Workshop Manual

2001 - 2006
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COMPONENTS

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REPLACEMENT
1. Disconnect the battery negative terminal first, then the positive terminal.
2. Disconnect the generator connector(A) and "B" terminal cable(B) from the generator(C).

3. Remove the adjusting bolt(A) and mounting bolt(B), then remove the generator belt(C).
4. Pull out the through bolt(C), then remove the generator(D).

5. Installation is the reverse of removal.

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6. Adjust the generator belt tension after installation (See page EE-33 ).
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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 : 8.5 ~ 11.5 mm (0.33 ~ 0.345 in)
New Belt : 5.5 ~ 8.0 mm (0.22 ~ 0.361 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 : 690~880 N (70~90 kgf, 150~200 lbf)

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If the belt is worn or damaged, replace it.

If adjustment is necessary :
[Link] the adjusting bolt(A) and the lock bolt(B).
[Link] the alternator to obtain the proper belt tension, then retighten the nuts.

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For the power steering pump belt and A/C compressor belt adjustments, refer to section 17 and section 22.

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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.

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INSPECTION
BATTERY DIAGNOSTIC TEST (1)
1. CHECKING FLOW

2. CHECKING SHEET

Responsibility
Inspection Items & contents Judgment criteria Remarks
User Manufacturer

1. Acid Leakage 1. Damage in the case or cover due

* Type of acid leakage to outside impact.
- Leakage on the fusion part for
2. Acid leakage on the molding part
joining the case and cover.
of the case or cover.
- Leakage on the terminal part (weld line or gate hole)
- Leakage on other parts
3. Damage on the terminal or cracks
* Conduct a visual inspection for
in the cover.
breakage, deformation, or cracks.
4. Acid leakage due to the tipped
battery or slant storage.

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5. Acid leakage due to poor welding

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of the cover.
(with no damage)

2. Outside damage and breakage 1. Outside damage due to causes

without damage due to mistreatment.

2. Outside damage due to

mistreatment.

3. Damage due to a spark between

terminals.

4. Damage and breakage due to

heat.

3. Measure the voltage for the Refer to

1. 12.0V
battery load test
; Wait at least one day before
2. 11.0V< battery voltage<12.0V due Refer to
measuring in case of recharging.
to over-discharge. load test

3. Below 11.0V due to charge Refer to

condition failure. load test

4. Below 11.0V due to discharged for Refer to

a long period. load test

5. Below 11.0V due to internal short Refer to

circuit. load test

4. Load test
; For 15 seconds with half of the
1. Load test result: below 9.5V
CCA value.
The voltage on the dischaarging
stage should be above 9.6V (81±9°F)
- Conduct the test with a battery
2. Load test result: above 9.6V
tester.
(Refer to the tester manual)

3. LOAD TEST
1. Perform the following steps to complete the load test procedure for maintenance free batteries.

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2. Connect the load tester clamps to the terminals and proceed with the test as follow :
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[Link] the battery has been on charge, remove the surface charge by connecting a 300 ampere load for 15 seconds.
[Link] the voltmeter and apply the specified load.
[Link] the voltage after the load has been applied for 15 seconds.
[Link] the load.
[Link] 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 higher than shown in the table, the battery is good.
- If the voltage is lower 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.

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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(4).
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 cleaming tool.
8. Clean the inside surface of the terminal clamps with a suitable battery cleaning tool. Replace damaged 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.

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DESCRIPTION
The charging system includes a battery, generator with a built-in regulator, The charging indicator light and wiring.
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.

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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. if 20 minutes have not passed since the engine was stopped, 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.

Standard voltage : 12.5~12.9V at 20°C (68°C)

If the voltage is less than specification, charge the battery.

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.

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2. Using a belt tension gauge, measure the drive belt tension.

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DRIVE BELT TENSION

New belt 690~880 N (150~200 lb)

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

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

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- "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 GENERATOR 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 generator 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 lit.
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 generator "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.

CONDITIONS FOR THE TEST

[Link] the engine.

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[Link] on the headlamps, blower motor and so on. And then, read the voltmeter under this condition.
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RESULT
[Link] voltmeter may indicate the standard value.

0.2V max.

[Link] 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 generator "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.
[Link] completion of the test, set the engine speed at idle. Turn off the head lamps, blower motor and the ignition switch.
PREPARATION
[Link] 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 generator drive belt. The belt tension check method is described in the section "COOLING".
[Link] off the ignition switch.
[Link] the battery ground cable.
[Link] the generator output wire from the generator "B" terminal.
[Link] 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.

[Link] a voltmeter (0 to 20V) between the "B" terminal and ground. Connect the (+) lead wire to the generator "B"
terminal and (-) lead wire to a good ground.
[Link] an engine tachometer and connect the battery ground cable.
[Link] the engine hood open.

TEST

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[Link] to see that the voltmeter reads as the same value as the battery voltage. If the voltmeter reads 0V, and the open
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circuit in the wire between the generator "B" terminal and battery (-) terminal, a blown fusible link or poor grounding is
suspected.
[Link] the engine and turn on the headlights.
[Link] 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
[Link] ammeter reading must be higher than the limit value. If it is lower but the generator output wire is in good condition,
remove the generator from the vehicle and test it.

63A min.

• The nominal output current value is shown on the nameplate affixed to the generator body.
• The output current value changes with the electrical load and the temperature of the generator 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.
The nominal output current may not be obtained if the temperature of the generator itself or ambient temperature is
too high.
In such a case, reduce the temperature before testing again.

[Link] completion of the output current test, lower the engine speed to idle and turn off the ignition switch.
[Link] the battery ground cable.
[Link] the ammeter and voltmeter and the engine tachometer.
[Link] the generator output wire to the generator "B" terminal.
[Link] the battery ground cable.
PREPARATION
[Link] to the test, check the following items and correct if necessary.
Check that the battery installed in the vehicle is fully charged. For battery checking method, see "BATTERY".
Check the generator drive belt tension. For belt tension check, see "COOLING" section.
[Link] ignition switch to "OFF".
[Link] the battery ground cable.
[Link] a digital voltmeter between the "B" terminal of the generator and ground. Connect the (+) lead of the voltmeter to
the "B" terminal of the generator. Connect the (-) lead to good ground or the battery (-) terminal.
[Link] the generator output wire from the generator "B" terminal.
[Link] 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.

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[Link] the engine tachometer and connect the battery ground cable.
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TEST
[Link] 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 generator "B" terminal and the battery (-), or the fusible link is
blown.
[Link] the engine. Keep all lights and accessories off.
[Link] the engine at a speed of about 2,500 rpm and read the voltmeter when the generator output current drops to 10A or
less.
RESULT
[Link] 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 generator is faulty.
Regulating Voltage Table

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

[Link] completion of the test, reduce the engine speed to idle, and turn off the ignition switch.
[Link] the battery ground cable.
[Link] the voltmeter and ammeter and the engine tachometer.
[Link] the generator output wire to the generator "B" terminal.
[Link] the battery ground cable.
[Link] sure to check the following before testing:
Generator installation and wiring connections
Generator drive belt tension
Fusible link
Abnormal noise from the generator while the engine is running
[Link] the ignition switch to the OFF position.
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[Link] the negative battery cable.

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[Link] the generator output wire from the generator "B" terminal. Connect a DC test ammeter with a range of 0-150A
in series between the "B" terminal and the disconnected output wire. (Connect the (+) lead of the ammeter to the "B"
terminal. Connect the (-) lead of the ammeter to the disconnected output wire).

An inductive-type ammeter which enables measurements to be taken without disconnecting the generator output wire
is recommended. Using this equipment will lessen the possibility of a voltage drop caused by a loose "B" terminal
connection.

[Link] a digital-type voltmeter between the generator "B" terminal and the battery (+) terminal. (Connect the (+) lead of
the voltmeter to the "B" terminal. Connect the (-) lead of the voltmeter to the battery (+) cable.)
[Link] the negative battery cable.
[Link] a tachometer or the scan tool.
[Link] the engine.
[Link] the engine running at approx. 2500 r/min, turn the headlights and other lights on and off to adjust the generator load
on the ammeter slightly above 30A.

max. 0.3V

When the generator output is high and the value displayed on the ammeter does not decrease to 30A, set the value to
[Link] the value displayed on the voltmeter. In this case the limit becomes max. 0.4V.

[Link] the value displayed on the voltmeter is still above the limit, a malfunction in the generator output wire may exist. Check
the wiring between the generator "B" terminal and the battery (+) terminal (including fusible link). If a terminal is not
sufficiently tight or if the harness has become discolored due to overheating, repair, the test again.
[Link] the test, run the engine at idle.
[Link] off all lights and turn the ignition switch to the OFF position.
[Link] the tachometer or the scan tool.
[Link] the negative battery cable.
[Link] the ammeter and voltmeter.
[Link] the generator output wire to the generator "B" terminal.
[Link] the negative battery cable.

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CIRCUIT DIAGRAM FOR CHARGING SYSTEM

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COMPONENTS LOCATION

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INSPECTION
CRUISE CONTROL 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).
3. Disconnect the control switch connector.

4. Check the continuity between the terminals of the connector in each switch position according to the table.
[Link] there is continuity, and it matches the table, the switch is O.K.
[Link] there is no continuity, replace the control switch.

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BRAKE SWITCH TEST

1. Disconnect the connector from the brake switch.
2. Remove the brake switch.

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

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

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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).

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).

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5. Turn the adjusting nut (A) until it is 3.75±0.5 mm (0.15±0.02 in.) away from the bracket (B).
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6. Pull the cable assembly so that the adjusting nut (A) touches the bracket, and tighten the locknut (B).

REPLACEMENT
CRUISE CONTROL UNIT AND CABLE

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1. Loosen the locknuts(A) and disconnect the actuator cable (B) from the throttle linkage(C).
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2. Disconnect the cruise control unit connector(D).

3. Loosen the three mounting bolts(E), and remove the cruise control unit with the bracket(F).

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4. Loosen the locknuts(A) and disconnect the actuator cable(B) from the cruise control unit.
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5. Installation is the reverse of removal.

CRUISE CONTROL 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).
3. Disconnect the control switch connector(A).
4. Loosen the two mounting screws(B), and remove the cruise control switch.

5. Installation is the reverse of removal.

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6. Connect the battery positive cable and negative cable to the battery.
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CIRCUIT DIAGRAM FOR CRUISE CONTROL SYSTEM

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THE MICRO 570 ANALYZER

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

KEYPAD

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BATTERY TEST PROCEDURE Ebay User ID: reveleus1

1. Connect the tester to the battery.
[Link] clamp to battery positive (+) terminal.
[Link] clamp to battery negative (-) terminal.

Connect clamps securely. If "CHECK CONNECTION" message is displyed 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.

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

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

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4. Set the CCA value displyed on the screen to the CCA value marked on the battery label by pressing up and
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down buttons and press ENTER.

The battery ratings(CCA) displyed on the tester must be identical to the ratings marked on the battery label.
5. The tester (Micro570) displays battery test results including voltage and battery ratings.
A relevant action must be taken according to the test results by referring to the battery test results as shown in
the table below.

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

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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 & Retest → Charge and test the battery again (Failure to 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 BATTERY",
Replace battery
retest the battery after removing cables and connecting the tester to the
battery terminal directly prior to replacing the battery)

Bad cell-replace → Charge and retest the battery.

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.

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2. After pressing ENTER key, start the engine.

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3. Cranking voltage and starter test results will be displayed on the screen.
Take relevant action according to the test results by referring to the starter test results as given below.

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4. To continue charging system test, press ENTER.

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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
→ Check wiring for open circuit, battery cable connection, starter and repair
Replace battery
or replace as necessary.
→ If the engine does crank, check fuel system.

CHARGING SYSTEM TEST PROCEDURE

1. Press ENTER to begin charging system test.

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2. If ENTER button is pressed, the tester displays the actual voltage of alternator.
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Press ENTER to test the charging system.

3. Turn off all electrical load and rev engine for 5 seconds.

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4. Press ENTER.
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5. The MICRO 570 analyzer charging system output at idle for comparision to other readings.

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6. Take relevant action according to the test results by referring to the table below after shutting off the engine
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and disconnect the tester clamps from the battery.

CHARGING SYSTEM TEST RESULTS

RESULT ON PRINTER REMEDY

Charging system normal/Diode

Charging system is normal
ripple normal

Generator does not supply charging current to battery

No charging voltage → Check belts, connection between generator and battery
Replace belts or cable or generator as necessary

Generator does not supply charging current to battery and electrical load to
Low charging voltage system fully
→ Check belts and generator and replace as necessary

The voltage from generator to battery is higher than normal limit during
High charging voltage voltage regulating.
→ Check connection and ground and replace regulator as necessary

One or more diodes in the generator is not functioning properly

Excess ripple detected
→ Check generator mounting and belts and replace as necessary

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ON-VEHICLE INSPECTION
INSPECT SPARK TEST
1. Remove the spark plug cable.
2. Using a spark plug socket, remove the spark plug.
3. Install the spark plugs to each spark plug cable.
4. Ground the spark plugs.
5. Check if spark occurs while engine is being cranked.

To prevent gasoline from being injected from injectors during this test, disconnect the injector connectors.
Be sure to clean away DTC codes the timing is complete after.

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

7. Install the spark plug cable.

INSPECT SPARK PLUG AND SPARK PLUG CABLE

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).

INSPECTION FO ELECTRODES
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CONDITION DARK
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ID: reveleus1 WHITE DEPOSITS

- Fuel mixture too rich - Fuel mixture too lean

DESCRIPTION - Low air intake - Advanced ignition timing
- Insufficient plug tightening

4. Check the electrode gap(A).

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

5. 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's broken or distorted,
replace the spark plug cable.
6. Connect the ohmmeter probes and measure resistance.

RESISTANCE : 5.6K/m ± 20%

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7. Resistance should not be higher than 2.6k 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.

Standard value : 0.58 ± 10%

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2. Measure the secondary coil resistance between the high-voltage terminal for the No.1 and No.4 cylinders, and between the
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high-voltage terminals for the No.2 and No.3 cylinders.

Standard value : 8.8k ± 15%

Be sure, when measuring the resistnace of the secondary coil, to disconnect the connector of the ignition coil.

INSPECT IGNITION SWITCH

1. Remove the connector located under the steering column.
2. Check for continuity between terminals.
If there is no continuity, replace the ignition switch.

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REPLACEMENT
IGNITION COIL
1. Remove the engine cover.
2. Disconnect the spark plug cable and connector.
3. Remove the ignition coil.
4. Installation is the reverse of removal.

CRANKSHAFT POSITION SENSOR

1. Disconnect the crankshaft position sensor connector.
2. Remove the crankshaft position sensor(A).

CAMSHAFT POSITION SENSOR

1. Remove the engine cover(B).
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2. Disconnect the camshaft position sensor connector.

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3. Remove the camshaft position sensor(C).

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SPECIFICATION
IGNITION SYSTEM

Items Specifications

Ignition coil Mold coil type

Type 0.58 ± 10% ()
Primary resistance 8.8 ± 15% (k)
Secondary resistance

Spark plugs
BKR5ES-11
NGK
RC10YCPB4
CHAMPION
1.0 ~ 1.1 mm (0.039 ~ 0.043 in.)
Gap

STARTING SYSTEM

Items Specifications

Starter
Type
Rated voltage Reduction drive (with planetary gear)
No. of pinion teeth 12V, 1.2KW
No-load characteristics 8
Voltage 11V
Amperage 90A, Max.
Speed 3,000 rpm, Min.
Commutator diameter 29.4 mm (1.157 in.)
Standard 28.4 mm (1.118 in.)
Limit 0.5 mm (0.02 in.)
Undercut depth 0.2 mm (0.008 in.)
Standard
Limit

CHARGING SYSTEM

Items Specifications

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Generator Ebay User ID: reveleus1

Battery voltage sensing
Type
13.5V, 90A
Rated voltage
1000 ~ 18,000 rpm
Speed in use
Electronic built-in type
Voltage regulator
14.4 ± 0.2V
Regulator setting voltage
-10 ± 3 mV/°C
Temperature compensation

Battery
MF60AH
Type
550A
Cold cranking amperage [at -18°C (0°F)]
92min
Reserve capacity
1,280 ± 0.01
Specific gravity [at 25°C (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 the 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

Items Specification

Setting error Within ± 1.5Km/h on level road (± 1MPH)

Vehicle speed memory variation No variation

Setting time 0.1sec max.

Resuming time 0.1sec max.

Minimum operating speed 40 ± 2Km/h (25 ± 1.2MPH)

Cancel speed range 15 ± 2Km/h (9 ± 1.2MPH)

Maximum memorized speed 160 ± 2Km/h (99 ± 1.2MPH)

Pulling force 127N(13Kgf)(28.6 Ib-force)

Main switch serial resistance value 3.9k ± 1%

SET switch : 220 ± 1%

Command switch serial resistance value
RESUME switch : 910 ± 1%

TIGHTENING TORQUE

Items Nm kg·cm lb·ft

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Generator terminal (B+) 5~

Ebay User ID:7reveleus1 50 ~ 70 3.6 ~ 5.1
Starter motor terminal (B+) 10 ~ 12 100 ~ 120 7.3 ~ 8.8
Battery terminal 4~6 40 ~ 60 2.9 ~ 4.3
Spark plug 20 ~ 30 200 ~ 300 15 ~ 22

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COMPONENTS

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INSPECTION
1. Remove the fuse box cover.
2. Remove the starter relay.

3. Inspect the relay continuity.

[Link] an ohmmeter, check that there is continuity between terminals 2 and 4.
If there is no continuity, replace the relay.
[Link] that there is no continuity between terminals 1 and 5.
If there is continuity, replace the relay.

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4. Inspect the relay operation.

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[Link] battery positive voltage across terminals 2 and 4.
[Link] 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.

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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 connecto(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 negative cable to the battery.

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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.

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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

After this test, or any subsequent repair, reset the ECM/PCM to clear any codes.
Check the Starter Engagement :
1. Remove the No.8(10A) fuse from the fuse/relay box.
2. Turn the ignition switch to START (III) with the shift lever in "P" or " N" position (A/T) or with the clutch pedal
depressed (M/T). The starter should crank the engine.
[Link] the starter does not crank the engine, go to step 3.
[Link] 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.

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Ebay User ID: reveleus1

[Link] the starter still does not crank the engine, remove it, and diagnose its internal problem.
[Link] the starter cranks the engine, go to step 6.
6. Check the ignition switch (see page EE-20 ).
7. Check the starter relay (see page EE-46 ).
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.
If cranking voltage is too low, or current draw too high, check for :
• dead or low battery.
• open circuit in starter armature commutator segments.
• starter armature dragging.
• shorted armature winding.
• excessive drag in engine.
Check Cranking rpm
Engine speed during cranking should be above 100 rpm.
If speed is too low, check for :
• loose battery or starter terminals.
• excessively worn starter brushes.
• open circuit in commutator segments.
• dirty or damaged helical splines or drive gear.
• defective drive gear overrunning clutch.
Check starter disengagement
With the shift lever in N or P position (A/T) or with the clutch pedal depressed (M/T), turn the ignition switch to
START(III), and release to ON(II).
The starter drive gear should disengage from the flywheel or flywheel ring gear when you release the key.
If the drive gear hangs up on flywheel ring gear, check for :
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• solenoid plunger and switch malfunction. Ebay User ID: reveleus1

• dirty drive gear assembly or damaged overrunning clutch.

STARTER SOLENOID TEST

1. Check the hold-in coil for continuity between the S terminal and the armature housing (ground). The coil is OK
if there is continuity.

2. Check the pull-in coil for continuity between the S and M terminals. The coil is OK if there is continuity.

FREE RUNNING TEST

1. Place the starter motor in a vise equipped with soft jaws and connecta fully-charged 12-volt battery to starter
motor as follows :
2. Connect a test ammeter (100-ampere scale) and carbon pile rheostatas 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 startermotor body.
6. Adjust the carbon pile 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 :

: Max. 90 Amps
: Min. 2,800 rpm

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CIRCUIT DIAGRAM FOR STARTING SYSTEM

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 Purchased
from Ebay seller
Reveleus1

Thank-you for purchasing from me, it

is much appreciated.
To contact me please email
suzlever@[Link]
[Link]

Ebay User ID: reveleus1

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TROUBLESHOOTING
IGNITION SYSTEM

Symptom Suspect Area Remedy (See Page)

Engine will not start or is hard to start Ignition lock switch See page EE-20
(Cranks OK) Ignition coil See page EE-19
Spark plugs See page EE-17
Ignition wiring disconnected or broken See page EE-21
Spark plug cable See page EE-18

Rough idle or stalls Ignition wiring Inspect

Ignition coil See page EE-19
Spark plug cable See page EE-18

Engine hesitates/poor acceleration Spark plugs and spark plug cable See page EE-18
Ignition wiring Inspect

Poor mileage Spark plugs and spark plugs cable See page EE-18

CHARGING SYSTEM

Symptom Suspect Area Remedy (See Page)

Charging warning Fuse blown Check fuses

indicator does not light Light burned out Replace light
with ignition switch "ON" Wiring connection loose Tighten loose connections
and engine off Electronic voltage regulator See page EE-26

Charging warning Drive belt loose or worn See page EE-24, 35

indicator does not go out Battery cables loose, corroded or worn See page EE-32
with engine running Fuse blown Check fuses
(Battery requires frequent Fusible link blown Replace fusible link
recharging) Electronic voltage regulator or generator See page EE-26
Wiring Repair wiring

Engine hesitates/poor Drive belt loose or worn See page EE-24, 35

acceleration Wiring connection loose or open circuit Tighten loose connection or repair
Overcharge Fusible link blown wiring
Poor grounding Replace fusible link
Electronic voltage regulator or generator Repair
Worn battery See page EE-26
Electronic voltage regulator Replace battery
Voltage sensing wire See page EE-26
Repair wire

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STARTING SYSTEM
Ebay User ID: reveleus1

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 Replace fusible link
Starter motor faulty See page EE-42
Ignition switch faulty See page EE-20

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-42

Starter keeps running Starter motor See page EE-42

Ignition switch See page EE-20

Starter spins but engine Short in wiring Repair wiring

will not crank Pinion gear teeth broken or starter motor See page EE-44
Ring gear teeth broken See page EM group-fly wheel

CRUISE CONTROL SYSTEM

Before troubleshooting :
- Check the No.2(10A), No.8(10A), No.10(10A) and No.16(15A) fuse in the under - hood fuse/relay box.
- Check that the horn sounds.
- Check the tachometer to see if it works properly.

Symptom Suspect Area See Page

Cruise control cannot be set See page EE-50

Cruise control switch
See page EE-51
Brake switch
See page TR group-automatic
A/T gear position switch
transaxle
Cruise control unit
See page EE-7

Cruise control cannot be set and Dimming circuit in gauge See page EE-7
indicator light does not go on Cruise control unit See page EE-7

Cruise speed is noticeably higher or Vehicle speed sensor See page TR group-automatic
lower than what was set Cruise control unit and actuator cable transaxle
deflection See page EE-53
Cruise control unit See page EE-7

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Excessive overshooting or Cruise control

Ebay Userunit and actuator cable
ID: reveleus1 See page EE-53
undershooting when trying to set deflection See page TR group-automatic
speed Vehicle speed sensor transaxle
Cruise control unit See page EE-7

Speed fluctuation on a flat road with Vehicle speed sensor See page TR group-automatic
cruise control set Cruise control unit and actuator cable transaxle
deflection See page EE-53
Cruise control unit See page EE-7

Vehicle does not decelerate or Cruise control switch See page EE-50
accelerate accordingly when SET/ Cruise control unit See page EE-7
RESUME/CANCEL button is pushed

See page TR group-automatic

Cruise control does not cancel when A/T gear position switch
transaxle
shift lever is moved to N position (A/T) Cruise control unit
See page EE-7

Set speed is not cancelled when Brake switch See page EE-51
brake pedal is pushed Cruise control unit See page EE-7

Cruise control will not cancel when Cruise control switch See page EE-50
main switch is pushed OFF Cruise control unit See page EE-7

Cruise control will not cancel when Cruise control switch See page EE-50
CANCEL button is pushed Cruise control unit See page EE-7

Set speed will not resume when Cruise control switch See page EE-50
RESUME button (with main switch Cruise control unit See page EE-7
on, when set speed is temporarily
cancelled) is depressed

The transmission shifts down slower Troubleshooting the cruise control See page EE-7
than normal when going up a hill with communication circuit
the cruise control on (A/T)

CRUISE CONTROL COMMUNICATION CIRCUIT TROUBLESHOOTING (A/T)

1. Start the engine.
2. Turn on the cruise control main switch, then drive the vehicle to speeds over 25 mph (40km/h) with the cruise
control.
Does the cruise control operate ?
- Go to step 3.
- Check the cruise control unit or cruise control actuator.

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3. Measure the voltage between the No.4 terminal of the cruise control unit connector and ground.
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Is there approx. 1V?

- Go to step 4.
- Replace the cruise control unit.
4. Measure the voltage between the No.8 terminal of the TCM connector and ground.

Is there approx. 1V?

- Repair short or open in the wire between the No.8 terminal and cruise control unit.

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