil is spilt over the engine, exhaust pipe or the under cover, completely wipe it off to avoid emission of smoke or causing a fire.

- Vehicle components are extremely hot immediately after driving. Be wary of receiving burns from heated parts.

- When performing a repair, identify the cause of trouble and avoid unnecessary work.

- Before disconnecting connectors of sensors or units, be sure to disconnect the ground terminal from the battery sensor.

- Always use the jack-up point when the lifting device, shop jacks or rigid racks are used to support the vehicle.

- Before starting works, remove dirt and corrosion around the target area.

- Keep the removed parts in order and protect them from dust and dirt.

- All removed parts, if to be reused, should be reinstalled in the original positions with attention to the correct directions, etc.

- For the parts except for the non-reusable parts, replace then with new parts if necessary.

- Be sure to tighten bolts and nuts to the specified torque.

STARTING/CHARGING SYSTEMS(H4DO) > General Description
PREPARATION TOOL
1. SPECIAL TOOL

ILLUSTRATION | TOOL NUMBER | DESCRIPTION | REMARKS
| — | SUBARU SELECT MONITOR 4 | Used for setting of each function and troubleshooting for electrical system. For detailed operation procedures, refer to “Help” of application.

2. GENERAL TOOL

TOOL NAME | REMARKS
Circuit tester | Used for measuring resistance, voltage and current. When measuring the standby current, prepare a circuit tester which can measure down to 1 mA. When measuring the standby current for models with keyless access function, prepare an analog type.

STARTING/CHARGING SYSTEMS(H4DO) > Charging System
WIRING DIAGRAM
STARTING/CHARGING SYSTEMS(H4DO) > Charging System
INSPECTION

Inspection when charge warning light illuminates

If the alternator overheats, the charge warning light illuminates temporarily.

1. CHECK DTC.

Read the DTC using Subaru Select Monitor.

Is DTC detected?

(1) Repair the corresponding system.

(2) 2

2

2. CHECK V-BELT.

Check the V-belt for abnormalities. MECHANICAL(H4DO)>V-belt>INSPECTION

Is the V-belt normal?

3

Replace the V-belt or V-belt tensioner assembly. MECHANICAL(H4DO)>V-belt

3. CHECK VOLTAGE OF GENERATOR B TERMINAL.

Check the voltage of the generator terminal B.

Is the battery voltage applied?

4

Repair the harness between generator and MAIN SBF.

4. CHECK CONTINUITY BETWEEN GENERATOR MAIN BODY AND CHASSIS GROUND.

Check continuity between generator main body and chassis ground.

Is there continuity?

5

Check and repair the installation condition of the generator, chassis ground and engine ground. STARTING/CHARGING SYSTEMS(H4DO)>Generator

5. CHECK COMBINATION METER.

Perform the self-diagnosis of combination meter. INSTRUMENTATION/DRIVER INFO>Combination Meter System>OPERATION > SELF-DIAGNOSIS DISPLAY MODE

Is the charge warning light OK?

Repair or replace the generator. STARTING/CHARGING SYSTEMS(H4DO)>Generator

Replace the combination meter. INSTRUMENTATION/DRIVER INFO>Combination Meter

STARTING/CHARGING SYSTEMS(H4DO) > Starter
REMOVAL

- When replacing the starter, be sure to perform [Start count clearing] after the service. AUTO START STOP (DIAGNOSTICS)>Work Support

- When replacing the starter, be sure to replace the fuel pump relay at the same time. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Pump Relay

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

3.

Remove the clip from the air intake boot, and loosen the clamp.

4.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

Be careful not to pull out the PCV hose.

5.

Remove the front wheel LH. WHEEL AND TIRE SYSTEM>Tire and Wheel>REMOVAL

6.

Disconnect the connector, terminal B and ground terminal.

In order to prevent damaging the ground terminal, fix the ground terminal when loosing the bolt, and avoid the part from rotating together while loosening the bolt.

7.

Remove the cable stay (A) and starter (B).

Remove from the upper side of the vehicle.

STARTING/CHARGING SYSTEMS(H4DO) > Starter
INSTALLATION

- When replacing the starter, be sure to perform [Start count clearing] after the service. AUTO START STOP (DIAGNOSTICS)>Work Support

- When replacing the starter, be sure to replace the fuel pump relay at the same time. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Pump Relay

1.

Install the starter and cable stay.

Tightening torque:

50 N·m (5.1 kgf-m, 36.9 ft-lb)

2.

Connect the terminal B and connector to the starter.

Tightening torque:

11 N·m (1.1 kgf-m, 8.1 ft-lb)

3.

Connect the ground terminal to the cable stay.

Tightening torque:

14 N·m (1.4 kgf-m, 10.3 ft-lb)

4.

Install the front wheel LH. WHEEL AND TIRE SYSTEM>Tire and Wheel>INSTALLATION

5.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

6.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

7.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

STARTING/CHARGING SYSTEMS(H4DO) > Starter
INSPECTION
1. MAGNET SWITCH

Using a circuit tester, check there is continuity between S terminal and M terminal, and between S terminal and ground.

Also, check that there is no continuity between M terminal and B terminal.

(A) | Terminal S | (B) | Terminal M | (C) | Terminal B

Terminals | Standard
Terminal S — terminal M | 1 Ω or less
Terminal S — Ground | 1 Ω or less
Terminal M — terminal B | 1 MΩ or more

2. MAGNET SWITCH OPERATION

Perform the inspection in a short period of time. (Within 3 to 5 seconds)

1.

Loosen the nut which holds the cable to the M terminal.

This procedure is required to facilitate the cable removal from the M terminal.

2.

Connect the battery positive terminal to the S terminal, and connect the battery negative terminal to the starter housing. Then, if the pinion protrudes, it is normal.

The motor may rotate while the pinion protrudes. This occurs due to current that flows to the motor via pull-in coil. This is not a problem.

(A) | Terminal S |  |  |  |

3.

Disconnect the cable from the M terminal. Check that the pinion is being protruded at this time.

Hold the disconnected cable so that it does not contact the terminal or wiring.

4.

Disconnect the battery negative terminal from the starter housing. Then, if the pinion returns to its original position, it is normal.

(A) | Terminal S |  |  |  |

3. NO-LOAD TEST

- Use a thick cable due to large current flowing through the cable.

  - 1) For B terminal and ground, it is recommended that the cross-section area of continuity part (shaded part) should be 20 mm2 (0.00310 sq in) or more. For S terminal, 1.25 mm2 (0.00194 sq in) or more.

    (a) | Cable cross-section | (b) | Cable shield part | (c) | Cable continuity part

  - 2) It is possible to use a booster cable instead of wiring.

- Be careful not to burn yourself and cause a fire due to heat.

- Perform the no-load test in a short period of time. (Within 3 to 5 seconds)

For no-load test, use the circuit shown in figure.

(A) | Terminal S | (D) | Magnet switch | (G) | Circuit tester
(B) | Terminal M | (E) | Switch |  |
(C) | Terminal B | (F) | Circuit tester with clamp-type ammeter |  |

1.

Using a vise, secure the starter.

Be careful not to deform or damage the starter.

2.

Turn the switch ON, and check that the pinion protrudes rapidly into the specified position and rotates powerfully without noise.

3.

Check the current and voltage after its rotation speed stabilizes.

Standard (current/voltage)

90 A or less / approx. 11 V

4. OTHER INSPECTIONS

Check that there is no deformation, cracks or other damages.

STARTING/CHARGING SYSTEMS(H4DO) > Starter Relay
LOCATION

- Starter relay

- Starter cut relay

STARTING/CHARGING SYSTEMS(H4DO) > Starter Relay
INSPECTION
1.

Check that there is no deformation, cracks or other damages.

2.

Check the resistance between terminals.

- Starter relay

  Terminal No. | Inspection conditions | Standard
  3 — 4 | Always | 1 MΩ or more
  3 — 4 | Apply battery voltage between terminals 1 and 2. | Less than 1 Ω

- Starter cut relay

  Terminal No. | Inspection conditions | Standard
  3 — 4 | Always | 1 MΩ or more
  3 — 4 | Apply battery voltage between terminals 1 and 2. | Less than 1 Ω

STARTING/CHARGING SYSTEMS(H4DO) > Generator
REMOVAL
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the V-belts. MECHANICAL(H4DO)>V-belt>REMOVAL > V-BELT

3.

Disconnect the connector and terminal B.

4.

Remove the generator.

STARTING/CHARGING SYSTEMS(H4DO) > Generator
INSTALLATION
1.

Temporarily install the generator.

2.

Tighten the bolts in the numerical order as shown in the figure.

Tightening torque:

25 N·m (2.5 kgf-m, 18.4 ft-lb)

3.

Connect the connector and terminal B.

Tightening torque:

15.5 N·m (1.6 kgf-m, 11.4 ft-lb)

4.

Install the V-belts. MECHANICAL(H4DO)>V-belt>INSTALLATION > V-BELT

5.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

STARTING/CHARGING SYSTEMS(H4DO) > Generator
DISASSEMBLY
1.

Remove the cover.

2.

Remove the terminal B.

3.

Remove the rear cover.

4.

Remove the brush holder.

Set the socket with suitable size etc. (a) to the brush holder, and slide the brush holder toward the socket etc. (a) to remove so that the brush does not pop out.

5.

Remove the IC regulator.

STARTING/CHARGING SYSTEMS(H4DO) > Generator
ASSEMBLY
1.

Install the IC regulator.

Tightening torque:

3.9 N·m (0.4 kgf-m, 2.9 ft-lb)

2.

Install the brush holder.

Use a socket with suitable size etc. to install the brush while being pushed.

Tightening torque:

2 N·m (0.2 kgf-m, 1.5 ft-lb)

3.

Install the rear cover.

4.

Install the terminal B.

Tightening torque:

8.9 N·m (0.9 kgf-m, 6.6 ft-lb)

5.

Install the cover on the installation location of terminal B.

6.

Manually turn the pulley to check that the rotor rotates smoothly.

STARTING/CHARGING SYSTEMS(H4DO) > Generator
INSPECTION

For the disassembly or assembly procedures required for inspection, refer to “DISASSEMBLY” and “ASSEMBLY” of Generator.

- STARTING/CHARGING SYSTEMS(H4DO)>Generator>DISASSEMBLY

- STARTING/CHARGING SYSTEMS(H4DO)>Generator>ASSEMBLY

1. BRUSH
1.

Measure the length of each brush. Replace the brush if wear exceeds service limits. There is a service limit mark (A) on each brush.

Brush length:

Standard

L1: 22.5 mm (0.886 in)

Limit

L2: 5.0 mm (0.197 in)

2.

Check that there is appropriate pressure on the brush spring. Using a spring pressure indicator, push the brush into the brush holder until its tip protrudes 2 mm (0.0787 in). Then measure the pressure of brush spring. If the pressure is 1.7 N (173 g, 6.11 oz) or less, replace the brush spring with a new part. 4.1 — 5.3 N (418 — 540 g 14.75 — 19.06 oz) pressure is required on the new spring.

2. OTHER INSPECTIONS

- Check that there is no deformation, cracks or other damages.

- Check that no foreign substances are clogged.

STARTING/CHARGING SYSTEMS(H4DO) > Battery
REMOVAL
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Disconnect the connector from battery sensor. (When the battery is not replaced)

3.

Remove the battery sensor. (When replacing the battery) STARTING/CHARGING SYSTEMS(H4DO)>Battery Sensor>REMOVAL

4.

Disconnect the positive terminal of battery.

5.

Remove the battery cable holder.

6.

Remove the battery holder.

7.

Remove the battery.

STARTING/CHARGING SYSTEMS(H4DO) > Battery
INSTALLATION

- If the battery terminal is worn and the terminal section is loose, replace it with a new battery.

- After connecting the ground terminal to the battery sensor, the initial diagnosis of the electronic throttle control is conducted by the vehicle. Therefore, wait for 10 seconds or more after turning the ignition switch to ON, and then start the engine.

1.

Install the battery.

2.

Install the battery holder.

Tightening torque:

3.5 N·m (0.4 kgf-m, 2.6 ft-lb)

3.

Install the battery cable holder.

4.

Connect the battery positive terminal.

Tightening torque:

6 N·m (0.6 kgf-m, 4.4 ft-lb)

5.

Install the battery sensor. (When the battery is replaced) STARTING/CHARGING SYSTEMS(H4DO)>Battery Sensor>INSTALLATION

6.

Connect the connector to the battery sensor. (When the battery has not been replaced)

7.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

STARTING/CHARGING SYSTEMS(H4DO) > Battery
INSPECTION

- As batteries produce flammable gases, be careful not to bring an open flame close to the batteries.

- Ventilate sufficiently when using or charging battery in enclosed space.

- Electrolyte is corrosive acid, and has toxicity; be careful of handling the fluid.

- For safety, in case an explosion does occur, wear protective goggles, etc. to shield your eyes when working near any battery. In addition, never lean over the battery.

- Be careful that the electrode does not come into contact with skin, eyes or clothing. Especially at contact with eyes, flush with water for 15 minutes and get prompt medical attention.

- Be careful not to let the electrode contact with the coated parts.

- Before starting work, remove rings, metal watch-bands, and other metal jewelry.

- Be careful not to let the metal tools contact the positive battery terminal and anything connected to it. When the operation using a metal tool to the positive terminal or anything connected to it is required, disconnect the ground terminal from the battery sensor before starting the operation.

1. APPEARANCE

Check the battery case, top cover and terminals for dirt or cracks, and perform the following work as necessary.

- Clean the battery with water and wipe with a dry cloth.

- Apply a thin coat of grease on the terminals to prevent corrosion.

Check

- Normal → Go to the check item 2.

- Abnormal → Replace the battery.

2. ELECTROLYTE LEVEL

Check the electrolyte level in each cell.

Do not fill beyond MAX level.

If the level is below the middle point between MIN level and MAX level, pour distilled water into the battery cell to bring the level to MAX.

Check

Model without Auto Start Stop

- MAX level → Go to the check item 4.

- Below the middle point between MIN level and MAX level → Fill → Go to the check item 4.

Model with Auto Start Stop

- MAX level → Go to the check item 3.

- Below the middle point between MIN level and MAX level → Fill → Go to the check item 3.

3. BATTERY VOLTAGE

Measure the battery terminal voltage.

- This operation is required to judge the presence of the internal short circuit (dendrite phenomenon) of the battery.

- When the battery voltage is below 11.0 V, replacement of the battery is recommended in order to avoid possible occurrence of the internal short circuit (dendrite phenomenon) of the battery.

Check

- 11.0 V or more → Go to the check item 4.

- Less than 11.0 V → Replace the battery (recommended) or charge the battery. (After charging, go to the check item 4.)

4. SPECIFIC GRAVITY OF ELECTROLYTE

Check the specific gravity of the electrolyte using a hydrometer and a thermometer.

- Specific gravity varies with temperature of electrolyte so that it must be corrected at 20°C (68°F) using the following calculation:

  S20 = St + 0.0007 × (t − 20)

  S20: Specific gravity corrected at electrolyte temperature of 20°C

  St: Measured specific gravity

  t: Measured temperature (°C)

- When measuring in a simplified manner using the battery terminal voltage, calculate the specific gravity by the following formula.

  Specific gravity = [0.187 × battery terminal voltage (V)] − 1.1

  Perform the steps 1) and 2) before measuring the voltage in order to stabilize the voltage.

  1) Turn the ignition switch to OFF and illuminate the headlight for 30 seconds.

  2) After turning off the headlight, leave the vehicle for one minute.

- Measuring the specific gravity of the electrolyte in the battery will disclose the state of charge of the battery. The relation between specific gravity and state of charge is as shown in the figure.

  (A) | Specific gravity [20°C (68°F)] | (C) | Good | (D) | Need to charge or replace
  (B) | Amount of discharge (%) |  |  |  |

  (A) | Specific gravity [20°C (68°F)] | (C) | Good | (E) | Need charging
  (B) | Electrolyte temperature | (D) | Caution |  |

Check

- Specific gravity: 1.250 — 1.290, and difference between cells is 0.04 or less → Battery is normal

- Specific gravity: Less than 1.250, or difference between cells is 0.04 or more → Battery needs to be charged or replaced

5. STANDBY CURRENT
1.

Prepare the circuit tester which can measure down to 1 mA.

For model with keyless access function, the standby current changes regularly. Therefore, prepare the analog type circuit tester.

2.

Using the circuit tester, check the standby current.

The standby current may be displayed lower than the actual value if the battery is weak, so charge or replace the battery as necessary.

(1)

Check the battery.

Appearance:

STARTING/CHARGING SYSTEMS(H4DO)>Battery>INSPECTION > APPEARANCE

Electrolyte level:

STARTING/CHARGING SYSTEMS(H4DO)>Battery>INSPECTION > ELECTROLYTE LEVEL

Battery voltage:

STARTING/CHARGING SYSTEMS(H4DO)>Battery>INSPECTION > BATTERY VOLTAGE

Specific gravity of electrolyte:

STARTING/CHARGING SYSTEMS(H4DO)>Battery>INSPECTION > SPECIFIC GRAVITY OF ELECTROLYTE

(2)

Check that the fuse is not blown out and is properly inserted.

(3)

When non-genuine electrical parts (including parts sold in authorized workshops) are installed, remove all parts.

(4)

Check that back-up fuse is inserted. PRE-DELIVERY INSPECTION>PRE-DELIVERY INSPECTION (PDI) PROCEDURE > FUSE INSTALLATION

(5)

Start the engine, and set the switch positions for each system as shown in the following table.

Some of the listed systems are not equipped depending on the vehicle. Set only the systems equipped on the vehicle to the positions as shown.

System | Position
Headlight | ON or Auto
Fog light | ON
Wiper (front and rear) | ON or Low speed
Audio and navigation system | ON
Rear defogger | ON
Room light | DOOR
Luggage light | DOOR
Map light | OFF
Auto A/C | ON (AUTO)
Manual A/C | ON (Speed 1)
Electronic parking brake | ON
Electrical parts other than listed above (electrical parts that users can confirm the operation with the key removed) | OFF

(6)

Turn the ignition switch to OFF.

(7)

Operate the front hood lock release lever to unlock the front hood.

(8)

Close all the doors (including rear gate and trunk lid) and then lock the doors. (Security alarm is in set condition)

For model with keyless access function, take the access key 1.5 m or more away from the vehicle after the door lock. And do not put the access key close to the vehicle while measuring the standby current.

(9)

Wait for 5 minutes after door lock until the standby current stabilizes.

(10)

Loosen the nut which holds the ground terminal to the battery sensor.

Do not remove the ground terminal.

(11)

Connect the circuit tester positive terminal to the ground terminal.

To prevent the damage to the circuit tester, set the circuit tester range to a large value first, then gradually change it to smaller values.

(12)

Connect the circuit tester negative terminal to the ground terminal installation part of the battery sensor.

(13)

While connecting the circuit tester positive terminal with the ground terminal as shown in the figure, remove the ground terminal from the battery sensor.

(14)

Check the standby current.

If the terminals and circuit tester are detached during standby current inspection, reconnect the ground terminal to the battery sensor and repeat the procedure from step (9).

- For model with keyless access function, the standby current changes periodically because the keyless access system continuously searches the access key (polling).

- When measuring the standby current, the reading of the circuit tester oscillates. Therefore, read the average value (median value).

- The standby current may become large when the vehicle system (ELCM) is activated 5 times at 30-minute intervals or 5 hours after turning the ignition switch to OFF. Therefore, the measurement should be completed in 20 minutes after the ignition switch is turned to OFF.

  If it takes more than 20 minutes, start the engine once, turn the ignition switch to OFF again, then perform the inspection.

  (A) | Current/mA | (C) | Ignition OFF | (E) | 5 seconds (system operation)
  (B) | Time/min | (D) | Less than 70 mA | (F) | 300 mA or more

Check

- When the maximum measurement value is less than 70 mA → Standby current is normal.

- When the maximum measurement value is 70 mA or more → Go to step (15).

(15)

Connect the ground terminal to the battery sensor, and wait for 55 minutes.

For 55 minutes after turning IG OFF, vehicle system (EPS) may still be active.

(16)

Measure the standby current with the same measurement procedures as in steps (10) through (14).

Check

- When the maximum measurement value is less than 70 mA → Standby current is normal.

- When the maximum measurement value is 70 mA or more → Go to step (17).

(17)

Remove all fuses one by one to identify which system changes the standby current value significantly. WIRING SYSTEM>Power Supply Circuit

(18)

Check the related part, harness and connector of the system whose standby current has changed significantly.

STARTING/CHARGING SYSTEMS(H4DO) > Battery
CHARGE

- Do not bring an open flame close to the battery.

- If the terminals are corroded, clean with a brush and common caustic soda solution.

- As batteries produce flammable gases while charging, be careful not to bring an open flame close to the batteries.

- Ventilate sufficiently when charging batteries.

- Observe instructions when handling the battery charger.

- Before charging the battery on the vehicle, disconnect the ground terminal from the battery sensor to prevent damage of generator diodes or other electrical units.

1. NORMAL CHARGE (CONSTANT CURRENT CHARGE)

Charge the battery with the current value specified by manufacturer or with approximately 1/10 of battery’s rating capacity. (See the table below.)

Type | Charging current (A) | CCA (A)
Q‐85 | 5.5 — 6.5 | 620

- The charge control feature and specifications for judgment of charge completion depend on the device. Follow the instruction manual of the charger used.

- Keep the electrolyte temperature at 45°C (113°F) or less while charging. Stop charging when the temperature exceeds this value.

The characteristics of typical charging methods are as follows.

- Constant current charging

  This method makes it easy to charge to 100%, since the electrolyte is agitated by the gassing occurred at the end of charging. However, the time for charging is comparatively long because the current value is kept constant.

- Constant voltage charging

  This method completes charging in a short period of time due to the large current. However, it is difficult to charge to 100% because no gassing occurred at the end of charging and the electrolyte is not agitated. Therefore, the combined use with the constant current charging is preferable.

- Quasi-constant voltage charging

  This method is widely used for commercially available chargers.

  Compared to the constant voltage charging whose charging current at the beginning of charging becomes large, it reduces the charging current by lowering the voltage at the initial stage, resulting in battery load reduction. The time for charging is comparatively long. However, this type of chargers can be manufactured comparatively inexpensive due to the simple control circuit (or manual settings). After the initial stage of charging is completed, it gradually raises the charging voltage so that the charging current is within the specification, until the battery is fully charged.

- Constant voltage/current charging

  In addition to the constant voltage charging, this method controls the upper limit of the current.

  The constant current charging is applied at the beginning of charging, and the constant voltage charging is applied at the end. This makes battery charge comparatively efficient in a short period of time. Charging by generators is similar to this method.

Judgment of charge completion

1.

Specific gravity of electrolyte should be held within the specific range of 1.250 — 1.290 for one hour or more.

2.

Voltage while charging should be held within the specified range of 15.0 — 16.8 V for one hour or more.

3.

Gas is actively generated in all cells.

4.

The amount of charge reaches 1.2 — 1.5 times of the amount of discharge.

The amount of discharge/charge can be calculated by the following formula.

- Amount of discharge (Ah) = remaining capacity calculated by specific gravity (%) × 5 hour rate capacity (Ah)

- Amount of charge (Ah) = Charging current value (A) × Time for charging

2. QUICK CHARGING

Charge the battery in a short period of time with a relatively large current by using a quick charger.

Charge the battery with the current value at approximately 1/2 of battery’s rating capacity. (See the table below.)

- Quick charging is accompanied by a large amount of heat generation. Charging should be completed in up to 30 minutes regardless of battery size.

- Quick charging is used to recover the battery until it can start the vehicle. For full charging, use the normal charging method.

- Keep the electrolyte temperature at 55°C (131°F) or less while quick charging. Stop charging when the temperature exceeds this value.

Type | Charging current (A) | CCA (A)
Q‐85 | 27.5 — 32.5 | 620

STARTING/CHARGING SYSTEMS(H4DO) > Battery Cable Assembly
REMOVAL
1.

Disconnect the ground terminal (A) and remove the ground cable from the clip (B).

2.

Disconnect the ground terminal (C) and remove the battery cable holder (D).

3.

Remove the battery sensor harness from the clip (E).

4.

Disconnect the terminal (A), terminal (B) and terminal (C).

5.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

6.

Remove the clip from the air intake boot, and loosen the clamp.

7.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

Be careful not to pull out the PCV hose.

8.

Disconnect the connector, terminal B and ground terminal.

In order to prevent damaging the ground terminal, fix the ground terminal when loosing the bolt, and avoid the part from rotating together while loosening the bolt.

9.

Disconnect the connector (A), connector (B) and terminal (C).

10.

Remove the clip (D) and clip (E) that secure the battery cable assembly.

11.

Disconnect the connector (A), and remove the engine wiring harness from the clip (B).

12.

Remove the clip (C) from the intake manifold assembly.

13.

Remove the claw (D) securing the battery cable assembly to the intake manifold assembly and separate the battery cable assembly from the intake manifold assembly.

14.

Remove the claw securing the battery cable assembly to the bracket and remove the battery cable assembly.

STARTING/CHARGING SYSTEMS(H4DO) > Battery Cable Assembly
INSTALLATION
1.

Secure the battery cable assembly to the bracket.

2.

Secure the battery cable assembly with the claw (D) and clip (C).

3.

Install the engine wiring harness to the clip (B), and connect the connector (A).

4.

Secure the battery cable assembly with the clip (A) and clip (B).

5.

Connect the connector (C), connector (D), and the terminal (E).

Tightening torque:

15.5 N·m (1.6 kgf-m, 11.4 ft-lb)

6.

Connect the terminal B and connector to the starter.

Tightening torque:

11 N·m (1.1 kgf-m, 8.1 ft-lb)

7.

Connect the ground terminal to the cable stay.

Tightening torque:

14 N·m (1.4 kgf-m, 10.3 ft-lb)

8.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

9.

Connect the terminal (C), terminal (B) and terminal (A).

Tightening torque:

7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

10.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

11.

Install the battery sensor harness to the clip (E).

12.

Install the battery cable holder (D), and connect the ground terminal (C).

Tightening torque:

7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

13.

Install the ground cable to the clip (B), and connect the ground terminal (A).

Tightening torque:

13 N·m (1.3 kgf-m, 9.6 ft-lb)

STARTING/CHARGING SYSTEMS(H4DO) > Battery Cable Assembly
INSPECTION

Check that the battery cable assembly has no deformation, cracks or other damages.

STARTING/CHARGING SYSTEMS(H4DO) > Battery Sensor
REMOVAL
1.

Disconnect the connector and ground terminal.

2.

Remove the battery sensor.

The end of the bolt (a) of the battery sensor is crimped. Therefore, do not loosen the nut (b) to the crimped portion.

STARTING/CHARGING SYSTEMS(H4DO) > Battery Sensor
INSTALLATION

- If the battery terminal is worn and the terminal section is loose, replace it with a new battery.

- After connecting the ground terminal to the battery sensor, the initial diagnosis of the electronic throttle control is conducted by the vehicle. Therefore, wait for 10 seconds or more after turning the ignition switch to ON, and then start the engine.

1.

Install the battery sensor.

(1)

Clean and degrease the battery terminal (A) and the inside (B) of the battery sensor terminal.

When wiping, be careful not to deform the battery sensor.

(2)

Loosen the battery sensor nut.

- The end of the bolt (a) of the battery sensor is crimped. Therefore, do not loosen the nut (b) to the crimped portion.

- Make sure that the seat (c) of battery sensor is fully in contact with the rotation stopper (d).

(3)

Set the battery sensor to the battery terminal, and tighten the nut.

- Set the battery sensor straight to the battery terminal.

- Insert until the battery terminal upper end (a) exceeds the height of the battery sensor terminal upper end (b).

Tightening torque:

3.4 N·m (0.3 kgf-m, 2.5 ft-lb)

2.

Connect the connector and ground terminal to the battery sensor.

Tightening torque:

7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

3.

Apply a thin coat of grease in the application range shown in the figure.

STARTING/CHARGING SYSTEMS(H4DO) > Battery Sensor
INSPECTION

Check that there is no deformation, cracks or other damages.

STARTING/CHARGING SYSTEMS(H4DO) > Auto Start Stop DC/DC Converter
LOCATION

Auto Start Stop DC/DC converter 2 is installed only on models with power amplifier with Auto Start Stop.

STARTING/CHARGING SYSTEMS(H4DO) > Auto Start Stop DC/DC Converter
REMOVAL
1. Auto Start Stop DC/DC CONVERTER 1
•
EXCEPT FOR MODEL WITH POWER AMPLIFIER
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Disconnect the connector from the Auto Start Stop DC/DC converter 1 and remove the clip.

3.

Remove the Auto Start Stop DC/DC converter 1 from the vehicle.

4.

Remove the Auto Start Stop DC/DC converter 1 from the bracket.

•
MODEL WITH POWER AMPLIFIER
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Disconnect the connector from the Auto Start Stop DC/DC converter 1 and Auto Start Stop DC/DC converter 2, and remove the clips.

3.

Remove the Auto Start Stop DC/DC converter 1 and Auto Start Stop DC/DC converter 2 from the vehicle.

4.

Remove the Auto Start Stop DC/DC converter 1 from the bracket.

2. Auto Start Stop DC/DC CONVERTER 2
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Disconnect the connector from the Auto Start Stop DC/DC converter 1 and Auto Start Stop DC/DC converter 2, and remove the clips.

3.

Remove the Auto Start Stop DC/DC converter 1 and Auto Start Stop DC/DC converter 2 from the vehicle.

4.

Remove the Auto Start Stop DC/DC converter 2 from the bracket.

STARTING/CHARGING SYSTEMS(H4DO) > Auto Start Stop DC/DC Converter
INSTALLATION
1. Auto Start Stop DC/DC CONVERTER 1
•
EXCEPT FOR MODEL WITH POWER AMPLIFIER
1.

Install the Auto Start Stop DC/DC converter 1 to the bracket.

Tightening torque:

7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

2.

Install the Auto Start Stop DC/DC converter 1 to the vehicle.

Tightening torque:

18 N·m (1.8 kgf-m, 13.3 ft-lb)

3.

Connect the connector to the Auto Start Stop DC/DC converter 1, and install the clip.

4.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

•
MODEL WITH POWER AMPLIFIER
1.

Install the Auto Start Stop DC/DC converter 1 to the bracket.

Tightening torque:

7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

2.

Install the Auto Start Stop DC/DC converter 1 and Auto Start Stop DC/DC converter 2 to the vehicle.

Tightening torque:

18 N·m (1.8 kgf-m, 13.3 ft-lb)

3.

Connect the connector to the Auto Start Stop DC/DC converter 1 and Auto Start Stop DC/DC converter 2, and install the clips.

4.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2. Auto Start Stop DC/DC CONVERTER 2
1.

Install the Auto Start Stop DC/DC converter 2 to the bracket.

Tightening torque:

7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

2.

Install the Auto Start Stop DC/DC converter 1 and Auto Start Stop DC/DC converter 2 to the vehicle.

Tightening torque:

18 N·m (1.8 kgf-m, 13.3 ft-lb)

3.

Connect the connector to the Auto Start Stop DC/DC converter 1 and Auto Start Stop DC/DC converter 2, and install the clips.

4.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

STARTING/CHARGING SYSTEMS(H4DO) > Auto Start Stop DC/DC Converter
INSPECTION

Check that there is no deformation, cracks or other damages.

STARTING/CHARGING SYSTEMS(H4DO) > Auto Start Stop OFF Switch
REMOVAL
1.

Disconnect the ground terminal from the battery sensor, and wait for at least 60 seconds before starting work. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the instrument panel lower cover. EXTERIOR/INTERIOR TRIM>Instrument Panel Lower Cover>REMOVAL

3.

Release the claws and remove the Auto Start Stop OFF switch.

STARTING/CHARGING SYSTEMS(H4DO) > Auto Start Stop OFF Switch
INSTALLATION
1.

Install the Auto Start Stop OFF switch.

2.

Install the instrument panel lower cover. EXTERIOR/INTERIOR TRIM>Instrument Panel Lower Cover>INSTALLATION

3.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

STARTING/CHARGING SYSTEMS(H4DO) > Auto Start Stop OFF Switch
INSPECTION
1.

Check that there is no deformation, cracks or other damages.

2.

Check the resistance between terminals shown in the following table.

Terminal No. | Inspection conditions | Standard
6 — 8 | Switch ON | Less than 1 Ω
Switch OFF | 1 MΩ or more

3.

Apply battery voltage between the terminals shown in the table below to check lighting condition of illumination inside the switch.

When applying battery voltage, do not mix up the positive (+) side and the negative (−) side.

Incorrect polarity connection may cause LED damage inside the switch.

Terminal No. | Inspection conditions | Condition
1 (+) — 4 (−) | Apply battery voltage. | Light ON