2015 > G 1.

2 MPI KAPPA > Engine Electrical System > General Information > General Information
English

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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.
※ When charging battery by test result, Battery must be fully charged.
To get accurate test result, battery surface voltage must have subsided ahead before test when you test battery after
charged. (See following Battery Test Results)

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Keypad
The Micro 570 button on the key pad provide the following functions :
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Battery Test Procedure

1. Connect the tester to the battery.
– Red clamp to battery positive (+) terminal.
– Black clamp to battery negative (­) terminal.

895 of 1992
 English

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 "IN­VEHICLE" or "OUT­OF­VEHICLE". Make your selection by pressing
the arrow buttons; then press ENTER.

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3. Select CCA and press the ENTER button.

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CCA : Cold cranking amps, is an SAE specification for cranking batteried at ­0.4°F (­18°C).

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.

896 of 1992
 The battery ratings(CCA) displayed on the tester must be identical to the ratings marked on battery label.

5. The tester will conduct battery test.

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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.
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Battery Test Results

Result On Printer Remedy
GOOD BATTERY No action is required.
GOOD RECHARGE Battery is in a good state.
Recharge the battery and use.
※ You have to follow instruction below when you charge battery and retest, otherwise
test result can be inaccurate. (See ‘Charge and Retest method after battery charge’
below.)
CHARGE & RETEST Battery is not charged properly.
– Charge and test the battery again.
※ You have to follow instruction below when you charge battery and retest, otherwise
test result can be inaccurate. (See ‘Charge and Retest method after battery charge’
below.)
897 of 1992
 REPLACE BATTERY Replace battery and recheck the charging system.
– Improper connection between battery and vehicle cables may cause "REPLACE
BATTERY". Retest the battery after removing cables and connecting the tester
to the battery terminal directly prior to replacing the battery.

BAD CELL­REPLACE Charge and retest the battery.

– If the Micro 570 recommends "REPLACE BATTERY", replace the battery and
recheck the charging system.

[Charge and Retest method after battery charge]

Battery charge
Set battery charger to ‘Auto Mode’ (The Mode that charging current drops as the battery charges.) and charge battery
until charging current down close to zero or the charger alerts you with an alarm when charge is complete.
(Minimum charging time recommended: More than 3 hours with Auto Mode that explained above)
• If battery is not fully charged, battery surface voltage will be high while the amount of current charged (CCA) in
battery is low. If you measure the battery under this condition, tester may misjudge that battery sulfation occurred
because the amount of current in battery is too low in comparison with battery voltage.
* Surface voltage: When battery is charged electrolyte temperature increases and chemical reaction become
active resulting in an excessive increase of battery voltage.
It is known that it takes approximate one day to subside this increased surface voltage completely.

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Battery Test after charge
Do not test battery right after the charge. Test battery after battery surface voltage has subsided as instructed in the
following procedure.
(1) When battery charge is complete, install the battery in the vehicle.
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(2) Put IG key to ON position and turn on head lamp with low beam, and wait 5 minutes. (Discharge for 5 minutes)

(3) Turn off the head lamp and IG key, and wait 5 minutes. (Waiting for 5 minutes)
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(4) Remove +, ­ cable from the battery and test battery.

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

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

8. Start the engine.

898 of 1992
9. Cranking voltage and starter test results will be displayed on the screen.
Refer to the following table and take the appropriate action as recommended by the Micro 570.

Starter Test Results om

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Result On Printer Remedy
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CRANKING VOLTAGE System shows a normal starter draw.
NORMAL
CRANKING VOLTAGE LOW Cranking voltage is lower than normal level.
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– Check starter.

CHARGE BATTERY The state of battery charge is too low to test.

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– Charge the battery and retest.

REPLACE BATTERY Replace battery.

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– 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.

Charging System Test Procedure

10. Press ENTER to begin charging system test.

899 of 1992
11. The tester displays the actual voltage of alternator.
Press ENTER to continue.

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12. Turn off all electrical load and rev engine for 5 seconds with pressing the accelerator pedal. (Follow the instructions on
the screen)
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900 of 1992
13. The message that engine RPM is detected will be displayed on the screen. Press ENTER to continue.

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14. If the engine RPM is not detected, press ENTER after revving engine.
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15. The tester will conduct charging system test during loads off.

901 of 1992
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. om
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18. Rev engine for 5 seconds with pressing the accelerator pedal. (Follow the instructions on the screen)

902 of 1992
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19. The message that engine RPM is detected will be displayed on the screen. Press ENTER to continue.
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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.

903 of 1992
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.

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Charging System Test Results

Result On Printer Remedy
CHARGING SYSTEM Charging system is normal.
NORMAL / DIODE RIPPLE
NORMAL
NO CHARGING VOLTAGE Alternator does not supply charging current to battery.
– Check belts, connection between alternator and battery and replace belts or
904 of 1992
 cable or alternator as necessary.

LOW CHARGING VOLTAGE Alternator does not supply charging current to battery and electrical load to system
fully.
– Check belts and alternator and replace as necessary.

HIGH CHARGING VOLTAGE The voltage from alternator to battery is higher than normal limit during 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.

The MDX­670P Analyzer

The MDX­670P battery conductance and electrical system analyzer tests batteries as well as starting and charging systems for
vehicle.
It displays the test results in seconds and features a built­in printer to provide a copy of the results.

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1) Because of the possibility of personal injury, always use extreme caution and appropriate eye protection when
working with batteries.
2) When charging battery by test result, Battery must be fully charged. To get accurate test result, battery surface
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voltage must have subsided ahead before test when you test battery after charged. (See following Battery Test
Results)

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.

1. Connect the red clamp to the positive (+) terminal and the black clamp to the negative (–) terminal.
905 of 1992
 For a proper connection, rock the clamps back and forth. The tester re¬quires that both sides of each clamp be
firmly connected before testing. A poor connection will produce a CHECK CONNECTION or WIGGLE CLAMPS
message. If the message appears, clean the terminals and reconnect the clamps.

2. Scroll to and select IN VEHICLE or OUT OF VEHICLE for a battery not connected to a vehicle.

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Following an IN VEHICLE test you will be prompted to test the starting and charging systems.

3. Scroll to and select REGULAR FLOODED, AGM FLAT PLATE, or AGM SPIRAL where applicable.
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If the vehicle equipped with ISG function, select the AGM FLAT PLATE.

4. Scroll to and select the battery’s rating system.

Mostly, the CCA value is marked on the battery label, but sometimes marked EN or SEA value. Select one of
them.

906 of 1992
 – CCA: Cold Cranking Amps, as specified by SAE. The most common rating for cranking batteries at 0 ºF (–17.8
ºC).
– EN: Europe­Norm
– SAE: Society of Automotive Engineers, the European labeling of CCA

5. Set the selected rating value displayed on the screen to the value marked on the battery label by pressing up and down
arrow buttons.

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6. Press ENTER to start test.

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7. After several seconds the tester displays the decision on the battery’s condition and the measured voltage. The tester
also displays your selected battery rating and the rating units.

907 of 1992
Battery Test Results
Result On Printer Remedy
GOOD BATTERY No action is required.
GOOD RECHARGE Battery is in a good state. Recharge the battery and use.
※ You have to follow instruction below when you charge battery and retest, otherwise test
result can be inaccurate. (See ‘Charge and Retest method after battery charge’ below.)
CHARGE & RETEST Battery is not charged properly.

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– Charge and test the battery again.
※ You have to follow instruction below when you charge battery and retest, otherwise test
result can be inaccurate. (See ‘Charge and retest method after battery charge’ below.)
REPLACE BATTERY Replace battery and recheck the charging system.
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– Improper connection between battery and vehicle cables may cause "REPLACE
BATTERY", retest the battery after removing cables and connecting the tester to the
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battery terminal directly prior to replacing the battery.

BAD CELLREPLACE Charge and retest the battery.

– If recommends "REPLACE BATTERY", replace the battery and recheck the charging
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system.
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[Charge and Retest method after battery charge]

Battery charge
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Set battery charger to ‘Auto Mode’ (The Mode that charging current drops as the battery charges.) and charge battery
until charging current down close to zero or the charger alerts you with an alarm when charge is complete.(Minimum
charging time recommended: More than 3 hours with Auto Mode that explained above)
• If battery is not fully charged, battery surface voltage will be high while the amount of current charged (CCA) in
battery is low. If you measure the battery under this condition, tester may misjudge that battery sulfation occurred
because the amount of current in battery is too low in comparison with battery voltage.
* Surface voltage: When battery is charged electrolyte temperature increases and chemical reaction become
active resulting in an excessive increase of battery voltage.
It is known that it takes approximate one day to subside this increased surface voltage completely.
Battery Test after charge
Do not test battery right after the charge. Test battery after battery surface voltage has subsided as instructed in the
following procedure.
(1) When battery charge is complete, install the battery in the vehicle.

(2) Put IG key to ON position and turn on head lamp with low beam, and wait 5 minutes. (Discharge for 5 minutes)

(3) Turn off the head lamp and IG key, and wait 5 minutes. (Waiting for 5 minutes)

(4) Remove +, ­ cable from the battery and test battery.

908 of 1992
 For an in­vehicle test, the display alternates between the test results and the message “PRESS FOR STARTER
TEST.

Before starting the test, inspect the alternator drive belt. A belt that is glazed or worn, or lacks the proper tension,
will prevent the en¬gine from achieving the rpm levels needed for the test.

8. Press the ENTER button to proceed with the starter test.

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9. Start the engine when prompted.
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10. The tester displays the decision on the starter system, cranking voltage, and cranking time in milliseconds.
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Starter Test Results

Result On Printer Remedy
CRANKING VOLTAGE System shows a normal starter draw.
NORMAL
CRANKING VOLTAGE LOW Cranking voltage is lower than normal level.
– Check starter.

CHARGE BATTERY The state of battery charge is too low to test.

909 of 1992
 – 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.

For an in­vehicle test, the display alternates between the test results and the message “PRESS FOR
CHARGING TEST.

Step 3: Charging System Test

11. Press the ENTER button to proceed with the charging test.

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12. Rev the engine with loads off. (Following the on­screen prompts)

13. The message that engine RPM is detected will be displayed on the screen, idle the engine.

910 of 1992
14. Turn on electrical loads (air conditioner, lamps, audio and etc). Press ENTER to continue.

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15. Turn on electrical loads (air conditioner, lamps, audio and etc). Press ENTER to continue.
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16. The message that engine RPM is detected will be displayed on the screen, idle the engine.

17. Turn off loads and engine.

911 of 1992
18. The Charging System decision is displayed at the end of the procedure.

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Result On Printer Remedy
NO PROBLEMS System is showing normal output from the alternator.
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NO OUTPUT No alternator output detected.

– Check all connections to and from the alternator, especially the
connection to the battery. If the connection is loose or heavily
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corroded, clean or replace the cable and retest.

– If the belts and connections are in good working condition, replace
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the alternator. (Older vehicles use external voltage regulators,

which may require only replacement of the voltage regulator.)
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LOW OUTPUT Alternator does not supply charging current to battery and electrical
load to system fully.
– Check belts and alternator and replace as necessary.

HIGH OUTPUT The voltage from alternator to battery is higher than normal limit during
voltage regulating.
– Check connection and ground and replace regulator as necessary.
– Check electrolyte level in the battery.

EXCESSIVE RIPPLE The voltage from alternator to battery is higher than normal limit during
voltage regulating.
– Check alternator mounting and belts and replace as necessary.

CHARGE BATTERY The starter voltage is low and the battery is discharged. Fully charge
the battery and repeat the starter system test.
REPLACE BATTERY Battery must be replaced before the starting system can be tested.

19. Press the BACK/PRINT button to print the test results or MENU to return to the Options Menu.

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912 of 1992
 2015 > G 1.2 MPI KAPPA > Engine Electrical System > General Information > Specifications English

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SPECIFICATIONS

Ignition System

Specification
Items 1.0 1.25
Petrol ISG Non­ISG
Primary resistance 0.75 ± 15 % (Ω) 0.82 ± 10 % (Ω)
Ignition coil
Secondary resistance 5.9 (kΩ) 15.5 ± 15 % (kΩ)
LKR6D­10E,
Type LKR6D­10E, ELR9SC10
ELR9SC10
Unleaded
0.9 ~ 1.0 mm 0.9 ~ 1.0 mm
Gap
Spark plugs (0.0354 ~ 0.0394 in.) (0.0354 ~ 0.0394 in.)

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Type LKR6D­E, ELR9SC8 ­ LKR6D­E, ELR9SC8
Leaded 0.7 ~ 0.8 mm 0.7 ~ 0.8 mm
Gap ­
(0.0276 ~ 0.0315 in.) (0.0276 ~ 0.0315 in.)
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Starting System
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Specification
Items 1.0 1.25
Non­ISG ISG Non­ISG ISG
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Rated voltage 12V, 0.9kW 12V, 1.2Kw 12V, 0.9kW 12V, 1.2Kw
No. of pinion teeth 8 11 8 11
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Starter Voltage 11.5V 11V 11.5V 11V

No­load
Ampere 70A, MAX 70A, MAX 70A, MAX 70A, MAX
characteristics
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Speed 3,000rpm, MIN 2,500rpm, MIN 3,000rpm, MIN 2,500rpm, MIN

Charging System
Specification
Items 1.0 1.25
Non­ISG ISG Non­ISG ISG
Rate voltage 13.5V, 70A 13.5V, 90A 13.5V, 70A 13.5V, 90A
Speed in use 1,000 ~ 18,000 rpm
Voltage regulator IC Regulator built­in type

Alternator Regulator External mode ECU control

setting voltage Internal mode 14.55 ± 0.3V
External mode ECU control
Temperature
compensation Internal mode ­3.5 ± 2mV/°C

Battery
▷CMF40L­BCI
913 of 1992
 Items Specification English
Capaticy [20HR/5HR] (AH) 40/32
Cold Cranking Amperage (A) 354 (SAE) / 283 (EN)
Reserve Capacity (Min) 55

▷CMF45L­DIN

Items Specification
Capaticy [20HR/5HR] (AH) 45/36
Cold Cranking Amperage (A) 410 (SAE) / 328 (EN)
Reserve Capacity (Min) 80

▷AGM60L­DIN: ISG

Items Specification
Capaticy [20HR/5HR] (AH) 60/48
Cold Cranking Amperage (A) 640 (SAE) / 512 (EN)
Reserve Capacity (Min) 100

• Model type description

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• Cold Cranking Ampere (CCA): Cold Cranking Amps is a rating used in the battery industry to define a battery's
ability to start an engine in cold temperatures.
– The rating is the number of amps a new, fully charged battery can deliver at ­18 °C(­0.4 °F) for 30 seconds, while
maintaining a voltage of at least 7.2 volts for a 12 volt battery.
– The higher the CCA rating, the greater the starting power of the battery.
• RESERVE CAPACITY (RC) : Reserve Capacity is a battery industry rating, defining a battery's ability to power a
vehicle with an inoperative alternator or fan belt.
– The rating is the number of minutes a battery at 26.7 °C(80 °F) can be discharged at 25 amps and maintain a
voltage of 10.5 volts for a 12 volt battery.
– The higher the reserve rating, the longer your vehicle can operate should your alternator or fan belt fail.

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914 of 1992
 2015 > G 1.2 MPI KAPPA > Engine Electrical System > General Information > Troubleshooting English

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TROUBLE SHOOTING

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

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Ignition coil Inspect ignition coil, or replace as
required
Spark plugs cable Inspect cable, or replace as required
Engine hesitates/poor acceleration Spark plugs and spark plug cables Inspect spark plugs / cable, or replace as
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required
Ignition wiring Repair wiring, or replace as required
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Poor mileage Spark plugs and spark plug cables Inspect spark plugs / cable, or replace as
required
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Charging System
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Symptom Suspect area Remedy

Charging warning indicator does not Fuse blown Check fuses
light with ignition switch "ON" and
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Light burned out Replace light

engine off.
Wiring connection loose Tighten loose connection
Electronic voltage regulator Replace voltage regulator
Charging warning indicator does not Drive belt loose or worn Adjust belt tension or replace belt
go out with engine running.
Battery cable loose, corroded or worn Inspect cable connection, repair or
(Battery requires frequent
replace cable
recharging)
Electronic voltage regulator or alternator Replace voltage regulator or alternator
Wiring Repair or replace wiring
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
replace wiring
Electronic voltage regulator or alternator Replace voltage regulator or alternator
Poor grounding Inspect ground or repair
Worn battery Replace battery

915 of 1992
Starting System English
Symptom Suspect area Remedy
Engine will not crank Battery charge low Charge or replace battery
Battery cables loose, corroded or worn Repair or replace cables
out
Transaxle range switch (Vehicle with Refer to A/T Group
automatic transaxle only)
Fuse blown Replace fuse
Starter faulty Replace
Ignition switch faulty Replace
Engine cranks slowly Battery charge low Charge or replace battery
Battery cables loose, corroded or worn Repair or replace cables
out
Starter faulty Replace
Starter keeps running Starter Replace
Ignition switch Replace
Starter spins but engine will not Short in wiring Repair wiring

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crank
Pinion gear teeth broken or starter motor Replace
Ring gear teeth broken
.c Replace fly wheel or torque converter

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916 of 1992
 2015 > G 1.2 MPI KAPPA > Engine Electrical System > General Information > Special Service Tools
English

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SPECIAL SERVICE TOOLS

Tool Name / Number Illustration Description

Alternator pulley remover

wrench Removal and installation of alternator pulley.
09373­27000

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917 of 1992
 2015 > G 1.2 MPI KAPPA > Engine Electrical System > Ignition System > Description and Operation
English

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DESCRITION

Ignition timing is controlled by the electronic control ignition timing system. The standard reference ignition timing data for the engine
operating conditions are pre­programmed in the memory of the ECM (Engine Control Module).
The engine operating conditions (speed, load, warm­up condition, etc.) are detected by the various sensors. Based on these sensor
signals and the ignition timing data, signals to interrupt the primary current are sent to the ECM. The ignition coil is activated, and
timing is controlled.
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918 of 1992
 2015 > G 1.2 MPI KAPPA > Engine Electrical System > Ignition System > Repair procedures English

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ON­VEHICLE INSPECTION

[1.0L]

1. Remove the engine cover.

2. Disconnect the ignition coil connectors (A).

3. Remove the ignition coils (A).

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4. Disconnect the injector connectors (A).

5. Using a spark plug socket, remove the spark plug.

6. Install the spark plug to the ignition coil.

7. Ground the spark plug to the engine.

919 of 1992
 English

8. Check if spark occurs while engine is being cranked.

To prevent fuel being injected from injectors while the engine is being cranked, disconnect the injector connector.
Crank the engine for no more than 5 ~ 10 seconds.

9. Inspect all the spark plugs.

10. Using a spark plug socket, install the spark plug.

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Tightening torque :
14.7 ~ 24.5N.m(1.5 ~ 2.5kgf.m, 10.8 ~ 18.1lb­ft)

11. Install the ignition coil.

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Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb­ft)
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12. Reconnect the injector connectors.

13. Reconnect the ignition coil connectors.

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[1.25L]
1. Remove the resonator.
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2. Disconnect the spark plug cable (A) from the spark plug.

[Non­ISG]
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Disconnect the ignition coil connectors (A).

[ISG]

920 of 1992
3. Remove the ignition coils (A).

[ISG]

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4. Disconnect the injector connectors (A).
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5. Using a spark plug socket, remove the spark plug.

6. Install the spark plug to the spark plug cable (or ignition coil).

7. Ground the spark plug to the engine.

8. Check if spark occurs while engine is being cranked.

921 of 1992
 To prevent fuel being injected from injectors while the engine is being cranked, disconnect the injector connector.
Crank the engine for no more than 5 ~ 10 seconds.

9. Inspect all the spark plugs.

10. Using a spark plug socket, install the spark plug.

Tightening torque :
14.7 ~ 24.5N.m(1.5 ~ 2.5kgf.m, 10.8 ~ 18.1lb­ft)

11. Reconnect the spark plug cables.(Non­ISG type)

12. Install the ignition coil. (ISG type)

Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb­ft)

13. Reconnect the injector connectors.

14. Reconnect the ignition coil connectors.

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922 of 1992
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Inspect Spark Plug

[1.0L]
1. Disconnect the ignition coil connectors (A).

923 of 1992
 When disconnecting the ignition coil connector, pull out the locking pin (A) and then pull out the connector while
pressing the clip (B).

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2. Remove the ignition coils (A).

Tightening torque :
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9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb­ft)

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3. Using a spark plug socket, remove the spark plug.

Tightening torque :
14.7 ~ 24.5N.m(1.5 ~ 2.5kgf.m, 10.8 ~ 18.1lb­ft)

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

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

924 of 1992
 Inspection Of Electrodes
Condition Dark deposits White deposits
– Fuel mixture too lean
– Fuel mixture too rich
Description – Advanced ignition timing
– Low air intake
– Insufficient plug tightening torque

5. Check the electrode gap (A).

Standard

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Unleaded : 0.9 ~ 1.0 mm (0.0354 ~ 0.0394 in.)
Leaded : 0.7 ~ 0.8 mm (0.0276 ~ 0.0315 in.)
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[1.25L]
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1. Disconnect the spark plug cable (A) from the spark plug.

[NON­ISG]

Disconnect the ignition coil connectors (A).

[ISG]

925 of 1992
 When disconnecting the ignition coil connector, pull out the locking pin (A) and then pull out the connector while
pressing the clip (B).

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2. Remove the ignition coils (A).

Tightening torque :
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9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb­ft)

[ISG]
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3. Using a spark plug socket, remove the spark plug.

Tightening torque :
14.7 ~ 24.5N.m(1.5 ~ 2.5kgf.m, 10.8 ~ 18.1lb­ft)

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

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

926 of 1992
 Inspection Of Electrodes
Condition Dark deposits White deposits
– Fuel mixture too lean
– Fuel mixture too rich
Description – Advanced ignition timing
– Low air intake
– Insufficient plug tightening torque

5. Check the electrode gap (A).

Standard

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Unleaded : 0.9 ~ 1.0 mm (0.0354 ~ 0.0394 in.)
Leaded : 0.8 ~ 0.9 mm (0.0315 ~ 0.0354 in.)
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Inspect Spark Plug Cable

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1. 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 has surface corrosion, clean it off, and if it
broken or distorted, replace the spark plug cable.

2. Connect the ohmmeter probes and measure resistance.

Resistance: 5.6kΩ/m ± 20 %

927 of 1992
3. Resistance should not be higher than 10kΩ/m.
If resistance is higher, replace the cable.

Inspect Ignition Coil

[1.25L Non­ISG]
1. Measure the primary coil resistance between terminals 1, 2 and 1, 3.

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Standard value: 0.82Ω±10%

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2. Measure the secondary coil resistance between the high­voltage terminals for the No.1 and No. 4 cylinders, and
between the high voltage terminals for the No. 2 and No. 3 cylinders.
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Standard value: 15.5kΩ/m ±15%

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

[1.0L Petrol/1.25L ISG]

1. Measure the primary coil reistance between terminals (+) and (­).

928 of 1992
 Standard value : 0.75Ω ± 15%

REPLACEMENT

[1.25L Non­ISG]

Ignition Coil

1. Disconnect the spark plug cables (A) and ignition coil connector.

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2. Remove the ignition coil (A).

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Tightening torque:
18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 [Link])
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3. Installation is the reverse of removal.

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929 of 1992
 2015 > G 1.2 MPI KAPPA > Engine Electrical System > Charging System > Description and Operation
English

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DESCRIPTION

The charging system consists a battery, an alternator with a built­in regulator, and the charging indicator light and wire.
The Alternator has built­in diodes, each rectifying AC current to DC current.
Therefore, DC current is present at the alternator "B" terminal.
Additionally, the alternator and charging voltage is regulated by the battery voltage detection system.
The alternators is regulated by the battery voltage detection system. The main components of the alternator are the rotor, stator,
rectifier, capacitor, brushes, bearings and V­ribbed belt pulley. The brush holder contains a built­in electronic voltage regulator.

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1. Brush
2. Drive belt pulley
3. Rotor
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4. Stator
5. Rectifier
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Alternator Management System (AMS)

Alternator management system controls the charging voltage set point in order to improve fuel economy, manage alternator load
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under various operating conditions, keep the battery charged, and protect the battery from over­charging. ECM controls generating
voltage by duty cycle (charging control, discharging control, normal control) based on the battery conditions and vehicle operating
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conditions.
The system lowers the charging rate when accelerating. Lowering the charging rate will allow more engine power for accelerating.
The system increases the charging rate when decelerating. The system uses the unused power of the decelerating engine and
increases the charging rate.
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930 of 1992
 2015 > G 1.2 MPI KAPPA > Engine Electrical System > Charging System > Repair procedures English

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ON­VEHICLE INSPECTION

• Check that the battery cables are connected to the correct terminals.
• Disconnect the battery cables when the battery is given a quick charge.
• 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.

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Standard voltage: 12.5 ~ 12.9V at 20°C(68°F)
If the voltage is less than specification, charge the battery.

Check The Battery Terminals And Fuses

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1. Check that the battery terminals are not loose or corroded.

2. Check the fuses for continuity.

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Inspect Drive Belt

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

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

2. Measure the drive belt tension and adjust it.

Drive belt tension measurement and adjustment

Belt tension measurement
Measure the belt tension using a sonic tension meter.
Belt tension
[1.0L]
931 of 1992
New belt:
English
980.7 ~ 1078.7 N (100 ~ 110 kg, 220.5 ~ 242.5 lb)
Used belt:
676.7 ~ 774.7 N (69 ~ 79 kg, 152.1 ~ 174.2 lb)
[1.25L]
[Without OAD]
New belt:
883.6 ~ 931.6N (85 ~ 95kg, 187.4 ~ 209.4lb)
Used belt:
637.4 ~ 735.5N (65 ~ 75kg, 143.3 ~ 165.3lb)
[With OAD]
New belt:
637.4 ~ 735.5N (65 ~ 75kg, 143.3 ~ 165.3lb)
Used belt:
490.3 ~ 588.4N (50 ~ 60kg, 110.2 ~ 132.3lb)

• If the engine has run for 5 minutes or more, the belt tension must be adjusted as a used belt.
• When installing the V­ribbed belt, all grooves on the pulley should be covered with belt ribs.
• A loose belt causes slip noise.

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• Too tight belt cause bearing of alternator and water pump to damage.

Using a sonic tension meter (U­505/507 type)

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1. Input the belt specifications into the tension meter (A).

Input data
Location of measurement
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M (Mass, g/[Link]) W (Width, rib) S (Span, mm)
Crankshaft pulley to idler [1.0L] 13.4 5 180
Crankshaft pulley to alternator pulley
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13.4 5 275
[1.25L]
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Measurement of S (Span): Calculate average value after measuring the distance 3~4 times.

932 of 1992
2. Locate the micro phone (B) close to the center of belt span (A) and bounce the belt by finger 2~3 times. Read a value
on the display.

[With A/C]
[1.0L]

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[1.25L]
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[Without A/C]
[1.0L]

[1.25L]
933 of 1992
If adjustment is necessary:

1. Loosen the mounting bolts (A, B).

2. Tighten the adjusting bolt (C) counterclockwise in loose tension; loosen the bolt clockwise in high tension.

[1.0L]

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[1.25L]
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3. Recheck tension of the belt.

4. After adjusting tension, tighten the mounting bolts.

Tightening torque
14 mm bolt:
29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 Ib­ft)
12 mm bolt:
21.6 ~ 32.4 N.m (2.2 ~ 3.3 kgf.m, 15.9 ~ 23.9 Ib­ft)

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

934 of 1992
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 is lit.

If the light does not go off as specified, troubleshoot the discharge light circuit.

Inspect Charging System

Voltage Drop Test Of Alternator Output Wire
This test determines whether or not the wiring between the alternator "B" terminal and the battery (+) terminal is good by the voltage
drop method.

Preparation
1. Turn the ignition switch to "OFF".

2. Disconnect the output wire from the alternator "B" terminal. Connect the (+) lead wire of ammeter to the "B" terminal of
alternator and the (­) lead wire of ammeter to the output wire. Connect the (+) lead wire of voltmeter to the "B" terminal
of alternator and the (­) lead wire of voltmeter to the (+) terminal of battery.

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Test
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1. Start the engine.

2. Turn on the headlamps and blower motor, and set the engine speed until the ammeter indicates 20A. And then, read the
voltmeter at this time.

Result
1. The voltmeter may indicate the standard value.
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 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 headlamps, blower motor and the ignition switch.

Output Current Test

This test determines whether or not the alternator gives an output current that is equivalent to the normal output.

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 good condition. The battery checking method is described
in the section "Battery".

935 of 1992
 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. The belt tension check method is described in the section "Inspect 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.

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.

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[AMS]
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[Non­AMS]
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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 alternator "B" terminal and battery (+) terminal or poor grounding is suspected.

2. Start the engine and turn on the headlamps.

3. Set the headlamps 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.

936 of 1992
 After the engine start 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.
Limit value : 60% of the voltage rate

• 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 headlamps 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.

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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.

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4. Remove the ammeter and voltmeter and the engine tachometer.

5. Connect the alternator output wire to the alternator "B" terminal.

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6. Connect the battery ground cable.

Regulated Voltage Test

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The purpose of this test is to check that the electronic voltage regulator controls voltage correctly.

Preparation
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1. Prior to the test, check the following items and correct if necessary.
Check that the battery installed on the vehicle is fully charged. The battery checking method is described in the section
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"Battery".
Check the alternator drive belt tension. The belt tension check method is described in the section "Inspect drive belt".

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.

[AMS]

937 of 1992
 [Non­AMS]

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Test
1. Turn on the ignition switch and check to see that the voltmeter indicates the following value.
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Voltage: 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 (­)
terminal.
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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
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less.

Result
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1. If the voltmeter reading dosen't agree with the standard value, the voltage requlator or the alternator is faulty.

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.

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938 of 1992
 2015 > G 1.2 MPI KAPPA > Engine Electrical System > Charging System > Alternator > Components
English
and Components Location

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COMPONENT

[1.0L]

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1. Nut 7. Rear bearing

2. Pulley 8. Stator
3. Front housing 9. Rear housing
4. Front bearing 10. Regulator
5. Retainer 11. Rear cover
6. Rotor

[1.25L]

939 of 1992
 English

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1. OAD cap 7. Rear bearing

2. OAD pulley 8. Stator
3. Front housing 9. Rear housing
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4. Front bearing 10. Regulator

5. Retainer 11. Rear cover
6. Rotor

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940 of 1992
 2015 > G 1.2 MPI KAPPA > Engine Electrical System > Charging System > Alternator > Repair English
procedures

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REMOVAL AND INSTALLATION

[1.0L]

1. Disconnect the battery negative terminal.

Tightening torque
Without battery sensor :
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb­ft)
With battery sensor :
4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb­ft)

2. Remove the drive belt.

(1) Loosen the alternator mounting bolts (A, B).

(2) Loosen the tension by turning the tension adjusting bolt (C) counterclockwise.

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(3) Remove the drive belt (D).

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3. Disconnect the intake OCV(Oil Control Valve) connector (A) and the knock sensor connector (B).
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4. Disconnect the alternator connector (C) and the cable (D) from alternator "B" terminal.
Tightening torque:
9.8 ~ 14.7 N.m (1.0 ~ 1.5 kgf.m, 7.2 ~ 10.8 lb­ft)

5. Remove the alternator (A).

Tightening torque
14mm bolt:
29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 Ib­ft)
12mm bolt:
21.6 ~ 32.4 N.m (2.2 ~ 3.3 kgf.m, 15.9 ~ 23.9 Ib­ft)

941 of 1992
 English

6. Installation is the reverse order of removal.

7. Adjust the alternator belt tension after installation.

[1.25L]
1. Disconnect the battery negative terminal first, then the positive terminal.
Tightening torque
(+) terminal:
7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb­ft)
(­) terminal:

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4.0 ~ 6.0 N.m (0.4 ~ 0.6 kgf.m, 3.0 ~ 4.4 lb­ft)

2. Remove the drive belt.

(1) Loosen the alternator mounting bolts (A, B).
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(2) Loosen the tension by turning the tension adjusting bolt (C) counterclockwise.
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(3) Remove the drive belt (A).

3. Disconnect the intake OCV(Oil Control Valve) connector (A) and the alternator connector (B).

4. Remove the intake OCV(Oil Control Valve) (C).

Tightening torque:
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb­ft)

942 of 1992
5. Disconnect the cable (A) from alternator "B" terminal.
Tightening torque:
9.8 ~ 14.7 N.m (1.0 ~ 1.5 kgf.m, 7.2 ~ 10.8 lb­ft)

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6. Remove the alternator (A).
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Tightening torque
14mm bolt:
29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 Ib­ft)
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12mm bolt:
21.6 ~ 32.4 N.m (2.2 ~ 3.3 kgf.m, 15.9 ~ 23.9 Ib­ft)
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7. Installation is the reverse order of removal.

8. Adjust the alternator belt tension after installation.

DISASSEMBLY

1. Remove the rear cover (A).

943 of 1992
2. Remove the slip ring guide (A) and regulator assembly (B).

When removing, be careful that other parts are not damaged.

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3. Remove the OAD cap. (with OAD)

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When installing, replace with new OAD cap.

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4. Remove the pulley (A). (without OAD)

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Using the SST (09373­27000), remove the OAD pulley (A). (with OAD)

944 of 1992
5. Disconnect the 3 stator leads (A).

6. Loosen the through bolts (A). om

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7. Disconnect the rotor (A) and housing (B).

INSPECTION

Inspect Rotor

1. Check that there is continuity between the slip rings (C).

945 of 1992
2. Check that there is no continuity between the slip rings and the rotor (B) or rotor shaft (A).

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).

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

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946 of 1992
 2015 > G 1.2 MPI KAPPA > Engine Electrical System > Charging System > DC DC converter > English
Components and Components Location

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COMPONENT LOCATION

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1. DC/DC Converter

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947 of 1992
 2015 > G 1.2 MPI KAPPA > Engine Electrical System > Charging System > DC DC converter > Schematic
English
Diagrams

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CIRCUIT DIAGRAM

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In case of IGN 2 with connecting battery, input the signal ‘ISG Start’ then BY PASS RELAY will be ON, after boosting
voltage (12±0.6V) of low battery, if the battery voltage is over 12±0.5V then BY PASS RELAY will be OFF.
In the ISG mode, if the power of an audio system turns OFF by drawdown while “Auto Starting” or “Idle Starting”
function operates, replace the DC/DC converter.

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948 of 1992
 2015 > G 1.2 MPI KAPPA > Engine Electrical System > Charging System > DC DC converter > Repair
English
procedures

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REMOVAL AND INSTALLATION

1. Disconnect the battery negative terminal.

Tightening torque
Without battery sensor :
7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb­ft)
With battery sensor :
4.0 ~ 6.0 N.m (0.4 ~ 0.6 kgf.m, 3.0 ~ 4.4 lb­ft)

2. Remove the audio assembly. (Refer to BE group)

3. Remove the glove box. (Refer to BD group)

4. Disconnect the connector (A) and then remove the DC/DC converter (B).

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5. Installation is reverse order of removal.

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After disconnecting then reconnecting the battery negative cable, the ISG function dose not operates until the
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system is stabilized, about 4 hours.

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949 of 1992
 2015 > G 1.2 MPI KAPPA > Engine Electrical System > Charging System > Battery > Description and
English
Operation

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DESCRIPTION

1. The maintenance­free 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 maintenance­free battery.

3. The battery is completely sealed, except for small vent holes in the cover.

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After disconnecting then reconnecting the battery negative cable, reset some parts that require the reset procedures.
(Refer to BE group – General Information)

[With ISG System]

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AGM battery is used for especially heavy load on the vehicle network depending on equipment and requirements. AGM stands for
Absorbent Glass Material Battery; that is absorbent glass fibre fleece. AGM batteries are fitted in models with electrical
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loads/consumers which have a high energy demand.

The constantly increasing energy demand of modern vehicle electrical systems calls for ever more powerful battery solutions.
The power consumption is considerable even when the vehicle is parked.
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The somewhat higher price compared with a battery of similar size is fully balanced by the following benefits:
– Significantly longer service life
– Increased starting reliability at low temperatures
– 100 % freedom from maintenance
– Low risk in event of an accident (reduced risk to the environment)

Recharging [With ISG System]

Check the battery condition
950 of 1992
The battery condition cannot be determined solely on the basis of the battery charge state. If there is a suspicion of a damaged
English
battery, check the battery condition whit battery tester and investigate the cause by means of the test module. With a low battery
charge state, recharge the battery.

Recharging the AGM battery

The battery may be charged using the battery chargers at a constant charge voltage of 14.8V.
If possible, the battery temperature during charging should be between 20°C (68°F) and 30°C (86°F).
Only chargers with voltage clamping (IU or WU curve) may be used or chargers with IUoU curve which have a trickle.
IU or WU charging technique
Optimized charging voltage for IU or WU: 14.7V (at 20°C ~ 30°C (68°F ~ 86°F)) about 24 hours
Min. charging voltage at 20°C (68°F): 14.4V
Max. charging voltage at 20°C (68°F): 14.8V
10% of capacity is recommended as charging current (e.g. 60Ah : 10 = 6,0A charging current).

Do not charge the AGM battery with>15.2V. No quick­charging routines.

If the battery is charged directly at the battery terminals on vehicles with battery sensor, misinterpretations of battery

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condition and under certain circumstances also unwanted Check Control messages or fault memory entire can occur.
After recharging finished, let the battery stand for over 10 hours with normal temperature for battery stabilization.

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951 of 1992
 2015 > G 1.2 MPI KAPPA > Engine Electrical System > Charging System > Battery > Components and
English
Components Location

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COMPONENTS

[NON­ISG Type]

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1. Battery 3. Battery mounting clamp

2. Battery tray

[ISG Type]

952 of 1992
 English

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1. Battery insulation pad 3. Battery tray

2. Battery 4. Battery mounting clamp

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953 of 1992
 2015 > G 1.2 MPI KAPPA > Engine Electrical System > Charging System > Battery > Repair procedures
English

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REMOVAL AND INSTALLATION

1. Disconnect the terminals (A) from the battery. The negative terminal first.
Tightening torque
(­) terminal (without battery sensor):
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb­ft)
(­) terminal (with battery sensor):
4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb­ft)
(+) terminal :
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb­ft)

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2. Remove the battery (A) after removing the clamp bolt.
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb­ft)
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3. Remove the battery tray (A).

Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb­ft)

954 of 1992
4. Installation is the reverse order of removal. English

• ISG (Idle stop & go) system equipped vehicle always use the AGM battery only. If flooded battery has
installed, this can potentially lead to engine electrical trouble or ISG system error.
• Replace same capacity of the AGM battery.

Ensure an AGM battery is fitted.

In all cases, an AGM battery must be installed and registered in the vehicle for the ISG function to work perfectly.
The vehicle with the new battery must be placed in the ignition switch OFF and door closed, hood switch OFF
state for at least 4 hours.
ISG system’s stabilization may take 4 hours after new battery installation.
ISG function is operates about 4 hours later and 2 times cranking by user.
But first 25 times, the ISG function can operates regardless of ISG system stability for ISG function operating
check.

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Do not open the AGM battery.
The AGM battery must not be opened under any circumstances as the introduction of oxygen from the air will
cause the battery to lose its chemical equilibrium and rendered non­operational.
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INSPECTION
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Battery Diagnostic Flow

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955 of 1992
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Vehicle parasitic current inspection

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1. Turn the all electric devices OFF, and then turn the ignition switch OFF.
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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.

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.
956 of 1992
 To prevent the battery from being reset during the inspection,
a. Connect a jump cable between the battery (­) terminal and the ground cable.
b. Disconnect the ground cable from the battery (­) terminal.
c. Connect an ammeter between the battery (­) terminal and the ground cable.
d. After disconnecting the jump cable, read the current value of the ammeter.

5. Read the current value of the ammeter.

• If the parasitic current is over the limit value, search for abnormal circuit by removing a fuse one by one and

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checking the parasitic current.
• Check the parasitic current again, and search for suspected unit by removing a unit connected with the abnormal
circuit one by one.
Limit value (after 10~20 min.) : Below 50mA
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CLEANING

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

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3. Remove the battery from the vehicle.

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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 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.

957 of 1992
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.

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958 of 1992
 2015 > G 1.2 MPI KAPPA > Engine Electrical System > Charging System > Battery Sensor > Description
English
and Operation

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DESCRIPTION

Vehicles have many control units that use more electricity. These units control their own system based on information from diverse
sensors. It is important to have a stable power supply as there diverse sensors giving a variety of information. Battery sensor (A) is
mounted on battery (­) terminal. It transmits battery voltage, current, temperature information to ECM. ECM controls generating
voltage by duty cycle based on these signals.

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When battery sensor signal fault occurs, inspect the vehicle parasitic draw in advance after inspecting the sensor
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because the sensor will behave abnormally when the parasitic draw is more than 100mA. (Refer to vehicle parasitic
current inspection)
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It takes a few hours for a new battery sensor to detect the battery state [Link] the following process after
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replacing the battery sensor.

1) Ignition switch ON/OFF.
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2) Park the vehicle about 4 hours.

3) After 4 hours later, check that the SOC (State of charge) of battery is displayed on GDS properly.
4) After engine start ON/OFF 2 times or more, check the SOF (State of function) of battery using GDS.

For the vehicle equipped with a battery sensor, be careful not to damage the battery sensor when the battery is
replaced or recharged.
• When replacing the battery, it should be same one (type, capacity and brand) that is originally installed on your
vehicle. If a battery of a different type is replaced, the battery sensor may recognize the battery to be abnormal.
• When installing the ground cable on the negative post of battery, tighten the clamp with specified torque of
4.0~6.0N.m (0.4~0.6kgf.m, 3.0~4.4lb­ft). An excessive tightening torque can damage the PCB internal circuit
and the battery terminal.
• When recharging the battery, ground the negative terminal of the booster battery to the vehicle body.

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959 of 1992
 2015 > G 1.2 MPI KAPPA > Engine Electrical System > Starting System > Description and Operation
English

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DESCRIPTION

The starting system includes the battery, starter, 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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1. Solenoid
2. Brush
3. Armature
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4, Over running clutch

[ISG Type]
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In conjunction with the ISG function, the starter motor must do a great deal more work. The starter motor is therefore configured for a
significantly higher number of start cycles. The components of the starter motor have been adapted to the higher requirements.
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There are two kinds of starter, ISG type starter and the other.
When replace the starter, confirm that the part number and connector shape.

ISG (Idle stop & go) system equipped vehicle always use the ISG type starter only. If the other starter has installed,
this can potentially lead to engine electrical trouble or ISG system error.

Do not disassemble the ISG type starter.

If the starter troubles occur, replace the starter.

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960 of 1992
 2015 > G 1.2 MPI KAPPA > Engine Electrical System > Starting System > Repair procedures English

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STARTER CIRCUIT TROUBLESHOOTING

The battery must be in good condition and fully charged.

1. Disconnect the injector connectors (A).

[1.0L]

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[1.25L]
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2. With the shift lever in N or P (A/T) or clutch pedal pressed (M/T), turn the ignition switch to START.
If the starter cranks the engine normally, starting system is OK. If the starter will not crank the engine at all, go to next
step.
If it won't disengage from the ring gear when you release key, check for the following until you find the cause.
• Solenoid plunger and switch malfunction.
• Dirty pinion gear or damaged overrunning clutch.

3. Check the battery condition. Check electrical connections at the battery, battery negative cable connected to the body,
engine ground cables, and the starter for looseness and corrosion. Then try starting the engine again.
If the starter cranks the engine normally, repairing the loose connection repaired the problem. The starting system is
now OK.
If the starter still does not crank the engine, go to next step.

4. Disconnect the connector from the S­terminal of solenoid. Connect a jump wire from the B­terminal of solenoid to the S­
terminal of solenoid.
If the starter cranks the engine, go to next step.
If the starter still does not crank the engine, remove the starter, and repair or replace as necessary.

5. Check the following items in the order listed until you find the open circuit.

961 of 1992
 • Check the wire and connectors between the driver's under­dash fuse/relay box and the ignition switch, and
English
between the driver's under­dash fuse/relay box and the starter.
• Check the ignition switch (Refer to Ignition system in BE group)
• Check the transaxle range switch connector or ignition lock switch connector.
• Inspect the starter relay.

Starter Solenoid Test

1. Disconnect the field coil wire from the M­terminal of solenoid switch.

2. Connect the battery as shown. If the starter pinion pops out (engages), it is working properly. To avoid damaging the
starter, do not leave the battery connected for more than 10 seconds.

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3. Disconnect the battery from the M [Link] the pinion does not retract, the hold­in coil is working properly. To avoid
damaging the starter, do not leave the battery connected for more than 10 seconds.
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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 fully­charged 12­volt battery to starter motor as
962 of 1992
 follows.

2. Connect a test ammeter (150­ampere scale) and carbon pile rheostats as shown in the illustration.

3. Connect a voltmeter (15­volt scale) across 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 11.5volts.

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7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and freely.

Items Current speed

Non­ISG 70A, MAX 3,000rpm, MIN
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1.0L
ISG 70A, MAX 2,500rpm, MIN
Non­ISG 70A, MAX 3,000rpm, MIN
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1.25L
ISG 70A, MAX 2,500rpm, MIN

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963 of 1992
 2015 > G 1.2 MPI KAPPA > Engine Electrical System > Starting System > Starter > ComponentsEnglish
and
Components Location

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COMPONENT

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1. Front housing 10. Lever plate

2. Stop ring 11. Lever packing
3. Stopper 12. Lever
4. Overrun clutch assembly 13. Magnet switch assembly
5. Internal gear assembly 14. Armature assembly
6. Planet shaft assembly 15. Yoke assembly
7. Planetary gear assembly 16. Brush holder assembly
8. Packing 17. Through bolt
9. Shield

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964 of 1992
 2015 > G 1.2 MPI KAPPA > Engine Electrical System > Starting System > Starter > Repair procedures
English

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REMOVAL AND INSTALLATION

[1.0L]

1. Disconnect the battery negative terminal.

Tightening torque
Without battery sensor :
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb­ft)
With battery sensor :
4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb­ft)

2. Remove the air duct and air cleaner. (Refer to EM group)

3. Remove the under cover. (Refer to EM group)

4. Disconnect the starter cable (A) from the B terminal on the solenoid then disconnect the connector (B) from the S
terminal.

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Tighting torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb­ft)
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5. Remove the 2 bolts holding the starter, then remove the starter.
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Tighting torque :
42.2 ~ 53.9N.m (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lb­ft)

6. Installation is the reverse of removal.

[1.25L]
1. Disconnect the battery terminals. Disconnect the negative terminal first.
Tightening torque
(+) terminal :

965 of 1992
 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb­ft)
English
(­) terminal (without battery sensor):
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb­ft)
(­) terminal (with battery sensor):
4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb­ft)

2. Remove the battery and battery tray. (Refer to Charging System in this group)

3. Remove the air duct and air cleaner assembly. (Refer to EM group)

4. Remove the under cover. (Refer to EM group)

5. Disconnect the starter cable (A) from the B terminal on the solenoid then disconnect the connector (B) from the S
terminal.
Tighting torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb­ft)

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6. Remove the 2 bolts holding the starter, then remove the starter.
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Tighting torque :
42.2 ~ 53.9N.m (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lb­ft)
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7. Installation is the reverse of removal.

DISASSEMBLY

1. Disconnect the M­terminal (A) on the magnet switch assembly.

966 of 1992
2. After loosening the screws (A), detach the magnet switch assembly (B).

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3. Loosen the through bolts and then remove the brush holder assembly (A), yoke (B) and armature (C).
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4. Remove the lever packing (A) and lever plate (B).

5. Remove the shield (A) and packing (B).

967 of 1992
6. Disconnect the planet gear (A).

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

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8. Press the stopper (A) using a socket (B).

9. After removing the stop ring (A) using stop ring pliers (B).

968 of 1992
10. Disconnect the stopper (A), overrunning clutch (B), internal gear (C) and planet shaft (D).

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Using a suitable pulling tool (A), pull the overrunning clutch stopper (C) over the stop ring (B).
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11. Reassembly is the reverse of disassembly.

INSPECTION

Armature Inspection And Test

1. Remove the starter.

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.

969 of 1992
4. Check the commutator (A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within the
following specifications, or recondition with #500 or #600 sandpaper (B).

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5. Check the commutator diameter. If the diameter is below the service limit, replace the armature.
Commutator diameter
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Standard (New) : 33.0mm (1.2992in.)
Service limit : 32.4mm (1.2756in.)
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6. Measure the commutator (A) runout.

– If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between
the segments.
– If the commutator run out is not within the service limit, replace the armature.
Commutator runout
Standard (New): 0.02mm (0.0008in.), max
Service limit: 0.05mm (0.002in.)

970 of 1992
7. Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw blade to the proper depth. Cut
away all the mica (C) between the commutator segments. The undercut should not be too shallow, too narrow, or v­
shaped (D).
Commutator mica depth
Standard (New) : 0.5mm (0.0197in.)
Limit : 0.2mm (0.0079in.)

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8. Check for continuity between the segments of the commutator. If an open circuit exists between any segments, replace
the armature.
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9. 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.

971 of 1992
Inspect Starter Brush
Brushes that are worn out, or oil­soaked, should be replaced.

The seat new brushes, slip a strip of #500 or #600 sandpaper, with the grit side up, between the commutator and each
brush, and smoothly rotate the armature. The contact surface of the brushes will be sanded to the same contour as
the commutator.

Starter Brush Holder Test

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1. Make sure there is no continuity between the (+) brush holder (A) and (­) plate (B). If there is continuity, replace the
brush holder assembly.
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Use a pipe (C) of suitable size for the brushes not to get removed from the brush holder.

Inspect Overrunning Clutch

1. Slide the overrunning clutch along the shaft.
Replace it if does not slide smoothly.

2. Rotate the overrunning clutch both ways.

Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction of it locks in both
directions, replace it.

972 of 1992
3. If the starter drive gear is worn or damage, 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.

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 overrunning clutch is pre­lubricated at the factory and solvent will
wash lubrication from the clutch.

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3. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.

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973 of 1992