Engine Electrical System ‘STARTING SYSTEM. CHARGING SYSTEM...EE2 ENGINE ELECTRICAL SYSTEM SYMPTOM-RELATED DIAGNOSTIC PROCEDURE Starter ‘Symptom guide We. ome 1 _|_Willnat erankestarter motor does nol operate im ‘Will not crank-starter motor Spins 3] Grant siowly 4_ | Geanerator warring ight lumninates with engine running 5 Discharged battery. Symptom troubleshooting 1 ‘Will not crank-starter motor does not operate ‘Step Inspection ‘ation 1 | Gheck engine cranks with fully cnarged battery. | Yes | Check charging system. : 'No_| Go to next step. 2 | Check i battery voliags is supplied at B terminal. | Yes | Go to next step. 'No_ | Check wiring hamess. Avzna10018 3. | Check i battory volage is supplied at S terminal with | Yes | Replace starter unit. clutch pedal depressed (M/T), car in PARK (A/T), and Ignition switch in START position. 'No | = Check transaxle range switch (ATT) (Roter to, Auto transaxle) + Check ignition switch + Check wiring hamess. 2 ‘Will not crank-starter motor spins ‘Step Inspection ‘ation + | Gheckf drve pinion is pulled out while cranking. | Yes | Remove starter and check flywheel ring gear teeth and (Cllck heard when pulled out) starter drive pinion teeth. No | Check solenoid. Ropair or replace as necessary.‘SYMPTOM-RELATED DIAGNOSTIC PROCEDURE EE-3 3 ‘Cranks slowly Inspection ‘Action 7 | Check engine cranks normally when fully charged. Yes ‘Chock charging aystem. No_| Gotonext stop. 2 |. Gheck starter cable connection foriooseness and Yes Repair or replace connection. corrosion. No | Gheck for seized motor armature. Repair of replace as necessary. 4 ‘Aternator warning lamp ituminates with engine running ‘Stop inepection ‘etn 1 | Chock for correct battery votage ati. ‘Yes | Check wing hamess between AtematorL terminal and {generator warning lamp. ‘Specification: 14.1~14.7V | Gheck charging system. 3 Discharged battery Step Inspection ‘Aetion i 1 | Check charging system. ‘Yes | Tum ignition switch ON and check dark current as shown. Dark current: Below 20mA 'No_ | Repair or replace parts as necessaryEE4 ENGINE ELECTRICAL SYSTEM SPECIFICATION Starter motor ‘Specification Engine / Transaxle {33 COMMON RAIL SYSTEM torn wT Cul Starter motor | Type. ro-engaged dive Ouput KW) 12:22 DESCRIPTION AND OPERATION Starter motor Structural view Magnetic Saal ‘amature Brush ‘Holchin coil. FH Putin colt a io} y tae Tm“. Dive pinion | duction gear [fe 5 ato] Es AVZASIO3ON-VEHICLE SERVICE PROCEDURE ON-VEHICLE SERVICE PROCEDURES Starter motor Pull in voltage 1. Inspect the battery voltage. Voltage: above 12.4V. 2. After starting the engine, check i he starter rotates smoothly. 8. Ifthe starter does not rotate, check the “S" terminal voltage during cranking engine. : Voltage: above 6V + Above 8V: Inspection the starter + Below 8V: Inspect witng (main fuse, ignition switch ‘and transaxle range switch) AVEAS 10054 EE-S Solenoid Pull-in coll 1% Notice a) Remove the battery negative cable. 1b) Remove the *M" terminal of starting motor. 1. Do the continuity test between *S" and 2. Ifitis opened, replace the solenoid. “MP terminal. versions Hold-in-coll 1. Do the continuity test between “S" and solenoid body. 2. itis opened, replace the solenoid. AvDAS 0054EES ENGINE ELECTRICAL SYSTEM REMOVAL AND REPLACEMENT PROCEDURES Starter Removal and replacement 1, Remove the battery negative cable. 2. Inspect the parts, replace and repair as necessary. 3. Install in the reverse order of removal. vaaos008Inspection Solenoid Pullout test ® Notice Be careful not to let electricity flow continuously tor ‘more than 10 seconds. 4. Apply battery power to the “S" terminal and ground starter motor body. Pinion wil eject outward and the ‘arzoostea7 2, Measure clearance (pinion gap) between pinion and stopper. Pinion gap: 0.020~0.079 In (0.5~2.0 mm) 0.020-0.07 in (06-20 mn) f ‘nrsocat008 3. Itpinion gap is not within specttied range, adjust it by increasing or decreasing the number of washers used between solenoid and drive housing. The gap will become smaller ifthe number of washers is increased. EE-7 Retum test 1. Disconnect the wire from the °S" terminal, and then connect ‘the battery between the "Mf terminal and the body. roto? 2. Pullout the over-running clutch witha fattip screwdriver, and then check that the over-running clutch returns to its original position when released. No-load test Form a test circuit with a volt meter and an ammeter. Notice Use wires as thick as possible and tighten each terminal uly. Aroosio1 2. Close switch to run the starter. 3. Check the following. [53 COMMON RAIL SYSTEM Votage Ww 11.0 ‘Current a) Below 130. ‘Gear shall speed __ipm) ‘Above 4500 4, If any abnormality is noted, check it according to “INSPECTION”.EES ENGINE ELECTRICAL SYSTEM SYMPTOM-RELATED DIAGNOSTIC PROCEDURE Alternator Diagnostic guide No. Teme: 1 Being not charged 2 | Engine stars. aternator warning lamp turns on : 3_| Discharging of baitory : ‘Symptom troubleshooting 1 Being net charged Sep Inspection ‘Action 1 | Chook the batty votage. Yes | Goto nex siop. Standord: about 124V ‘No | Gheck the battery 2 _| Sian engine and chock Wakemator waringlamp | Yes | Goto step 00s out. No | Gotonext step. 3 | Chock if vokage at alternator terminals are correct. | Yes | Check wire hamess between battery and terminal Terminal 1G: ONY) 1aev) ee 3 Fron a0 | “aa7 tL Apes. W | 14-14 ; 3 Heer tay [tata : io | Gheccwiing harness: Replace aerator 4 1. Connect an ammeter, (100A Max: KJ 2.9)] Yes | Charging system normal. Setwoon terminal 2" and hamess 2. Start engine. He ‘Ghaccil engine 2500-2000 pm. No} Gotoned sop Check ampere of ad (urn more one of many ‘lctealsystom on) ighe han ampere of Untoad Ture blower, ead amp, rer detest, etc of. 3 | Check dive bok onson OK Yes | Replace aterator. No | Check ave belt tension.SYMPTOM-RELATED DIAGNOSTIC PROCEDURE EE-9 Discharging of battery ingpection ‘Aetion ‘Measure open circuit volage of battery with a ‘igtal voltmeter capable of reading 0.01V. Voltage: above 12.4V Yes Goto next stop. ‘Quick charge for 2 hours and recheck valiage ifthe voltage is below 12.4V, replace battery. 2 | Apoly toad test to the battery By using a batory Yes | Goto nent stop. c load tester. Batley toad) Pre; soFt__ | : ‘Quick charge and record baitary votiag atthe ond * ‘at 15 Seconds Is the votage more than spocicalion? No | Replace batery. Battery voltage with load “Apprenate aterytemp.coy_|_ Minimum vousge 2 3 af 35 x0 ae + a3 7 ai 7 39 “2 ar z a5 ‘3 | Measure open circuit votage of battery. Yes. | Battery is OK. ‘Standard: above 12.4 No | Charge bation.EE-10 ENGINE ELECTRICAL SYSTEM SPECIFICATIONS Battery and alternator ‘Specifications Engine Transaxle ‘J3 COMMON RAIL SYSTEM ftom, wr Battery | Votage © Tav-negaiive Type PT90-S3FLMF Capacty eorex ia) (AR) B0AH ‘Atamaior | Type aC. Output wa T2110 Regulator Wpe Transistorized (Buln 1C regulon) Regulator votage My 141-16.7,DESCRIPTION AND OPERATION DESCRIPTION AND OPERATION Alternator Circuit diagram EE-11 ‘8-04 Atormator(@) 78:05 atorator (6) arsoszn07EE-12 ON-VEHICLE SERVICE PROCEDURES Battery Inspection Electrolyte level 1, Check whether or not the electrolyte level lines between “UPPER LEVEL" line and “LOWER LEVEL" line. 2. If low, add distilled water to “upper level’ line. Do not over Specific gravity of electrolyte 1. Measure spectic gravity with a hydrometer. Specific gravity: 1.27-4.29 (at 77°F 25°C) Terminal and cable 1. Check that battery terminal connections are tight to ensure good electrical connections. 2. Check for corroded or frayed battery cables. ‘3. Check rubber protector on positive terminal for proper coverage. 4, Clean terminals, f necessary, and lightly coat them with grease. Drive belt Inspection 4. Check drive belt and pulley for wear, cracks and praying. Replace if necessary. ENGINE ELECTRICAL SYSTEM Alternator’ Removal and replacement 1. Disconnect negative battery cable. 2. Lower an auto tensioner with spanner and then, remove drive belt. -AvzA100036 3. Remove “B" terminal lead and then disconnect alternator “L” and “S" terminal connector. 4. Remove alternator. 6. Install in reverse order of removal. Tightening torque: ‘98.2 Ib-ft (45.1 Nem, 4.6 kg-m)