Engine Electrical System
Engine Electrical System
Engine Electrical System
SPORTAGE(KM) > 2010 > G 2.7 DOHC > Engine Electrical System
Because of the possibility of personal injury, always use extreme caution and appropriate eye protection when
working with batteries.
cardiagn.com
Keypad
The Micro 570 button on the key pad provide the following functions :
Connect clamps securely. If "CHECK CONNECTION" message is displayed on the screen, reconnect
clamps securely.
cardiagn.com
2. The tester will ask if the battery is connected "IN-VEHICLE" or "OUT-OF-VEHICLE". Make your selection by
pressing the arrow buttons; then press ENTER.
CCA : Cold cranking amps, is an SAE specification for cranking batteried at -0.4°F (-
18°C).
Page 3 of 57
4. Set the CCA value displayed on the screen to the CCA value marked on the battery label by pressing up and
down buttons and press ENTER.
The battery ratings(CCA) displayed on the tester must be identical to the ratings marked on battery label.
cardiagn.com
6. The tester displays battery test results including voltage and battery ratings.
Refer to the following table and take the appropriate action as recommended by the Micro 570.
cardiagn.com
Whenever filing a claim for battery, the print out of the battery test results must be attached.
Starter Test Procedure
7. After the battery test, press ENTER immediately for the starter test.
cardiagn.com
LOW - Check starter
CHARGE BATTERY The state of battery charge is too low to test
- Charge the battery and retest
REPLACE BATTERY Replace battery
- If the vehicle is not started though the battery condition of "GOOD
BATTERY" is displayed, check wiring for open circuit, battery cable
connection, starter and repair or replace as necessary.
- If the engine does crank, check fuel system.
When testing the vehicle with old diesel engines, the test result will not be favorable if the glow plug is not
heated. Conduct the test after warming up the engine for 5 minutes.
12. Turn off all electrical load and rev engine for 5 seconds with pressing the accelerator pedal. (Follow the
instructions on the screen)
cardiagn.com
Page 7 of 57
13. The message that engine RPM is detected will be displayed on the screen. Press ENTER to continue.
14. If the engine RPM is not detected, press ENTER after revving engine.
cardiagn.com
15. The tester will conduct charging system test during loads off.
Page 8 of 57
16. Turn on electrical loads (air conditioner, lamps, audio and etc). Press ENTER to continue.
17. The tester will conduct charging system test during loads on.
cardiagn.com
18. Rev engine for 5 seconds with pressing the accelerator pedal. (Follow the instructions on the screen)
Page 9 of 57
19. The message that engine RPM is detected will be displayed on the screen. Press ENTER to continue.
cardiagn.com
20. If the engine RPM is not detected, press ENTER after revving engine.
21. Turn off electrical loads (air conditioner, lamps, audio and etc). Turn the engine off.
22. Charging voltage and charging system test results will be displayed on the screen.
Shut off engine end disconnect the tester clamps from the battery. Refer to the following table and take the
appropriate action as recommended by the Micro 570.
Page 10 of 57
cardiagn.com
Charging System Test Results
Result On Printer Remedy
CHARGING SYSTEM Charging system is normal
NORMAL / DIODE
RIPPLE NORMAL
NO CHARGING Alternator does not supply charging current to battery
VOLTAGE - Check belts, connection between alternator and battery and replace belts or
cable or alternator as necessary
LOW CHARGING Alternator does not supply charging current to battery and electrical load to
VOLTAGE system fully
- Check belts and alternator and replace as necessary
HIGH CHARGING The voltage from alternator to battery is higher than normal limit during voltage
VOLTAGE regulating.
- Check connection and ground and replace regulator as necessary
- Check electrolyte level in the battery
EXCESS RIPPLE One or more diodes in the alternator is not functioning properly
DETECTED - Check alternator mounting and belts and replace as necessary
Page 11 of 57
cardiagn.com
Poor mileage Spark plugs and spark plugs cable See page EE-17
CHARGING SYSTEM
Symptom Suspect Area Remedy (See Page)
Charging warning indicator Fuse blown Check fuses
does not light with ignition Light burned out Replace light
switch "ON" and engine off Wiring connection loose Tighten loose connections
Electronic voltage regulator See page EE-27
Charging warning indicator Drive belt loose or worn See page EE-23, 36
does not go out with engine Battery cables loose, corroded or worn See page EE-39
running (Battery requires Fuse blown Check fuses
frequent recharging) Fusible link blown Replace fusible link
Electronic voltage regulator or generator See page EE-27
Wiring Repair wiring
Engine hesitates/poor Drive belt loose or worn See page EE-23, 36
acceleration Wiring connection loose or open circuit Tighten loose connection or repair
Overcharge wiring
Fusible link blown Replace fusible link
Poor grounding Repair
Electronic voltage regulator or generator See page EE-27
Worn battery Replace battery
Electronic voltage regulator See page EE-27
Voltage sensing wire Repair wire
STARTING SYSTEM
Page 12 of 57
Symptom Suspect Area Remedy (See Page)
Engine will not crank Battery charge low Charge or replace battery
Battery cables loose, corroded or worn out Repair or replace cables
Transaxle range switch (Vehicle with See page TR group-automatic
automatic transaxle only) transaxle
Fusible link blown
Starter motor faulty Replace fusible link
Ignition switch faulty See page EE-44
Inspect
Engine cranks slowly Battery charge low Charge or replace battery
Battery cables loose, corroded or worn out Repair or replace cables
Starter motor See page EE-44
Starter keeps running Starter motor See page EE-44
Ignition switch Inspect
Starter spins but engine will Short in wiring Repair wiring
not crank Pinion gear teeth broken or starter motor See page EE-44
Ring gear teeth broken See page EM group-fly wheel
cardiagn.com
CRUISE CONTROL SYSTEM
Before troubleshooting :
- Check the ECM(10A), Horn(10A), ECU #3(10A) and ECU B+(15A) fuse in the under - hood fuse/relay box.
- Check that the horn sounds.
- Check the tachometer to see if it works properly.
cardiagn.com
The transmission shifts down slower Troubleshooting the cruise control See page EE-8
than normal when going up a hill with communication circuit
the cruise control on (A/T)
cardiagn.com
Is there approx. 1V?
- Check for loosen connectors. If necessary replace the TCM and recheck. (See Page TR group-automatic
transaxle)
- Repair short or open in the wire between the TCM (or PCM) terminal and cruise control unit.
STARTING SYSTEM
Page 15 of 57
Specifications
Item
2.7 2.0
Reduction drive (with planetary
Type
gear)
Rated voltage 12V, 1.2KW 12V, 1.2KW
No. of pinion teeth 8 8
Voltage 11V 11V
No-load Amperage 90A, MAX 90A, MAX
Starter charasteristics
2,800rpm, 3,000rpm,
Speed
MIN MIN
Commutator Standard 29.4 mm (1.157 in.)
diameter Limit 28.4 mm (1.118 in.)
Standard 0.5 mm (0.02 in.)
Undercut depth
Limit 0.2 mm (0.008 in.)
cardiagn.com
CHARGING SYSTEM
Specifications
Item
2.7 2.0
Type Battery voltage sensing
Rated voltage 12V, 120A 13.5V, 90A
Speed 1,000 ~ 18,000 rpm
Alternator
Voltage regulator Electronic built-in type
Regulator setting voltage 14.55 ± 0.2V 14.4 ± 0.3V
Temperrature compensation -3.5 ± 1mV/°C -10 ± 3mV/°C
Type MF 68 AH MF 60 AH
Cold cranking amperage at-
600A 550A
18°C (0°F)
Battery
Reserve capacity 113min 92min
Specific gravity at 20°C
1.280 ± 0.01 1.280 ± 0.01
(77°F)
- COLD CRANKING AMPERAGE is the amperage a battery can deliver for 30 seconds and maintain a
terminal voltage of 7.2V or greater at a specified temperature.
- REVERSE CAPACITY RATING is amount of time a battery can deliver 25A and maintain a minimum
terminal voltage of 10.5V at 26.7°C(80°F)
AUTO CRUISE CONTROL SYSTEM
Page 16 of 57
Items Specification
Setting error Within ± 1.5Km/h on level road
Vehicle speed memory variation No variation
Setting time 0.1sec max.
Resuming time 0.1sec max.
Minimum operating speed 40 ± 2Km/h
Cancel speed range 15 ± 2Km/h
Maximum memorized speed 160 ± 2Km/h
Pulling force 127N(13Kgf)
Main switch serial resistance value 3.9kΩ ± 1%
TIGHTENING TORQUE
cardiagn.com
Items Nm kg·cm lb-ft
Generator terminal
(B+) 5~7 50 ~ 70 3.6 ~ 5.1
Starter motor terminal 10 ~ 12 100 ~ 120 7.3 ~ 8.8
(B+) 4~6 40 ~ 60 2.9 ~ 4.3
Battery terminal 20 ~ 30 200 ~ 300 15 ~ 22
Spark plug
Engine Electrical System > Ignition System > Description and Operation
DESCRIPTION
To prevent gasoline from being injected from injectors during this test, crank the engine for no more then 5~10
seconds at time.
cardiagn.com
When removing the spark plug cable, pull on the spark plug cable boot (not the cable), as it may be
damaged.
Page 18 of 57
2. Using a spark plug socket, remove the spark plug(B).
cardiagn.com
2.7
1. Remove the engine cover.
2. Disconnect the VIS actuator connectors and injector connectors.
3. Remove the accelerator cable.
4. Remvoe surge tank sub assembly.
Standard (New)
1.0~1.1 mm (0.039~0.043 in.)
cardiagn.com
B. Carefully remove the spark plug cable by pulling on the rubber boots(A).
Check the condition of the spark plug cable terminals(B), if any terminal is corroded, clean it, and if it broken
or distorted, replace the spark plug cable.
Measure the primary coil resistance between terminals 1-4, 2-4 and 3-4.
cardiagn.com
Standard value :
0.58Ω ± 10% (2.0)
0.96Ω ± 10% (2.7)
2. Measure the secondary coil resistance between the high-voltage terminal for the No.1 and No.4 cylinders, and
between the high-voltage terminals for the No.2 and No.3 cylinders.
Standard value :
8.8kΩ ± 15% (2.0)
12.5kΩ ± 15% (2.7)
Be sure, when measuring the resistnace of the secondary coil, to disconnect the connector of the ignition
coil.
Page 21 of 57
Measure the secondary coil resistance between the high-voltage terminals for the No.1 and No.4 cylinders, No.2
and No.5 cylinders and No.3 and No.6 cylinders.
cardiagn.com
REPLACEMENT
IGNITION COIL
1. Remove the engine cover.
2. Disconnect the spark plug cable and connector.
3. Remove the ignition coil(A).
4. Installation is the reverse of removal.
Page 22 of 57
CRANKSHAFT POSITION SENSOR
1. Disconnect the crankshaft position sensor connector.
2. Remove the crankshaft position sensor(A).
Engine Electrical System > Charging System > Description and Operation
DESCRIPTION
GASOLINE
The charging system included a battery, an generator with a built-in regulator, and the charging indicator light and
wire.
The generator has eight built-in diodes (four positive and four negtive), each rectifying AC current to DC current.
Therefore, DC curent appears at generator "B" terminal.
In addition, the charging voltage of this generator is regulated by the battery voltage detection system.
The generator is regulated by the battery voltage detection system. The main components of the generator are the
rotor, stator, rectifier, capacitor brushes, bearings and V-ribbed belt pulley. The brush holder contains a built-in
electronic voltage regulator.
cardiagn.com
Engine Electrical System > Charging System > Repair procedures
ON-VEHICLE INSPECTION
• Check that the battery cables are connected to the correct terminals.
• Disconnect the battery cables when the battery is given a quick charge.
• Do not perform tests with a high voltage insulation resistance tester.
• Never disconnect the battery while the engine is running.
CHECK BATTERY VOLTAGE
1. After having driven the vehicle and in the case that 20 minutes have not passed after having stopped the engine,
turn the ignition switch ON and turn on the electrical system (headlamp, blower motor, rear defogger etc.) for 60
seconds to remove the surface charge.
2. Turn the ignition switch OFF and turn off the electrical systems.
3. Measure the battery voltage between the negative (-) and positive (+) terminals of the battery.
Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it
should be replaced.
cardiagn.com
DRIVE BELT TENSION
New belt 540~640 N (121~143 lb)
Used belt 340~490 N (77~110 lb)
- "New belt" refers to a belt which has been used less than 5 minutes on a running engine.
- "Used belt" refers to a belt which has been used on a running engine for 5 minutes or more.
- After installing a belt, check that it fits properly in the ribbed grooves.
- Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the
pulley.
- After installing a new belt, run the engine for about 5 minutes and recheck the belt tension.
cardiagn.com
1. Turn the ignition switch to "OFF".
To find abnormal conditions of the connection, actions should not be taken on the two terminals and each
connection during the test.
2. Connect a digital voltmeter between the alternator "B" terminal and battery (+) lead wire to the battery (+)
terminal. Connect the (+) lead wire of the voltmeter to the "B" terminal and the (-) lead wire to the battery (+)
terminal.
0.2V max.
2. If the value of the voltmeter is higher than expected (above 0.2V max.), poor wiring is suspected. In this case
check the wiring from the alternator "B" terminal to the fusible link to the battery (+) terminal. Check for loose
connections, color change due to an overheated harness, etc. Correct them before testing again.
Page 25 of 57
3. Upon completion of the test, set the engine speed at idle. Turn off the head lamps, blower motor and the ignition
switch.
PREPARATION
1. Prior to the test, check the following items and correct as necessary.
Check the battery installed in the vehicle to ensure that it is in good condition. The battery checking method is
described in "BATTERY".
The battery that is used to test the output current should be one that has been partially discharged. With a fully
charged battery, the test may not be conducted correctly due to an insufficient load.
Check the tension of the alternator drive belt.
2. Turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Disconnect the alternator output wire from the alternator "B" terminal.
5. Connect a DC ammeter (0 to 150A) in series between the "B" terminal and the disconnected output wire. Be
sure to connect the (-) lead wire of the ammeter to the disconnected output wire.
Tighten each connection securely, as a heavy current will flow. Do not rely on clips.
cardiagn.com
6. Connect a voltmeter (0 to 20V) between the "B" terminal and ground. Connect the (+) lead wire to the alternator
"B" terminal and (-) lead wire to a good ground.
7. Attach an engine tachometer and connect the battery ground cable.
8. Leave the engine hood open.
TEST
1. Check to see that the voltmeter reads as the same value as the battery voltage. If the voltmeter reads 0V, and the
open circuit in the wire between the alternator "B" terminal and battery (+) terminal, a blown fusible link or poor
grounding is suspected.
2. Start the engine and turn on the headlights.
3. Set the headlights to high beam and the heater blower switch to HIGH, quickly increase the engine speed to
2,500 rpm and read the maximum output current value indicated by the ammeter.
After the engine starts up, the charging current quickly drops. Therefore, the above operation must be
done quickly to read the maximum current value correctly.
RESULT
Page 26 of 57
1. The ammeter reading must be higher than the limit value. If it is lower but the alternator output wire is in good
condition, remove the alternator from the vehicle and test it.
63A min.
• The nominal output current value is shown on the nameplate affixed to the alternator body.
• The output current value changes with the electrical load and the temperature of the alternator itself.
Therefore, the nominal output current may not be obtained. If such is the case, keep the headlights on
the cause discharge of the battery, or use the lights of another vehicle to increase the electrical load.
The nominal output current may not be obtained if the temperature of the alternator itself or ambient
temperature is too high.
In such a case, reduce the temperature before testing again.
2. Upon completion of the output current test, lower the engine speed to idle and turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Remove the ammeter and voltmeter and the engine tachometer.
cardiagn.com
5. Connect the alternator output wire to the alternator "B" terminal.
6. Connect the battery ground cable.
PREPARATION
1. Prior to the test, check the following items and correct if necessary.
Check that the battery installed on the vehicle is fully charged. For battery checking method, see "BATTERY".
Check the alternator drive belt tension.
2. Turn ignition switch to "OFF".
3. Disconnect the battery ground cable.
4. Connect a digital voltmeter between the "B" terminal of the alternator and ground. Connect the (+) lead of the
voltmeter to the "B" terminal of the alternator. Connect the (-) lead to good ground or the battery (-) terminal.
5. Disconnect the alternator output wire from the alternator "B" terminal.
6. Connect a DC ammeter (0 to 150A) in series between the "B" terminal and the disconnected output wire.
Connect the (-) lead wire of the ammeter to the disconnected output wire.
7. Attach the engine tachometer and connect the battery ground cable.
TEST
1. Turn on the ignition switch and check to see that the voltmeter indicates the following value.
Battery voltage
If it reads 0V, there is an open circuit in the wire between the alternator "B" terminal and the battery and the
battery (-), or the fusible link is blown.
Page 27 of 57
2. Start the engine. Keep all lights and accessories off.
3. Run the engine at a speed of about 2,500 rpm and read the voltmeter when the alternator output current drops to
10A or less.
RESULT
1. If the voltmeter reading agrees with the value listed in the Regulating Voltage Table below, the voltage regulator is
functioning correctly. If the reading is other than the standard value, the voltage regulator or the alternator is
faulty.
REGULATING VOLTAGE TABLE
GASOLINE
Voltage regulator ambient temperature °C (°F) Regulating voltage (V)
-20 (-4) 14.2 ~ 15.4
20 (68) 14.0 ~ 15.0
60 (140) 13.7 ~ 14.9
80 (176) 13.5 ~ 14.7
2. Upon completion of the test, reduce the engine speed to idle, and turn off the ignition switch.
3. Disconnect the battery ground cable.
cardiagn.com
4. Remove the voltmeter and ammeter and the engine tachometer.
5. Connect the alternator output wire to the alternator "B" terminal.
6. Connect the battery ground cable.
Engine Electrical System > Charging System > Alternator > Components and Components Location
COMPONENTS
GASOLINE (2.0)
Page 28 of 57
cardiagn.com
GASOLINE (2.7)
Page 29 of 57
cardiagn.com
Engine Electrical System > Charging System > Alternator > Repair procedures
REPLACEMENT
1. Disconnect the battery negative terminal first, then the positive terminal.
Page 30 of 57
2. Deisconnect the alternator connector(A) and "B" terminal cable(B) from the alternator(C).
cardiagn.com
3. Remove the adjusting bolt(A) and mounting bolt(B), then remove the alternator belt.
4. Pull out the through bolt(C), then remove the alternator(D).
DISASSEMBLY
GASOLINE (2.0)
Page 31 of 57
1. Remove the rear cover(A).
- When soldering or unsoldering, be careful not to heat the diodes for too
long.
- Be careful that excesive force is not exerted on the leads of the diodes.
cardiagn.com
3. Remove the rectifier assembly(A).
Page 32 of 57
4. Unsolder between rectifier(A) and brush holder(B).
cardiagn.com
6. Remove the nut(A), pulley(B) and spacer(C).
Before the rotor is attached to the rear bracket, insert a wire through the small hole in the rear bracket to
lock the brush. After the rotor has been installed, the wire can be removed.
GASOLINE (2.7)
1. Remove the alternator cover(A) using a screw driver(B).
cardiagn.com
2. Loosen the mounting bolts(A) and disconnect the brush holder assembly(B).
Page 34 of 57
3. Remove the slip ring guide(A).
cardiagn.com
5. Loosen the 4 through bolts(A).
INSPECTION
INSPECT ROTOR
Page 35 of 57
1. Check that there is continuity between the slip rings(A).
2. Check that there is no continuity between the slip rings and the rotor(B) or rotor shaft(C).
3. If the rotor fails either continuity check, replace the alternator.
INSPECT STATOR
1. Check that there is continuity between each pair of leads(A).
cardiagn.com
2. Check that there is no continuity between each lead and the coil core.
3. If the coil fails either continuity check, replace the generator.
ALTERNATOR BELT INSPECTION AND ADJUSTMENT (GASOLINE 2.0)
When using a new belt, first adjust the deflection or tension to the values for the new belt, then readjust the
deflection or tension to the values for the used belt after running engine for five minutes.
Deflection method :
Apply a force of 98N (10 kgf, 22 lbf), and measure the deflection between the alternator and crankshaft pulley.
Deflection
Used Belt : 5.0 ~ 6.0 mm (0.20 ~ 0.23 in)
New Belt : 4.0 ~ 5.0 mm (0.16 ~ 0.20 in)
Tension
Used Belt : 340~490 N (35~50 kgf, 77~110 lbf)
New Belt : 540~640 N (55~65 kgf, 121~143 lbf)
cardiagn.com
If the belt is worn or damaged, replace it.
If adjustment is necessary :
1. Loosen the adjusting bolt(A) and the lock bolt(B).
2. Move the alternator to obtain the proper belt tension, then retighten the nuts.
Engine Electrical System > Charging System > Battery > Description and Operation
DESCRIPTION
Page 37 of 57
1. The maintenance-free battery is, as the name implies, totally maintenance free and has no removable battery cell
caps.
2. Water never needs to be added to the maintenance-free battery.
3. The battery is completely sealed, except for small vent holes in the cover.
Engine Electrical System > Charging System > Battery > Repair procedures
Inspection
Battery Diagnostic Flow
cardiagn.com
Page 38 of 57
cardiagn.com
Vehicle parasitic current inspection
1. Turn the all electric devices OFF, and then turn the ignition switch OFF.
2. Close all doors except the engine hood, and then lock all doors.
(1) Disconnect the hood switch connector.
(2) Close the trunk lid.
(3) Close the doors or remove the door switches.
Page 39 of 57
3. Wait a few minutes until the vehicle’s electrical systems go to sleep mode.
For an accurate measurement of a vehicle parasitic current, all electriacl systems should go to sleep mode.
(It takes at least one hour or at most one day.) However, an approximate vehicle parasitic current can be
measured after 10~20 minutes.
4. Connect an ammeter in series between the battery (-) terminal and the ground cable, and then disconnect the
clamp from the battery (-) terminal slowly.
Be careful that the lead wires of an ammeter do not come off from the battery (-) terminal and the ground
cable to prevent the battery from being reset. In case the battery is reset, connect the battery cable again,
and then start the engine or turn the ignition switch ON for more than 10 sec. Repeat the procedure from
No. 1.
To prevent the battery from being reset during the inspection,
1) Connect a jump cable between the battery (-) terminal and the ground cable.
2) Disconnect the ground cable from the battery (-) terminal.
3) Connect an ammeter between the battery (-) terminal and the ground cable.
cardiagn.com
4) After disconnecting the jump cable, read the current value of the ammeter.
Cleaning
1. Make sure the ignition switch and all accessories are in the OFF position.
2. Disconnect the battery cables (negative first).
Page 40 of 57
3. Remove the battery from the vehicle.
Care should be taken in the event the battery case is cracked or leaking, to protect your skin from the
electrolyte.
Heavy rubber gloves (not the household type) should be wore when removing the battery.
4. Inspect the battery tray for damage caused by the loss of electrolyte. If acid damage is present, it will be
necessary to clean the area with a solution of clean warm water and baking soda. Scrub the area with a stiff brush
cardiagn.com
and wipe off with a cloth moistened with baking soda and water.
5. Clean the top of the battery with the same solution as described above.
6. Inspect the battery case and cover for cracks. If cracks are present, the battery must be replaced.
7. Clean the battery posts with a suitable battery post tool.
8. Clean the inside surface of the terminal clamps with a suitable battery cleaning tool. Replace damaged or frayed
cables and broken terminal clamps.
9. Install the battery in the vehicle.
10. Connect the cable terminals to the battery post, making sure tops of the terminals are flush with the tops of the
posts.
11. Tighten the terminal nuts securely.
12. Coat all connections with light mineral grease after tightening.
When batteries are being charged, an explosive gas forms beneath the cover of each cell. Do not smoke
near batteries being charged or which have recently been charged. Do not break live circuit at the
terminals of batteries being charged.
A spark will occur when the circuit is broken. Keep open flames away from battery.
Engine Electrical System > Starting System > Description and Operation
DESCRIPTION
Page 41 of 57
The starting system includes the battery, starter motor, solenoid switch, ignition switch, inhibitor switch(A/T), ignition
lock switch, connection wires and the battery cable.
When the ignition key is turned to the start position, current flows and energizes the starter motor's solenoid coil.
The solenoid plunger and clutch shift lever are activated, and the clutch pinion engages the ring gear.
The contacts close and the starter motor cranks. In order to prevent damage caused by excessive rotation of the
starter armature when the engine starts, the clutch pinion gear overruns.
cardiagn.com
Engine Electrical System > Starting System > Repair procedures
CLEANING
1. Do not immerse parts in cleaning solvent. Immersing the yoke assembly and/or armature will damage the
insulation. Wipe these parts with a cloth only.
2. Do not immerse the drive unit in cleaning solvent. The overrun clutch is pre-lubricated at the factory and solvent
will wash lubrication from the clutch.
3. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.
INSPECTION
START TEST
The air temperature must be between 59 and 100°F (15 and 38°C) before testing.
Recommended procedure :
• Use a starter system tester.
• Connect and operate the equipment in accordance with the manufacturer's instructions.
• Test and troubleshoot as described.
Alternate Procedure :
• Use the following equipment :
- Ammeter, 0~400A
- Voltmeter, 0~20V (accurate within 0.1 volt)
- Tachometer, 0~1,200 rpm
• Hook up a voltmeter and ammeter as shown.
After this test, or any subsequent repair, reset the ECM/PCM to clear any codes.
Check the Starter Engagement :
1. Remove the ECM(B+) fuse from the fuse/relay box.
Page 42 of 57
2. Turn the ignition switch to START (III) with the shift lever in N or P position (A/T) or with the clutch pedal
depressed (M/T). The starter should crank the engine.
A. If the starter does not crank the engine, go to step 3.
B. If it cranks the engine erratically or too slowly, go to "Check for Wear and Damage" on the next page.
3. Check the battery, battery positive cable, ground, starter cut relay, and the wire connections for looseness and
corrosion. Test again.
If the starter still does not crank the engine, go to step 4.
4. Unplug the connector from the starter.
5. Connect a jumper wire from the battery positive (+) terminal to the solenoid terminal.
The starter should crank the engine.
A. If the starter still does not crank the engine, remove it, and diagnose its internal problem.
B. If the starter cranks the engine, go to step 6.
6. Check the ignition switch.
7. Check the starter relay (see page EE-54).
8. Check the A/T gear position switch (A/T) or the clutch interlock switch (M/T).
9. Check for an open in the wire between the ignition switch and starter.
STARTER SOLENOID TEST
1. Disconnect the wires from the Sterminal and the M terminal.
2. Connect the battery as shown. If the starter pinion pops out, it is working properly. To avoid damaging the
cardiagn.com
starter, do not leave the battery connected for more than 10 seconds.
cardiagn.com
6. Adjust until battery voltage shown on the voltmeter reads 11 volts.
7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and
freely :
2.7
: Max. 90 Amps
: Min. 2,800 rpm
2.0
: Max. 90 Amps
: Min. 3,000 rpm
Engine Electrical System > Starting System > Starter > Components and Components Location
COMPONENTS
GASOLINE
Page 44 of 57
cardiagn.com
Engine Electrical System > Starting System > Starter > Repair procedures
INSPECTION
ARMATURE INSPECTION AND TEST
1. Remove the starter (see page EE-47).
2. Disassemble the starter as shown at the beginning of this procedure.
Page 45 of 57
3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage,
replace the armature.
Commutator Runout
cardiagn.com
Standard (New) : 0.02mm (0.001 in.) max.
Service limit : 0.05mm (0.002 in.)
5. Check for continuity between the segments of the commutator. If an open circuit exists between any segments,
replace the armature.
Page 46 of 57
6. Check with an ohmmeter that no continuity exists between the commutator (A) and armature coil core (B), and
between the commutator and armature shaft (C). If continuity exists, replace the armature.
cardiagn.com
STARTER BRUSH HOLDER TEST
3. If the starter driver gear (B) is worn or damaged, replace the overrunning clutch assembly: the gear is not
available separately.
Check the condition of the flywheel or torque converter ring gear if the starter drive gear teeth are damaged.
DISASSEMBLY
cardiagn.com
GASOLINE
1. Disconnect the M-terminal(A) on the magnet switch assembly(B).
cardiagn.com
5. Remove the yoke(A) and armature(B).
cardiagn.com
9. Press the stop ring(A) using a socket(B).
Using a suitable pulling tool(A), pull the overrunning clutch stopring(B) over the
stopper(C).
cardiagn.com
REPLACEMENT
1. Disconnect the battery negative cable.
2. Disconnect the starter cable(A) from the B terminal(B) on the solenoid(C), then disconnect the connector(D)
from the S terminal(E).
3. Remove the 2 bolts holding the starter, then remove the starter.
4. Installation is the reverse of removal.
5. Connect the battery positive cable and negative cable to the battery.
Engine Electrical System > Starting System > Starter Relay > Repair procedures
INSPECTION
1. Remove the fuse box cover.
Page 51 of 57
2. Remove the starter relay(A).
cardiagn.com
B. Using an ohmmeter, check that there is continuity between terminals 30 and 87.
If there is no continuity, replace the relay.
Engine Electrical System > Cruise Control System > Schematic Diagrams
CIRCUIT DIAGRAM FOR CRUISE CONTROL SYSTEM
Page 52 of 57
cardiagn.com
Engine Electrical System > Cruise Control System > Components and Components Location
COMPONENTS LOCATION
Page 53 of 57
cardiagn.com
Engine Electrical System > Cruise Control System > Repair procedures
INSPECTION
CRUISE REMOCON SWITCH TEST
1. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least three minutes.
2. Remove the driver's airbag (See page RT group-air bag module).
Page 54 of 57
3. Disconnect the remocon switch connector(A).
4. Check the continuity between the terminals of the connector in each switch position according to the table.
A. If there is continuity, and it matches the table, the switch is O.K.
B. If there is no continuity, replace the remocon switch.
cardiagn.com
BRAKE SWITCH TEST
1. Disconnect the connector(A) from the brake switch.
2. Remove the brake switch(B).
Page 55 of 57
3. Check for continuity between the terminals according to the table.
cardiagn.com
2. position, M/T in neutral) until the radiator fan comes on, then let it idle.
3. Measure the amount of movement of the output linkage (B) until the engine speed starts to increase.
At first, the output linkage should be located at the fully closed position (C). The free play (D) should be
3.75±0.5 mm (0.15±0.02 in.)
4. If the free play is not within specs, move the cable to the point where the engine speed starts to increase, and
tighten the locknut (A) and adjusting nut (B).
5. Turn the adjusting nut (A) until it is 3.75±0.5 mm (0.15±0.02 in.) away from the bracket (B).
Page 56 of 57
6. Pull the cable so that the adjusting nut (A) touches the bracket, and tighten the locknut (B).
REPLACEMENT
CRUISE CONTROL UNIT AND CABLE
1. Loosen the locknuts(A) and disconnect the actuator cable (B) from the throttle linkage(C).
cardiagn.com
2. Disconnect the cover, actuator cable and connector.
3. Loosen the three mounting bolts(E), and remove the actuator(F) with the bracket.
Page 57 of 57
4. Installation is the reverse of removal.
CRUISE REMOCON SWITCH REPLACEMENT
1. Disconnect the battery negative cable, them disconnect the positive cable, and wait at least three minutes.
2. Remove the driver's airbg (See page RT group-air bag module).
3. Disconnect the remocon switch connector(A).
4. Loosen the two mounting screws(B), and remove the cruise remocon switch(C).
cardiagn.com