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SPORTAGE(SL) > 2012 > G 2.0 T-GDI > Engine Electrical System

Engine Electrical System > General Information > Specifications

Specifications
Ignition System
Items Specifications
Primary resistance 0.62 ± 10 % (Ω)
Ignition coil
Secondary resistance 7.0 ± 15 % (kΩ)
Type ZXU20HCR8
Spark plugs
Gap 1.0 ~ 1.1 mm (0.0394 ~ 0.0433 in.)

Starting System
Items Specifications
Rated voltage 12V, 1.2kW

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No. of pinion teeth 11
Starter Voltage 11.5V
No-load characteristics Ampere 105A, MAX
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Speed 2,950rpm, MIN
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Charging System
Items Specifications
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Type Battery voltage sensing

Rate voltage 13.5 V, 130A
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Speed in use 1,000 ~ 18,000 rpm

Voltage regulator IC regulator built-in type
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Alternator
External mode ECU control
Regulator setting voltage
Internal mode 14.55 ± 0.3V
External mode ECU control
Temperature compensation
Internal mode -7 ± 2mV / °C
Type 54-26GL
Cold cranking amperage [at -18°C(-0.4°F)] 600A
Battery
Reserve capacity 113min
Specific gravity [at 25°C(77°F)] 1.280 ± 0.01
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• COLD CRANKING AMPERAGE is the amperage a battery can deliver for 30 seconds and maintain a
terminal voltage of 7.2V or greater at a specified temperature.
• RESERVE CAPACITY RATING is amount of time a battery can deliver 25A and maintain a minimum
terminal voltage of 10.5V at 26.7°C(80.1°F).

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Engine Electrical System > General Information > Troubleshooting

Trouble Shooting
Ignition System

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Symptom Suspect area Remedy
Engine will not start or is hard to Ignition lock switch Inspect ignition lock switch, or replace
start (Cranks OK) as required
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
Rough idle or stalls Ignition wiring Repair wiring, or replace as required
Ignition coil Inspect ignition coil, or replace as
required
Engine hesitates/poor Spark plugs and spark plug cables Inspect spark plugs / cable, or replace
acceleration as required
Ignition wiring Repair wiring, or replace as required
Poor mileage Spark plugs and spark plug cables Inspect spark plugs / cable, or replace

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as required

Charging System
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Symptom Suspect area Remedy
Charging warning indicator does Fuse blown Check fuses
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not light with ignition switch "ON" Light burned out
Replace light
and engine off.
Wiring connection loose Tighten loose connection
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Electronic voltage regulator Replace voltage regulator

Charging warning indicator does Drive belt loose or worn Adjust belt tension or replace belt
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not go out with engine running.

Battery cable loose, corroded or worn Inspect cable connection, repair or
(Battery requires frequent replace cable
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recharging)
Electronic voltage regulator or Replace voltage regulator or alternator
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 Inspect wiring connection, repair or
circuit replace wiring
Electronic voltage regulator or Replace voltage regulator or alternator
alternator
Poor grounding Inspect ground or repair
Worn battery Replace battery

Starting System
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Symptom Suspect area Remedy
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 automatic Refer to AT group-automatic
transaxle only) transaxle
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 out Repair or replace cables
Starter faulty Replace
Starter keeps running Starter Replace
Ignition switch Replace

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Starter spins but engine will Short in wiring Repair wiring
not crank Pinion gear teeth broken or Starter Replace
Ring gear teeth broken Replace fly wheel or torque
converter
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Engine Electrical System > General Information > Special Service Tools
Special Service Tools
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Tool (Number and name) Illustration Use

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Alternator pulley remover Removal and installation of alternator pulley

wrench
(09373-27000)
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Engine Electrical System > Ignition System > Description and Operation
Description
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, warm-up 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.

Engine Electrical System > Ignition System > Repair procedures

On-vehicle Inspection
Spark Test

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1. Disconnect the ignition coil connectors (A).

2. Remove the ignition coils (A).

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3. Using a spark plug socket, remove the spark plug.
4. Install the spark plug to the ignition coil.
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5. Ground the spark plug to the engine.
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6. 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.
7. Inspect all the spark plugs.
8. Using a spark plug socket, install the spark plug.
9. Install the ignition coil.
10. Reconnect the ignition coil connector.
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Inspect Spark Plug

1. Disconnect the ignition coil connectors (A).

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2. Remove the ignition coils (A).

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

Be careful that no contaminates enter through the spark plug

holes.

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

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Inspection Of Electrodes
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Condition Dark deposits White deposits

- Fuel mixture too lean
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- Fuel mixture too rich

Description - Advanced ignition timing
- Low air intake
- Insufficient plug tightening torque
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5. Check the electrode gap (A).

Standard
Unleaded : 1.0 ~ 1.1 mm (0.0394 ~ 0.0433 in.)

Inspect Ignition Coil

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

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Standard value: 0.62Ω ± 10%

Removal and Installation

1. Disconnect the ignition coil connectors (A).

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2. Remove the ignition coils (A).

Tightening torque :
3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)

3. Installation is the reverse of removal.

Engine Electrical System > Charging System > Description and Operation

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Description
The charging system includes a battery, an alternator with a built-in regulator, and the charging indicator light and
wire.
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The Alternator has built-in diodes, each rectifying AC current to DC current.
Therefore, DC current appears at alternator "B" terminal.
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In addition, the charging voltage of this alternator is regulated by the ECM.
The main components of the alternator are the rotor, stator, rectifier, capacitor brushes, bearings and V-ribbed belt
pulley. The brush holder contains a built-in electronic voltage regulator.
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1. Brush
2. Dirve belt pulley
3. Rotor
4. Stator
5. Rectifier
Alternator Management System (AMS)
Alternator management system controls the charging voltage set point in order to improve fuel economy, manage
alternator load under various operating conditions, keep the battery charged, and protect the battery from over-
charging. ECM controls generating voltage by duty cycle (charging control, discharging control, normal control)
based on the battery conditions and vehicle operating conditions.
The system conducts discharging control when accelerating a vehicle. Vehicle reduces an alternator load and
consumes an electric power form a battery.
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The system conducts charging control when decelerating a vehicle. Vehicle increases an alternator load and charges
a battery.

Engine Electrical System > Charging System > Repair procedures

On-vehicle Inspection

• Check that the battery cables are connected to the correct terminals.
• Disconnect the battery cables when the battery is given a quick charge.
• Never disconnect the battery while the engine is running.
Check The Battery Terminals And Fuses
1. Check that the battery terminals are not loose or corroded.
2. Check the fuses for continuity.
Inspect Drive Belt
Visually check the belt for excessive wear, frayed cords etc.
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 be
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Visually Check Alternator Wiring And Listen For Abnormal Noises

1. Check that the wiring is in good condition.
2. Check that there is no abnormal noise from the alternator while the engine is running.
Check Discharge Warning Light Circuit
1. Warm up the engine and then turn it off.
2. Turn off all accessories.
3. Turn the ignition switch "ON". Check that the discharge warning light is lit.
4. Start the engine and Check that the light goes off.
If the light does not go off as specified, troubleshoot the discharge light circuit.
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".

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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.

Test
1. Start the engine.

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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.
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Standard value: 0.2V max
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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
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change due to an over-heated harness, etc. Correct them before testing again.
3. Upon completion of the test, set the engine speed at idle.
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Turn off the headlamps, blower motor and the ignition switch.
Output Current Test
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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 in good condition. The battery checking method is
described in the section "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.
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.
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6. Connect a voltmeter (0 to 20V) between the "B" terminal and ground. Connect the (+) lead wire to the alternator
"B" terminal and (-) lead wire to a good ground.
7. Attach an engine tachometer and connect the battery ground cable.
8. Leave the engine hood open.

Test
1. Check to see that the voltmeter reads as the same value as the battery voltage. If the voltmeter reads 0V, and the
open circuit in the wire between alternator "B" terminal and battery (+) terminal or poor grounding is suspected.
2. Start the engine and turn on the headlamps.

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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.
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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.
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Result
1. The ammeter reading must be higher than the limit value. If it is lower but the alternator output wire is in good
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condition, remove the alternator from the vehicle and test it.

Limit value : 60% of the voltage rate

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• The output current value changes with the electrical load and the temperature of the alternator itself.
Due to temperature the maximum output current may not be obtained. If such is the case, keep the
headlamps on to increase the electrical load.
The nominal output current may not be obtained if the temperature of the alternator itself or ambient
temperature is too high.
In such a case, reduce the temperature before testing again.

2. Upon completion of the output current test, lower the engine speed to idle and turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Remove the ammeter and voltmeter and the engine tachometer.
5. Connect the alternator output wire to the alternator "B" terminal.
6. Connect the battery ground cable.
Regulated Voltage Test
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 "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.

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Test
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1. Turn on the ignition switch and check to see that the voltmeter indicates the following value.

Voltage: Battery voltage

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If it reads 0V, there is an open circuit in the wire between the alternator "B" terminal and the battery and the
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battery (-) terminal.

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
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10A or less
Result
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.
Regulating Voltage Table (Internal mode)
Voltage regulator ambient
Regulating voltage (V)
temperature °C (°F)
-30 (-22) 14.1 ~ 15.0
25 (77) 14.0 ~ 14.7
130 (266) 13.5 ~ 14.6

Regulating Voltage Table (External mode)

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Engine Electrical System > Charging System > Alternator > Components and Components Location
Components

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1. Pulley 6. Rear bracket
2. Front bracket 7. Through bolt
3. Front bearing 8. Regulator
4. Rotor assembly
5. Rear bearing 9. Regulator bolt
10. Rear cover

Engine Electrical System > Charging System > Alternator > Repair procedures
Removal and Installation
1. Disconnect the battery negative terminal first, then the positive terminal.

Tightening torque :
(+) terminal : 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
(-) terminal : 4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb-ft)

2. Disconnect the A/C compressor switch connector (A) the alternator connector (B), and the cable from alternator

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"B" terminal (C).
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3. Remove the drive belt (A) after turning the drive belt tensioner (B) counterclockwise.
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4. Pull out the through bolt and then remove the alternator (A).

Tightening torque :
49.0 ~ 63.7N.m (5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lb-ft)

5. Installation is the reverse order of removal.

Disassembly

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1. Remove the alternator cover (A) using a screw driver after loosening the nuts (B).
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2. Remove the slip ring guide (A) and then loosen the mounting bolts and disconnect the brush holder assembly (B).
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3. Remove the pulley (A) using the SST (09373-27000) (B).

4. Loosen the 4 through bolts (A).

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5. Disconnect the rotor (A) and cover (B).
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6. Reassembly is the reverse order of disassembly.

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

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

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

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

Engine Electrical System > Charging System > Battery > Components and Components Location
Components

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1. Battery insulation pad 4. ECM & bracket

2. Battery assembly
3. Battery tray 5. Battery mounting
bracket

Engine Electrical System > Charging System > Battery > Repair procedures
Removal and Installation
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1. Remove the battery.
(1) Disconnect the battery negative terminal (A).

Tightening torque :
4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb-ft)

(2) Disconnect the battery positive terminal (B).

Tightening torque :
7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)

(3) Remove the battery insulation pad (C).

(4) Remove the battery mounting bracket (D), and the battery (E).

Tightening torque :
Bracket bolt: 8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)

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2. Remove the air duct and air cleaner assembly. (Refer to EM group).
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3. Remove the ECM (A) after disconnecting the connectors (B). (Refer to FL group)
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4. Remove the battery tray (A).

Tightening torque:
8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)

5. Installation is the reverse order of removal.

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When installing the battery, fix the mounting bracket on the tray
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Inspection
Battery Diagnostic Flow
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Vehicle parasitic current inspection

1. Turn the all electric devices OFF, and then turn the ignition switch OFF.
2. Close all doors except the engine hood, and then lock all doors.
(1) Disconnect the hood switch connector.
(2) Close the trunk lid.
(3) Close the doors or remove the door switches.

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3. Wait a few minutes until the vehicle’s electrical systems go to sleep mode.

For an accurate measurement of a vehicle parasitic current, all electriacl systems should go to sleep mode.
(It takes at least one hour or at most one day.) However, an approximate vehicle parasitic current can be
measured after 10~20 minutes.
4. Connect an ammeter in series between the battery (-) terminal and the ground cable, and then disconnect the
clamp from the battery (-) terminal slowly.

Be careful that the lead wires of an ammeter do not come off from the battery (-) terminal and the ground
cable to prevent the battery from being reset. In case the battery is reset, connect the battery cable again,
and then start the engine or turn the ignition switch ON for more than 10 sec. Repeat the procedure from
No. 1.
To prevent the battery from being reset during the inspection,
1) Connect a jump cable between the battery (-) terminal and the ground cable.
2) Disconnect the ground cable from the battery (-) terminal.

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3) Connect an ammeter between the battery (-) terminal and the ground cable.
4) After disconnecting the jump cable, read the current value of the ammeter.
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5. Read the current value of the ammeter.

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A. If the parasitic current is over the limit value, search for abnormal circuit by removing a fuse one by one and
checking the parasitic current.
B. 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

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

Care should be taken in the event the battery case is cracked or leaking, to protect your skin from the
electrolyte.
Heavy rubber gloves (not the household type) should be wore when removing the battery.

4. Inspect the battery tray for damage caused by the loss of electrolyte. If acid damage is present, it will be

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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.
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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
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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
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posts.
11. Tighten the terminal nuts securely.
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12. Coat all connections with light mineral grease after tightening.
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When batteries are being charged, an explosive gas forms beneath the cover of each cell. Do not smoke
near batteries being charged or which have recently been charged. Do not break live circuit at the
terminals of batteries being charged.
A spark will occur when the circuit is broken. Keep open flames away from battery.

Engine Electrical System > Charging System > Battery Sensor > Description and Operation
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 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
because the sensor will behave abnormally when the parasitic draw is more than 100mA. (Refer to vehicle
parasitic current inspection)

Perform the following process after replacing the battery sensor.

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1. Ignition switch ON/OFF.
2. Park the vehicle about 4 hours.
3. After 4 hours later, check the SOC (State of charge) of battery using GDS.
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For the vehicle equipped with a battery sensor, be careful not to damage the battery sensor when the battery is
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replaced or recharged.
1. 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.
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2. 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, 3.0~4.4lb-ft). An excessive tightening torque can damage the PCB internal circuit
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and the battery terminal.

3. When recharging the battery, ground the negative terminal of the booster battery to the vehicle body. If the
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negative cable from a battery charger is connected to the negative terminal of the battery, the battery sensor can
make an error. In this case, repeat the above process for battery sensor replacement (1~3) after disconnecting
and reconnecting the battery connector.

Engine Electrical System > Starting System > Description and Operation
Description
The starting system includes the battery, starter, solenoid switch, ignition switch, inhibitor switch (A/T), clutch pedal
switch (M/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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[Link]
[Link] assembly
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[Link] clutch

Engine Electrical System > Starting System > Repair procedures

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Starter Circuit Troubleshooting
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The battery must be in good condition and fully charged.
1. Disconnect the fuel pump relay (A) in the fuse box.
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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 normally cranks the engine, 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.
A. Solenoid plunger and switch malfunction.
B. 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 normally the engine, 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 S-terminal of solenoid. Connect a jumper wire from the B-terminal 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.
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5. Check the following items in the order listed until you find the open circuit.
A. Check the wire and connectors between the driver's under-dash fuse/relay box and the ignition switch, and
between the driver's under-dash fuse/relay box and the starter.
B. Check the ignition switch (Refer to BE group - Ignition System)
C. Check the transaxle range switch connector or ignition lock switch connector.
D. Inspect the starter relay.
Starter Solenoid Test
1. Disconnect the field coil wire from the M-terminal of solenoid switch.
2. Connect the battery as shown. If the starter pinion pops out, it is working properly. To avoid damaging the
starter, do not leave the battery connected for more than 10 seconds.

3. Disconnect the battery from the M terminal.

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If the pinion does not retract, the hold-in coil is working properly. To avoid damaging the starter, do not leave the
battery connected for more than 10 seconds.
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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

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1. Place the starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to starter
motor as follows.
2. Connect a test ammeter (150-ampere scale) and carbon pile rheostats as shown in the illustration.
3. Connect a voltmeter (15-volt 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.
7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and

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freely.

Current : 105A, MAX

Speed : 2,950 rpm, MIN
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Engine Electrical System > Starting System > Starter > Components and Components Location
Components
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1. Front housing 8. Shield

2. Starter solenoid 9. Amature assembly
assembly 10. Brush holder assembly
3. Lever 11. Yoke assembly
4. Lever packing 12. Rear housing
5. Planet shaft assembly 13. Through bolt
6. Planetary gear assembly
7. Packing

Engine Electrical System > Starting System > Starter > Repair procedures
Removal and Installation
1. Remove the engine cover.
 Page 30 of 44
2. Disconnect the battery negative terminal (A).

Tightening torque :
4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb-ft)

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

4. Remove the ETC (Electronic throttle control) module. (Refer to FL group)
5. Remove the intake manifold stay. (Refer to EM group)

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6. Disconnect the starter cable (A) from the B terminal on the solenoid, then disconnect the connector (B) from the
S terminal.
7. Remove the 2 bolts (C) holding the starter, then remove the starter.
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Tightening torque :
42.2 ~ 53.9N.m (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lb-ft)
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8. Installation is the reverse of removal.

Disassembly
1. Disconnect the M-terminal (A) on the magnet switch assembly (B).

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

3. Loosen the through bolts (A).

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4. Remove the brush holder assembly (A), yoke (B) and armature (C).
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5. Remove the lever plate (B) and lever packing (A).

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

7. Disconnect the planet gear (A).

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8. Disconnect the planet shaft assembly (or reducer assembly) (A) and lever (B).
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9. Press the stopper (A) using a socket (B).

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

11. Disconnect the stopper (A), overrunning clutch (B), internal gear (C), planet shaft (D) and/or gasket sheet (E).

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12. Reassembly is the reverse of disassembly.
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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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Inspection
Armature Inspection And Test
1. Remove the starter.
2. Disassemble the starter as shown at the beginning of this procedure.
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3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage,
replace the armature.

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. Measure the commutator (A) runout.
A. If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips
between the segments.
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B. If the commutator run out is not within the service limit, replace the armature.
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Commutator runout
Standard (New): 0.02mm (0.0007in.) max
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Service limit: 0.05mm (0.0020in.)

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6. 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) : 0.7 ~ 0.9mm (0.0276 ~ 0.0354in)
Limit : 0.4mm (0.0157 in.)

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7. Check for continuity between the segments of the commutator. If an open circuit exists between any segments,
replace the armature. .c
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8. Check with an ohmmeter that no continuity exists between the commutator (A) and armature coil core (B), and
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between the commutator and armature shaft (C). If continuity exists, replace the armature.

Inspect Starter Brush

Brushes that are worm out, or oil-soaked, should be replaced.
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Starter Brush Holder Test

Check that there is no continuity between the (-) plate (A) and (+) brush holder (B). If there is continuity, replace
the brush holder assembly.

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Inspect Overrunning Clutch

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

2. Rotate the overrunning clutch both ways.
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Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction or it locks in
both directions, replace it.
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3. If the starter drive gear is worn or damaged, replace the overrunning clutch assembly. (the gear is not available
separately).
Check the condition of the flywheel or torque converter ring gear if the starter drive gear teeth are damaged.
Cleaning
1. Do not immerse parts in cleaning solvent. Immersing the yoke assembly and/or armature will damage the
insulation. Wipe these parts with a cloth only.
2. Do not immerse the drive unit in cleaning solvent. The overrun clutch is pre-lubricated at the factory and solvent
will wash lubrication from the clutch.
3. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.
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Engine Electrical System > Starting System > Starter Relay > Repair procedures
Inspection
1. Remove the fuse box cover.
2. Remove the starter relay (A).

3. Using an ohmmeter, check that there is continuity between each terminal.

Terminal Continuity

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30 - 87 NO
85 - 86 YES
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4. Apply 12V to terminal 85 and ground to terminal 86.
Check for continuity between terminals 30 and 87.
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5. If there is no continuity, replace the starter relay.

6. Install the starter relay.
7. Install the fuse box cover.

Engine Electrical System > Cruise Control System > Schematic Diagrams
System Block Diagram
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Component Parts And Function Outline
Component part Function
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Vehicle-speed sensor Converts vehicle speed to pulse.
ECM Receives signals from sensor and control switches.
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Cruise control indicator Illuminate when CRUISE main switch is ON (Built into
cluster)
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Cruise Control switches ON/OFF switch Switch for automatic speed control power supply.
Resume/Accel switch Controls automatic speed control functions by
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Set/Coast switch Resume/Accel switch (Set/Coast switch)

Cancel switches Cancel switch Sends cancel signals to ECM.

Brake-pedal switch
Transaxle range switch
(A/T)
ETS motor Regulates the throttle valve to the set opening by ECM.

* ETS : Electronic Throttle System

Engine Electrical System > Cruise Control System > Description and Operation
Cruise Control
The cruise control system is engaged by the cruise "ON/OFF" main switch located on right of steering wheel
column. The system has the capability to cruise, coast, accelerate and resume speed.
It also has a safety interrupt, engaged upon depressing brake or shifting select lever.
The ECM is the control module for this system. The main components of cruise control system are mode control
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switches, transmission range switch, brake switch, vehicle speed sensor, ECM and ETS motor that connect throttle
body.
The ECM contains a low speed limit which will prevent system engagement below a minimum speed of 40km/h
(25mph).
The operation of the controller is controlled by mode control switches located on steering wheel.
Transmission range switch and brake switch are provided to disengage the cruise control system. The switches are
on brake pedal bracket and transmission. When the brake pedal is depressed or select lever shifted, the cruise
control system is electrically disengaged and the throttle is returned to the idle position.
Cruise main switch (ON/OFF)
The cruise control system is engaged by pressing the cruise "ON/OFF" main switch. Pressing the cruise "ON/OFF"
main switch again releases throttle, clears cruise memory speed, and puts vehicle in a non-cruise mode.
Set/Coast switch (SET/–)
The "SET/–" switch located on right of steering wheel column has two functions.
The set function - Push the "SET/–" switch and release it at the desired speed. The SET indicator light in the
instrument cluster will illuminate. Release the accelerator pedal. The desired speed will automatically be maintained.
The coast function - Push the "SET/–" switch and hold it when the cruise control is on. The vehicle will gradually
slow down. Release the switch at the desired speed. The desired speed will be maintained.
Push the "SET/–" switch and release it quickly. The cruising speed will decrease by 1.6km/h (1.0mph).
Resume/Accel switch (RES/+)

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The "RES/+" switch located on right of steering wheel column has two functions.
The resume function - If any method other than the cruise “ON/OFF” main switch was used to cancel cruising speed
temporarily and the system is still activated, the most recent set speed will automatically resume when the "RES/+"
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switch is pushed. It will not resume, however, if the vehicle speed has dropped below approximately 40km/h
(25mph).
The accel function - Push the "RES/+" switch and hold it when the cruise control is on. The vehicle will gradually
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accelerate. Release the switch at the desired speed. The desired speed will be maintained.
Push the "RES/+" switch and release it quickly. The cruising speed will increase by 1.6km/h (1.0mph).
Cancel switch (CANCEL)
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The cruise control system is temporarily disengaged by pushing the "CANCEL" switch.
Cruise speed canceled by this switch can be recovered by pushing the "RES/+" switch.
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Engine Electrical System > Cruise Control System > Troubleshooting

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Trouble Symptom Charts

Trouble Symptom 1
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Trouble Symptom 2
Trouble symptom Probable cause Remedy
The set vehicle speed varies greatly upward or Malfunction of the vehicle Repair the vehicle speed sensor
downward speed sensor circuit system, or replace the part
"Surging" (repeated alternating acceleration and Check input and output signals at
deceleration) occurs after setting Malfunction of ECM
ECM

Trouble Symptom 3
Trouble symptom Probable cause Remedy
Damaged or disconnected wiring of Repair the harness or replace
The CC system is not canceled when the the brake pedal switch the brake pedal switch
brake pedal is depressed Check input and output signals
Malfunction of the ECM signals
at ECM
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Trouble Symptom 4
Trouble symptom Probable cause Remedy
Damaged or disconnected
wiring of inhibitor switch input Repair the harness or
circuit repair or replace the
The CC system is not canceled when the shift lever is
moved to the "N" position (It is canceled, however, Improper adjustment of inhibitor switch
when the brake pedal is depressed) inhibitor switch
Malfunction of the ECM Check input and output
signals signals at ECM

Trouble Symptom 5
Trouble symptom Probable cause Remedy
Temporary damaged or disconnected wiring Repair the harness or replace
Cannot decelerate (coast) by of "SET/–" switch input circuit the "SET/–" switch
using the "SET/–" switch Check input and output signals
Malfunction of the ECM signals
at ECM

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Trouble Symptom 6
Trouble symptom Probable cause Remedy
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Damaged or disconnected wiring, or short Repair the harness or
Cannot accelerate or resume speed circuit, or "RES/+" switch input circuit replace the "RES/+" switch
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by using the "RES/+" switch Check input and output

Malfunction of the ECM signals
signals at ECM
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Trouble Symptom 7
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Trouble symptom Probable cause Remedy

Malfunction of the Repair the vehicle speed
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CC system can be set while driving at a vehicle speed of vehicle-speed sensor sensor system, or replace
less than 40km/h (25mph), or there is no automatic circuit the part
cancellation at that speed Malfunction of the ECM Check input and output
signals signals at ECM

Trouble Symptom 8
Trouble symptom Probable cause Remedy
Damaged or disconnected bulb of cruise
The cruise main switch indicator lamp does not main switch indicator lamp Repair the harness or
illuminate (But CC system is normal) replace the part.
Harness damaged or disconnected

Engine Electrical System > Cruise Control System > Cruise Control Switch > Schematic Diagrams
Circuit Diagram
 Page 42 of 44

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Engine Electrical System > Cruise Control System > Cruise Control Switch > Repair procedures
Removal and Installation
1. Disconnect the battery (-) terminal.

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

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2. Remove the air-bag module from the steering wheel. ( Refer to RT group)
3. Remove the steering wheel. (Refer to ST group)
4. Remove the cruise control switch (A) after unfastening the 2 screws and disconnecting the switch connector.

5. Installation is reverse order of removal.

Inspection
Measuring Resistance
1. Disconnect the cruise control switch connector from the control switch.

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2. Measure resistance between terminals on the control switch when each function switch is ON (switch is
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depressed).
Function switch Terminal Resistance
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CANCEL 6-7 0Ω ± 5%
SET/– 6-7 220Ω ± 5%
RES/+ 6-7 910Ω ± 5%
ON/OFF 7-8 3900Ω ± 5%

3. If not within specification, replace switch.

Measuring Voltage
1. Connect the cruise control switch connector to the control switch.
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2. Measure voltage between terminals on the harness side connector when each function switch is ON (switch is
depressed).
Function switch Terminal Voltage
CANCEL 6-7 0.0 ± 0.22V
SET/– 6-7 1.5 ± 0.22V
RES/+ 6-7 3.0 ± 0.22V
ON/OFF 7-8 -

3. If not within specification, inspect the control switch resistance.

The measuring resistance value is not within specification, replace the switch and measure the voltage again.
4. If resistance is OK but, measuring voltage is not within specification, inspect the wiring harness and connectors
between the switch and the ECM.

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