TUCSON(JM) > 2008 > G 2.

7 DOHC > Engine Electrical System

Engine Electrical System > General Information > General Information

THE MICRO 570 ANALYZER

The MICRO 570 Analyzer provides the ability to test the charging and starting systems, including the
battery, starter and alternator.

Because of the possibility of personal injury, always use extreme caution and appropriate eye
protection when working with batteries.

KEYPAD
The MICRO570 button on the key pad provides the following functions :

BATTERY TEST PROCEDURE

1. Connect the tester to the battery.
A. Red clamp to battery positive (+) terminal.
B. Black clamp to battery negative (-) terminal.
 Connect clamps securely. If "CHECK CONNECTION" message is displayed on the screen,
reconnect clamps securely.

2. The tester will ask if the battery is connected "IN A VEHICLE" or "OUT OF A VEHICLE". Make your
selection by pressing the arrow buttons; then press ENTER.

3. Choose either CCA or CCP and press the ENTER button.

• CCA : Cold cranking amps, is an SAE specification for cranking batteries at -18°C (0°F).
• CCP : Cold cranking amps, is an SAE specification for korean manufacturer's for cranking
batteries at -18°C (0°F).

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.

5. The tester (Micro570) displays battery test results including voltage and battery ratings.
A relevant action must be given according to the test results by referring to the battery test results
as shown in the table below.

The battery ratings (CCA) displayed on the tester must be identical to the ratings marked on
battery label.

6. To conduct starter test, continuously, press ENTER.

BATTERY TEST RESULTS
RESULT ON PRINTER REMEDY

Good battery No action is required

Battery is in a good state

Good recharge
Recharge the battery and use

Battery is not charged properly

=> Charge and test the battery again (Failure to
Charge & Retest
charge the battery fully may read incorrect
measurement value)
 => Replace battery and recheck the charging
system. (Improper connection between battery
and vehicle cables may cause "REPLACE
Replace battery
BATTERY", retest the battery after removing
cables and connecting the tester to the battery
terminal directly prior to replacing the battery)

=> Charge and retest the battery. And then, test

Bad cell-replace results may cause "REPLACE BATTERY",
replace battery and recheck the charging system

Whenever filing a claim for battery, the print out of the battery test results must be attached.

STARTER TEST PROCEDURE

1. After the battery test, press ENTER immediately for the starter test.

2. After pressing ENTER key, start the engine.

3. Cranking voltage and starter test results will be displayed on the screen.
Take a relevant action according to the test results by referring to the starter test results as given
below.
4. To continue charging system test, press ENTER.
STARTER TEST RESULTS
RESULT ON PRINTER REMEDY

Cranking voltage normal System shows a normal starter draw

Cranking voltage is lower than normal level

Cranking voltage low
=> Check starter

The state of battery charge is too low to test

Charge battery
=> Charge the battery and retest

=> Replace battery

=> If the vehicle is not started though the battery
condition of "Good and fully charged" is displayed.
Replace battery => Check wiring for open circuit, battery cable
connection, starter and repair or replace as
necessary.
=> If the engine does crank, check fuel system.

CHARGING SYSTEM TEST PROCEDURE

1. Press ENTER to begin charging system test.

2. ENTER button is pressed, the tester displays the actual voltage of alternator.
Press ENTER to test the charging system.
3. Turn off all electrical load and rev engine for 5 seconds by pressing the accelerator pedal.

4. Press ENTER.

5. The MICRO 570 analyzer charging system output at idle for comparison to other readings.
6. Take a relevant action according to the test results by referring to the table below after shutting off
the engine and disconnect the tester clamps from the battery.

CHARGING SYSTEM TEST RESULTS

RESULT ON PRINTER REMEDY

Charging system normal/Diode ripple

Charging system is normal
normal

Alternator does not supply charging current to battery

No charging voltage => Check belts, connection between alternator and battery
Replace belts or cable or alternator as necessary

Alternator does not supply charging current to battery and

Low charging voltage electrical load to system fully
=> Check belts and alternator and replace as necessary

The voltage from alternator to battery is higher than normal

limit during voltage regulating.
High charging voltage => Check connection and ground and replace regulator as
necessary
=> Check electrolyte level in the battery

One or more diodes in the alternator is not functioning

properly
Excess ripple detected
=> Check alternator mounting and belts and replace as
necessary

Engine Electrical System > General Information > Troubleshooting

TROUBLE SHOOTING

IGNITION SYSTEM

Symptom Suspect area Remedy

Engine will not Ignition lock switch Inspect ignition lock switch, or replace as
start or is hard to Ignition coil required
start (Cranks OK) Spark plugs Inspect ignition coil, or replace as required
Ignition wiring disconnected or Inspect spark plugs, or replace as required
broken Repair wiring, or replace as required
Rough idle or stalls Ignition wiring Repair wiring, or replace as required
Ignition coil Inspect ignition coil, or replace as required

Engine Spark plugs and spark plug cables Inspect spark plugs / cable, or replace as
hesitates/poor Ignition wiring required
acceleration Repair wiring, or replace as required

Poor mileage Spark plugs and spark plug cables Inspect spark plugs / cable, or replace as
required

CHARGING SYSTEM
Symptom Suspect area Remedy

Charging warning Fuse blown

Check fuses
indicator does not Light burned out
Replace light
light with ignition Wiring connection loose
Tighten loose connection
switch "ON" and Electronic voltage regulator
Replace voltage regulator
engine off.

Charging warning Drive belt loose or worn

Adjust belt tension or replace belt
indicator does not Battery cable loose, corroded or worn
Inspect cable connection, repair or
go out with engine Electronic voltage regulator or
replace cable
running. (Battery alternator
Replace voltage regulator or alternator
requires frequent Wiring
Repair or replace wiring
recharging)

Overcharge Electronic voltage regulator Replace voltage regulator

Voltage sensing wire Repair or replace wiring

Discharge Drive belt loose or worn Adjust belt tension or replace belt
Wiring connection loose or short circuit Inspect wiring connection, repair or
Electronic voltage regulator or replace wiring
alternator Replace voltage regulator or alternator
Poor grounding Inspect ground or repair
Worn battery Replace battery

STARTING SYSTEM
Symptom Suspect area Remedy

Engine will not Battery charge low Charge or replace battery

crank Battery cables loose, corroded or worn out Repair or replace cables
Transaxle range switch (Vehicle with Refer to TR group-automatic
automatic transaxle only) transaxle
Fuse blown Replace fuse
Starter motor faulty Replace
Ignition switch faulty Replace

Engine cranks Battery charge low Charge or replace battery

slowly Battery cables loose, corroded or worn out Repair or replace cables
Starter motor faulty Replace

Starter keeps Starter motor Replace

running Ignition switch Replace
Starter spins but Short in wiring Repair wiring
engine will not Pinion gear teeth broken or starter motor Replace
crank Ring gear teeth broken Replace fly wheel or torque
converter

Engine Electrical System > General Information > Specifications

SPECIFICATION
IGNITION SYSTEM
Specifications
Item
2.7 2.0

Type Mold coil type Mold coil type

Ignition coil Primary resistance 0.96 ± 10%(Ω) 0.58 ± 10%(Ω)

Secondary resistance 12.5 ± 15%(kΩ) 8.8 ± 15%(kΩ)

NGK IFR5G-11 PFR5N-11

Unleaded
CHAMPION - RC10PYPB4

Gap 1.0 mm ~ 1.1 mm

STARTING SYSTEM
Specifications
Item
2.7 2.0

Type Reduction drive (with planetary gear)

Rated voltage 12V, 1.2KW 12V, 1.2KW

No. of pinion teeth 8 8

Voltage 11V 11V

No-load charasteristics Amperage 90A, MAX 90A, MAX

Starter
Speed 2,800rpm, MIN 2,800rpm, MIN

Standard 29.4 mm (1.157 in.)

Commutator diameter
Limit 28.4 mm (1.118 in.)

Standard 0.5 mm (0.02 in.)

Undercut depth
Limit 0.2 mm (0.008 in.)

CHARGING SYSTEM
Item Specifications
 2.7 2.0

Type Internal

Rated voltage 13.5V, 120A 13.5V, 90A

Speed 1,000 ~ 18,000 rpm

Alternator Voltage regulator Electronic built-in type

Regulator setting
14.55 ± 0.2V 14.55 ± 0.2V
voltage

Temperrature
-3.5 ± 1mV/°C -7 ± 3mV/°C
compensation

Type 56-26FL 48-23FL

Cold cranking amperage

600A 550A
at-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.
- RESERVE 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)

TIGHTENING TORQUES
Items Nm kgf.m lb-ft

Alternator terminal (B+) 5~7 0.5 ~ 0.7 3.6 ~ 5.1

Starter motor terminal (B+) 10 ~ 12 1.0 ~ 1.2 7.3 ~ 8.8
Battery terminal 4~6 0.4 ~ 0.6 2.9 ~ 4.3
Spark plug 20 ~ 30 2.0 ~ 3.0 15 ~ 22

Engine Electrical System > Ignition System > Description and Operation

DESCRIPTION
Engine Electrical System > Ignition System > Repair procedures

ON-VEHICLE INSPECTION

INSPECT SPARK PLUG AND SPARK PLUG CABLE

2.0
1. Remove the spark plug cable(A).

When removing the spark plug cable, pull on the spark plug cable boot (not the cable), as it
may be damaged.

2. Using a spark plug socket, remove the spark plug(B).

Be careful that no contaminats enter through the spark plug holes.

3. Inspect the electrodes(A) and ceramic insulator(B).

INSPECT SPARK TEST

1. Remove the spark plug cable.
2. Using a spark plug socket, remove the spark plug.
3. Remove the ignition coil.
4. Install the spark plugs to each spark plug cable.
5. Ground the spark plugs.
6 Check is spark occurs while engine is being cranked.
.

To prevent gasoline from being injected from injectors during this test, crank the engine for no
more then 5~10 seconds at time.

7. Using a spark plug socket, install the spark plugs.

8. Install the spark plug cable and ignition coil.
2.7
1. Remove the engine cover.
2. Disconnect the VIS actuator connectors and injector connectors.
3. Remove the accelerator cable.
4. Remove surge tank sub assembly.

5. Remove the spark plug cable.

6. Remvoe the spark plug.
7. Inspect the electrodes and ceramic insulator.
INSPECTION OF ELECTRODES
CONDITION DARK DEPOSITS WHITE DEPOSITS

• Fuel mixture too lean

DESCRIPTION • Fuel mixture too rich
• Advanced ignition timing
• Low air intake
• Insufficient plug tightening

1 Check the electrode gap(A).

.
Standard (New)
1.0~1.1 mm (0.039~0.043 in.) - Unleaded
2. 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.

3 Connect the ohmmeter probes and measure resistance.

.
RESISTANCE : 5.6KΩ/m ± 20%
4. Resistance should not be higher than 10KΩ per meter of cable.
If resistance is higher, replace the cable.

INSPECT IGNITION COIL

1 Measure the primary coil resistance between terminals 1-2 and 1-3.
.

Measure the primary coil resistance between terminals 1-4, 2-4 and 3-4.
 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.

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.
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.
Engine Electrical System > Charging System > Description and Operation

DESCRIPTION
GASOLINE
The charging system included a battery, an alternator with a built-in regulator, the charging indicator
light, and wiring.
The alternator has six built-in diodes (three positive and three negtive), each rectifying AC current to
DC current.
Therefore, DC curent appears at alternator "B" terminal.
In addition, the charging voltage of this alternator is regulated by the battery voltage detection system.
The main components of the alternator are the rotor, stator, rectifier, capacitor brushes, bearings and
V-ribbed belt pulley. The brush holder contains a built-in electronicvoltage regulator.

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 TERMINALS, FUSIBLE LINK AND FUSES

1. Check that the battery terminals are not loose or corroded.
2. Check the fusible link and fuses for continuity.

INSPECT DRIVE BELT

1. Visually check the belt for excessive wear, frayed cords etc.
If any defect has been found, replace the drive belt.

Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from
the ribs, it should be replaced.

2. Using a belt tension gauge(A), measure the drive belt(B) tension.

DRIVE BELT TENSION
New belt 540~640 N (121~143 lb)

Used belt 340~490 N (77~110 lb)

If the belt tension is not as specified, adjust it.

 - "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.

VISUALLY CHECK ALTERNATOR WIRING AND LISTEN FOR ABNORMAL

NOISES
1. Check that the wiring is in good condition.
2. Check that there is no abnormal noise from the alternator while the engine is running.

CHECK DISCHARGE WARNING LIGHT CIRCUIT

1. Warm up the engine and then turn it off.
2. Turn off all accessories.
3. Turn the ignition switch "ON". Check that the discharge warning light is lt.
4. Start the engine. Check that the light goes off.
INSPECT CHARGING SYSTEM
PREPARATION
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.

CONDITIONS FOR THE TEST

1. Start the engine.
2. Switch on the headlamps, blower motor and so on. And then, read the voltmeter under this
condition.
RESULT
1 The voltmeter may indicate the standard value.
.
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.
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 connectthe (-) 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.

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 groundingis 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 andread 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
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.

50% of the rate voltage

• 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 to 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.
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 voltmeterto 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.
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
Voltage regulator ambient temperature °C Regulating voltage (V)
 (°F)

-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.
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

(2.0)
(2.7)
Engine Electrical System > Charging System > Alternator > Repair procedures
REPLACEMENT
1. Disconnect the battery negative terminal first, then the positive terminal.
2. Deisconnect the alternator connector(A) and "B" terminal cable(B) from the alternator(C).

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).
5. Installation is the reverse of removal.
6. Adjust the alternator belt tension after installation.

DISASSEMBLY
(2.0)
1. Remove the rear cover(A).
2. Unsolder the 4 stator leads(A) to the main diodes on the rectifier(B).

- 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.

3. Remove the rectifier assembly(A).

4. Unsolder between rectifier(A) and brush holder(B).

5. Remove the rear bracket(A).

6. Remove the nut(A), pulley(B) and spacer(C)..

7. Disconnect the stator(A), rotor(B) and front bracket(C).

8. Remove the rear bearing(A) and cover(B).

9. Reassembly is the reverse or disassembly.

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.

(2.7)
1. Remove the alternator cover(A) using a screw driver(B).
2. Loosen the mounting bolts(A) and disconnect the brush holder assembly(B).

3. Remove the slip ring guide(A).

4. Remvoe the nut, pully(A) and spacer.

5. Loosen the 4 through bolts(A).

6. Disconnect the rotor(A) and cover(B).

7. Reassembly is the reverse of disassembly.

INSPECTION

INSPECT ROTOR
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).
2. Check that there is no continuity between each lead and the coil core.
3. If the coil fails either continuity check, replace the alternator.

ALTERNATOR BELT INSPECTION AND ADJUSTMENT

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)

If the belt is worn or damaged, replace it.

Belt tension gauge method :
Attach the belt tension gauge to the belt and measure the tension. Follow the gauge manufacturer's
instructions.

Tension
Used Belt : 340~490 N (35~50 kgf, 77~110 lbf)
New Belt : 540~640 N (55~65 kgf, 121~143 lbf)

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.

3. Recheck the deflection or tension of the belt.

Engine Electrical System > Charging System > Battery > Description and
Operation

DESCRIPTION
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 TEST (1)

1. CHECKING FLOW
2. LOAD TEST
1. Perform the following steps to complete the load test procedure for maintenance free batteries.
2. Connect the load tester clamps to the terminals and proceed with the test as follow :
A. If the battery has been on charge, remove the surface charge by connect a 300 ampere load for
15 seconds.
B. Connect the voltmeter and apply the specified load.
 C. Read the voltage after the load has been applied for 15 seconds.
D. Disconnect the load.
E. Compare the voltage reading with the minimum and replace the battery if battery test voltage is
below that shown in the voltage table.

Voltage Temperature

9.6 20°C (70°F) and above

9.5 16 °C (60 °F)

9.4 10 °C (50 °F)

9.3 4 °C (40 °F)

9.1 -1 °C (30 °F)

8.9 -7 °C (20 °F)

8.7 -12 °C (10 °F)

8.5 -18 °C (0 °F)

- If the voltage is greater than shown in the table, the battery is good.
- If the voltage is less than shown in the table, replace the battery.

BATTERY DIAGNOSTIC TEST (2)

1. Make sure the ignition switch and all accessories are in the OFF position.
2. Disconnect the battery cables (negative first).
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 worn when
removing the battery.

4. Inspect the battery carrier 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 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 in Step(3).
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 the 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 circuits at the terminals of batteries being charged. A spark will occur when the circuit is
broken. Keep open flames away from the battery.

Engine Electrical System > Starting System > Description and Operation

DESCRIPTION
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.
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.
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 (see page EE-23).
7. Check the starter relay (see page EE-69).
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 S terminal and the M terminal.
2. Connect the battery as shown. If the starter pinion pops out, it is working properly. To avoid
damaging the starter, do not leave the battery connected for more than 10 seconds.

3. Disconnect the battery from the M terminal.

If the pinion does not retract, the hold-in coil is working properly. To avoid damaging the starter, do
not leave the battery connected for more than 10 seconds.
4. Disconnect the battery also from the body. If the pinion retracts immediately, it is working properly.
To avoid damaging the starter, do not leave the battery connected for more than 10 seconds.

FREE RUNNING TEST

1. Place the starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery
to starter motor as follows :
2. Connect a test ammeter (100-ampere scale) and carbon pile rheostat as shown in the illustration.
3. Connect a voltmeter (15-volt scale) across the starter motor.
4. Rotate carbon pile to the off position.
5. Connect the battery cable from battery's negative post to the starter motor body.
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. 2,800 rpm
Engine Electrical System > Starting System > Starter > Components and
Components Location

COMPONENTS

GASOLINE
Engine Electrical System > Starting System > Starter > Repair procedures
INSPECTION

ARMATURE INSPECTION AND TEST

1. Remove the starter (see page EE-57).
2. Disassemble the starter as shown at the beginning of this procedure.
3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear
or damage, replace the armature.

4 Measure the commutator (A) runout.

. A. If the commutator runout is within the service limit, check the commutator for carbon dust or
brass chips between the segments.
B. If the commutator runout is not within the service limit, replace the armature.

Commutator Runout
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.
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.

INSPECT STARTER BRUSH

STARTER BRUSH HOLDER TEST

INSPECT OVERRUNNING CLUTCH
1. Slide the overrunning clutch along the shaft.
Replace if it does not slide smoothly.
2. Rotate the overrunning clutch (A) both ways.
Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction or
it locks in both directions, replace it.

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
1. Disconnect the M-terminal(A) on the magnet switch assembly(B).
2. After loosening the 2 screws(A), detach the magnet switch assembly(B).

3. Loosen the brush holder mounting screws(A) and through bolts(B).

4. Remove the rear bracket(A) and brush holder assembly(B).

5. Remove the yoke(A) and armature(B).

6. Remove the, lever plate(A) and planet shaft packing(B).

7. Disconnect the planet gear(A).

8. Disconnect the planet shaft assembly(A) and lever(B).

9. Press the stop ring(A) using a socket(B).

10. After removing the stopper(A) using stopper pliers(B).

11. Disconnect the stop ring(A), overrunning clutch(B), internal gear(C) andplanet shaft(D).

12. Reassembly is the reverse of disassembly.

Using a suitable pulling tool(A), pull the overrunning clutch stopring(B) over the stopper(C).
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.
2. Remove the starter relay(A).
3. Inspect the relay continuity.
A. Using an ohmmeter, check that there is continuity between terminals 2 and 4.
If there is no continuity, replace the relay.
B. Check that there is no continuity between terminals 1 and 5.
If there is continuity, replace the relay.

4. Inspect the relay operation.

A. Apply battery positive voltage across terminals 2 and 4.
B. Using an ohmmeter, check that there is continuity between terminals 1 and 5.
If there is no continuity, replace the relay.
5. Install the starter relay.
6. Install the fuse box cover.

Engine Electrical System > Cruise Control System > Schematic Diagrams

CIRCUIT DIAGRAM FOR CRUISE CONTROL SYSTEM

Engine Electrical System > Cruise Control System > Components and
Components Location
COMPONENTS LOCATION

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).
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.
BRAKE SWITCH TEST
1. Disconnect the connector(A) from the brake switch.
2. Remove the brake switch(B).

3. Check for continuity between the terminals according to the table.

4. If necessary, replace the switch or adjust the switch.

ACTUATOR CABLE ADJUSTMENT
1. Check that the actuator cable (A) moves smoothly with no binding or sticking.

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).
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).
2. Disconnect the cover, actuator cable and connector.

3. Loosen the three mounting bolts(E), and remove the actuator(F) with the bracket.
4. Installation is the reverse of removal.

CRUISE REMOCON SWITCH REPLACEMENT

1. Disconnect the battery negative cable, then 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).

5. Installation is the reverse of removal.

6. Connect the battery positive cable and negative cable to the battery.