Hyundai Santa Fe (TM): Charging System - Engine Electrical SystemHyundai Santa Fe (TM): Charging System

Description and operation

Description
The charging system includes a battery, an alternator with a built-in regulator, and the charging indicator light and wire.
The Alternator has eight built-in diodes, each rectifying AC current to DC current.
Therefore, DC current appears at alternator "B" terminal.
In addition, the charging voltage of this alternator is regulated by the battery voltage detection system.
The main components of the alternator are the rotor, stator, rectifier, capacitor brushes, bearings and V-ribbed belt pulley. The brush holder contains a built-in electronic voltage regulator.
Alternator Management System
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.
The system conducts charging control when decelerating a vehicle. Vehicle increases an alternator load and charges a battery.

Components and components location

Components

1. ECM
2. Battery
3. Alternator
4. Starter
 5. Instrument Cluster
6. Ignition switch or start/stop button
7. Battery sensor
8. Hood switch

Troubleshooting

Troubleshooting
  
•
Be careful not to short-circuit the wiring by the body or other wirings.
•
In case of discharging problem, measure dark current at all times.
(Charging System - "Dark Current Inspection").
•
When checking the alternator main fuse, perform continuity test and voltage test between terminals as well as visual check to confirm normal operation.
•
When checking the ground, repair or replace after inspecting for defective ground cable, defective installation or defective contact due to foreign object.
•
It is not recommended to use non-authentic parts as installing non-authentic parts may cause malfunction of charging system.
•
Be careful as misassembly may cause short-circuit of wiring, which may result in battery discharge.
•
As it will reset and appear as normal if the battery negative (-) terminal is disconnected while measuring dark current, measure by using a hook meter without disconnecting the negative (-) terminal.
•
Note that there may be various phenomenons / possible causes / repair measures apart from above.
•
For more effective repairs, refer to DTC guide and ETM.
Symptom
Suspected Area
Remedy
Charging warning lamp does not turn on during IG ON.
 Broken alternator main fuse
 Inspect / Repair / Replace fuse.
Broken instrument cluster fuse
 Inspect / Repair / Replace fuse.
Broken instrument cluster internal bulb
 Inspect / Repair / Replace instrument cluster.
Defective connection of wiring connector
 Inspect / Repair / Replace wiring connection.
Defective voltage regulator or alternator
 Inspect / Repair / Replace voltage regulator or alternator.
Defective connection of battery terminal
 Inspect tightening of (+) and (-) battery terminals to specified torque.
Communication error
 Inspect wiring between regulator and ECM.
Inspect transmission signal of ECM.
Inspect / Repair / Replace alternator if the wiring and ECM are normal.
Charging warning lamp does not turn off during engine running.
 Worn drive belt or lack of tension
 Inspect / Repair / Replace drive belt.
Defective connection, corroded or worn battery cable
 Inspect connection of battery cable and Inspect / Repair / Replace cable.
Broken alternator main fuse
 Inspect / Replace alternator main fuse or battery cable.
Defective voltage regulator or alternator
 Inspect / Replace voltage regulator or alternator.
Defective wiring
 Inspect / Replace wiring.
Defective instrument cluster
 Inspect / Replace instrument cluster
Slip in alternator pulley
 Inspect / Replace alternator pulley.
Adjust tension / Replace drive belt.
Defective connection of battery terminal
 Inspect tightening of (+) and (-) battery terminals to specified torque.
Charging warning lamp turns on.
 Slip, worn or lack of tension in drive belt
 Adjust tension / Replace drive belt.
Inspect / Replace auto tensioner (only for auto tensioner type).
Error in Alternator Management System (AMS) voltage
 Inspect battery sensor connecting harness and connection with body.
Error in battery sensor
 Inspect / Repair / Replace battery sensor.
Short between battery sensor wiring and body
 Inspect / Repair / Replace battery sensor.
Defective alternator L terminal output power
 Inspect / Repair / Replace alternator or regulator.
Degradation due to defective contact of battery (+) terminal
 Check tightening to specified torque / Inspect / Repair / Replace battery wiring.
Short in alternator connecting extension connector internal pin
 Inspect / Repair / Replace wiring.

Short circuit between body and mission ground
 Inspect / Repair / Replace ground.
Communication error
 Inspect / Repair / Replace wiring between regulator and ECM.
Inspect transmission signal of ECM.
Inspect / Repair / Replace alternator if wiring and ECM are normal.
Short in the middle of connection to alternator L terminal
(L terminal applied vehicle model)
 Inspect / Repair / Replace wiring.
Drive belt rotation stops due to slip in crankshaft damper pulley or defective pulley.
 Inspect or replace crankshaft damper pulley / Inspect, repair or replace drive belt tensioner bearing.
Slip, worn or lack of tension in drive belt
 Adjust tension / Inspect / Repair / Replace drive belt.
Defective voltage regulator
 Inspect / Repair / Replace voltage regulator.
Defective alternator
 Inspect / Repair / Replace alternator.
Broken alternator main fuse
 Inspect / Repair / Replace alternator main fuse or battery wiring cable.
Defective ground
 Inspect / Repair / Replace ground.
Discharged battery
 Adjust tension / Inspect / Repair / Replace drive belt.
Inspect / Repair / Replace wiring connection.
Inspect / Repair / Replace alternator main fuse.
Inspect / Repair / Replace alternator.
Inspect / Repair / Replace voltage regulator.
Inspect / Repair / Replace battery unit.
Inspect for dark current / Repair / Replace.
Learn / Inspect / Repair / Replace battery sensor.
Inspect for short / Repair / Replace battery cable.
Inspect / Repair / Replace ECM.
Inspect / Repair / Replace body electrical related parts.
Inspect / Repair / Replace installation status of alternator connector.
Inspect / Repair / Replace tightening of (+) and (-) battery terminals to specified torque.
Swollen battery
 Defective battery
 Inspect / Replace battery.
Defective voltage regulator or alternator
 Inspect / Repair / Replace voltage regulator or alternator.
Defective charging related parts or wiring
 Inspect / Repair / Replace charging related parts and wiring.
After inspection, repair or replace related parts in case of malfunction.

Schematic diagrams

Circuit Diagram

Repair procedures

Inspection
Inspection Item
•
Battery efficiency inspection
•
Battery voltage inspection
•
Charging voltage insptection
•
General inspection
•
Terminal tightening state inspection
•
Engine/ transaxle ground state inspection
•
Wiring harness ground state inspection
•
Electrical Specified Value Inspection
•
Vehicle parasitic current inspection
•
Battery capacity inspection
Battery Efficiency 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.
  
•
Inspect the battery test using the load tester and battery tester.
Battery Voltage Inspection
1.
After having driven the vehicle and in the case that 20 minutes have not passed after having stopped the engine, turn the ignition switch ON and turn on the electrical system (headlamp, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge.
2.
Turn the ignition switch OFF and turn off the electrical systems.
3.
Measure the battery voltage between the negative (-) and positive (+) terminals of the battery.
Standard voltage : About 12.5 - 12.9V (20°C)
If the voltage is less than specification, charge the battery.
General Inspection
1.
Check that the battery terminals are not loose or corroded.
(Refer to Charging System - "Battery")
2.
Check the fuses for continuity.
Alternator Fuse
(1)
Check the alternator fuse for continuity.
(2)
Measure the voltage as shown in the image below.
Standard value : Approximately 0V

(3)
If the alternator fuse is blown, replace it as in the procedure below:
a.
Turn ignition switch OFF and disconnect the battery negative (-) terminal.
b.
Remove the battery positive (+) cable mounting nuts (A).
c.
Remove the battery positive (+) cable (B).
d.
Replace the norminal alternator fuse or battery cable.
e.
Install in the reverse order of removal.
Battery Sensor Fuse
(4)
Check the battery sensor fuse for continuity.
(5)
If the alternator fuse is blown, replace the battery sensor fuse.
(6)
Measure the voltage.
Standard value : Approximately 0V
3.
Inspect Drive Belt
(1)
Visually check the belt for excessive wear, frayed cords etc.
If any defect has been found, replace the drive belt.
  
•
Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced.

4.
Measure and adjust drive belt tension.
(Refer to Engine Mechanical System - "Drive Belt")
5.
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.
6.
Check Discharge Warning Light Circuit
(1)
Warm up the engine and then turn it off.
(2)
Turn off all accessories.
(3)
Turn the ignition switch "ON". Check that the discharge warning light is lit.
(4)
Start the engine. Check that the light is lit.
If the light does not go off as specified, troubleshoot the discharge light circuit.
Terminal Tightening State Inspection
  
•
Alternator B+ terminal state
•
Alternator B+ termina tightening nut
•
Battery positive (+) terminal state
•
Battery positive (+) terminal tightening nut state
•
Battery negative (-) terminal state
•
Battery negative (-) terminal tightening nut state
•
Battery negative (-) terminal mounting bolt tightening state (Chassis ground)
•
Battery sensor negative (-) terminal state (With battery sensor)
•
Battery sensor negative (-) terminal tightening nut state (With battery sensor)
•
Battery sensor negative (-) terminal mounting bolt tightening state (Chassis ground) [With battery sensor]
•
Engine room fuse & relay box positive (+) harness state
•
Engine room fuse & relay box positive (+) harness tightening nut state
•
Check the status of ground fault by chassis paint
Inspection Component Location

1. Alternator B+ terminal
2. Engine room fuse & relay box positive (+) terminal
3. Battery positive (+) terminal
 4. Battery negative (-) terminal
5. Chassis ground

Engine / Transmission Ground State Inspection
  
•
Ground state
•
Mounting bolt tightening state (Chassis)
•
Mounting bolt tightening state (Engine)
•
Check the status of ground fault by chassis paint
Wiring harness ground state inspection
  
•
Ground state
•
Mounting bolt tightening state (Chassis)
•
Mounting bolt tightening state (Engine)
•
Check the status of ground fault by chassis paint
Electrical Specified Value Inspection (Using the Voltmeter and Ammeter)
1.
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.
(1)
Preparation
a.
Turn the ignition switch to "OFF".
b.
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.
(2)
Test
a.
Start the engine.
b.
Turn on the headlamps and blower motor, adjust the engine speed until the ammeter indicates 20A and read the voltmeter.
(3)
Result
a.
The voltmeter may indicate the standard value.
Standard value : 0.2V max
b.
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 over-heated harness, etc. Correct them before testing again.
c.
Upon completion of the test, set the engine speed at idle.Turn off the headlamps, blower motor and the ignition switch.
2.
Output Current Test
This test determines whether or not the alternator gives an output current that is equivalent to the normal output.
(1)
Preparation
a.
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. Refer to the "Battery" section for checking battery.
The battery used to test the output current should be 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. Refer to the "Inspect drive belt" section for checking the belt tension.
b.
Turn off the ignition switch.
c.
Disconnect the battery ground cable.
d.
Disconnect the alternator output wire from the alternator "B" terminal.
e.
Connect a DC ammeter (0 to 90A) 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.
f.
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.
g.
Connect the battery ground cable.
h.
Leave the engine hood open.
(2)
Test
a.
Check to see that the voltmeter reads the same value as the battery voltage. If the voltmeter reads 0V, open circuit in the wire between alternator "B" terminal and battery (+) terminal or poor grounding is suspected.
b.
Start the engine and turn on the headlamps.
c.
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.
  
•
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.
(3)
Result
a.
The ammeter reading must be higher than the limit value. If it is lower despite 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 to discharge the battery or use lights of other vehicles 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.
b.
Upon completion of the output current test, lower the engine speed to idle and turn off the ignition switch.
c.
Disconnect the battery negative (-) terminal.
d.
Remove the ammeter and voltmeter and the engine tachometer.
e.
Connect the alternator output wire to the alternator "B" terminal.
f.
Connect the battery negative (-) terminal.
3.
Regulated Voltage Test
The purpose of this test is to check that the electronic voltage regulator controls voltage correctly.
(1)
Preparation
a.
Prior to the test, check the following items and correct if necessary.
Check that the battery installed on the vehicle is fully charged. Refer to the "Battery" section for checking the battery.
Check the alternator drive belt tension. Refer to the "Inspect drive belt" section for checking the belt tension.
b.
Turn ignition switch to "OFF".
c.
Disconnect the battery negative (-) terminal.
d.
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.
e.
Disconnect the alternator output wire from the alternator "B" terminal.
f.
Connect a DC ammeter (0 to 90A) in series between the "B" terminal and the disconnected output wire. Connect the (-) leadwire of the ammeter to the disconnected output wire.
g.
Connect the battery negative (-) terminal.
(2)
Test
a.
Turn on the ignition switch and check to see that the voltmeter indicates the following value.
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.
b.
Start the engine. Keep all lights and accessories off.
c.
Run the engine at a speed of about 2,500 RPM and read the voltmeter when the alternator output current drops to 10A or less
(3)
Result
a.
If the voltmeter reading doesn't agree with the standard value, the voltage regulator or the alternator is faulty.
Regulated Voltage : 11.7 - 15.3V
b.
If the voltmeter reading doesn't agree with the standard value, the voltage regulator or the alternator is faulty.
c.
Disconnect the battery negative (-) terminal.
d.
Remove the voltmeter and ammeter.
e.
Connect the alternator output wire to the alternator "B" terminal.
f.
Connect the battery negative (-) terminal.
Electrical Specified Value Inspection (Using the Voltmeter and Clamp type Ammeter)
1.
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.
(1)
Preparation
a.
Turn the ignition switch to "OFF".
b.
Install the clamp type ammeter between battery positive (+) and alternator "B" terminal.
c.
Connect the (+) lead wire of voltmeter to the "B" terminal of alternator and the (-) lead wire of voltmeter to the (+) terminal of battery.

(2)
Test
a.
Start the engine.
b.
Turn on the headlamps and blower motor, adjust the engine speed until the ammeter indicates 20A and read the voltmeter.
(3)
Result
a.
The voltmeter may indicate the standard value.
Standard value : 0.2V max
b.
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 over-heated harness, etc. Correct them before testing again.
c.
Upon completion of the test, set the engine speed at idle.Turn off the headlamps, blower motor and the ignition switch.
2.
Output Current Test
This test determines whether or not the alternator gives an output current that is equivalent to the normal output.
(1)
Preparation
a.
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. Refer to the "Battery" section for checking the battery.
The battery used to test the output current should be 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. Refer to the "Inspect drive belt" section for checking the belt tension.
b.
Turn off the ignition switch.
c.
Disconnect the battery negative (-) terminal.
d.
Install the clamp type ammeter between battery positive (+) and alternator "B" terminal.
e.
Connect a DC ammeter (0 to 90A) 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.
f.
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.
g.
Connect the battery negative (-) terminal.
h.
Leave the engine hood open.
(2)
Test
a.
Check to see that the voltmeter reads the same value as the battery voltage. If the voltmeter reads 0V, open circuit in the wire between alternator "B" terminal and battery (+) terminal or poor grounding is suspected.
b.
Start the engine and turn on the headlamps.
c.
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.
  
•
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.
(3)
Result
a.
The ammeter reading must be higher than the limit value. If it is lower despite 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 to discharge the battery or use lights of other vehicles 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.
b.
Upon completion of the output current test, lower the engine speed to idle and turn off the ignition switch
c.
Disconnect the battery negative (-) terminal.
d.
Remove the ammeter and voltmeter and the engine tachometer.
e.
Connect the alternator output wire to the alternator "B" terminal.
f.
Connect the battery negative (-) terminal.
3.
Regulated Voltage Test
The purpose of this test is to check that the electronic voltage regulator controls voltage correctly.
(1)
Preparation
a.
Prior to the test, check the following items and correct if necessary.
Check that the battery installed on the vehicle is fully charged. Refer to the "Battery" section for checking the battery.
Check the alternator drive belt tension. Refer to the "Inspect drive belt" section for checking the belt tension.
b.
Turn ignition switch to "OFF".
c.
Disconnect the battery negative (-) terminal.
d.
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.
e.
Disconnect the alternator output wire from the alternator "B" terminal.
f.
Connect a DC ammeter (0 to 90A) in series between the "B" terminal and the disconnected output wire.Connect the (-) lead wire of the ammeter to the disconnected output wire.
g.
Connect the battery negative (-) terminal.
(2)
Test
a.
Turn on the ignition switch and check to see that the voltmeter indicates the following value.
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.
b.
Start the engine. Keep all lights and accessories off.
c.
Run the engine at a speed of about 2,500 RPM and read the voltmeter when the alternator output current drops to 10A or less
(3)
Result
a.
If the voltmeter reading does not agree with the standard value, the voltage regulator or the alternator is faulty.
Regulated Voltage : 11.7 - 15.3V
b.
If the voltmeter reading does not agree with the standard value, the voltage regulator or the alternator is faulty.
c.
Disconnect the battery negative (-) terminal.
d.
Remove the voltmeter and ammeter.
e.
Connect the alternator output wire to the alternator "B" terminal.
f.
Connect the battery negative (-) terminal.
Vehicle parasitic current inspection
[Using the Ammeter]
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.
3.
Wait for a few minutes until the vehicle’s electrical systems go to sleep mode.
  
•
For an accurate measurement of a vehicle parasitic current, all electrical 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.
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.

5.
Read the current value of the ammeter.
•
If the parasitic current is over the limit value, search for abnormal circuit by removing the fuses one by one and checking for parasitic current.
•
Reconnect only the fuse suspected of parasitic current and search for the trouble unit by removing the components connected to the circuit one by one until the parasitic draw drops below limit value.
Limit value (after 10 - 20 min.) : Below 50mA
[Using the Clamp type Ammeter]
6.
Turn the all electric devices OFF, and then turn the ignition switch OFF.
7.
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.
8.
Wait for a few minutes until the vehicle’s electrical systems go to sleep mode.
  
•
For an accurate measurement of a vehicle parasitic current, all electrical 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.
9.
Install the clamp type ammerter on battery negative (-) terminal.
10.
Read the current value of the ammeter.
•
If the parasitic current is over the limit value, search for abnormal circuit by removing the fuses one by one and checking for parasitic current.
•
Reconnect only the fuse suspected of parasitic current and search for the trouble unit by removing the components connected to the circuit one by one until the parasitic draw drops below limit value.
Limit value (after 10 - 20 min.) : Below 50mA

Alternator. Description and operation

Description
The Alternator has eight built-in diodes, each rectifying AC current to DC current.
Therefore, DC current appears at alternator "B" terminal.
In addition, the charging voltage of this alternator is regulated by the battery voltage detection system.
The alternator is regulated by the battery voltage detection system.
The main components of the alternator are the rotor, stator, rectifier, capacitor brushes, bearings and V-ribbed belt pulley.
The brush holder contains a built-in electronic voltage regulator.

1. Brush
2. Drive belt pully
3. Rotor
4. Stator

Alternator. Specifications

Specification
Item
Specification
Rated voltage
 13.5V , 130A
Speed in use
 1,000 - 18,000rpm
Pin
 1 (LIN)
Pulley Type
OAP pulley

Alternator. Repair procedures

Removal
  
•
Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift.
(Refer to General Information - "Lift and Support Points")
1.
Turn the ignition switch OFF and disconnect the battery (-) terminal.
2.
Remove the drive belt.
(Refer to Engine Mechanical System - "Drive Belt")
3.
Disconnect the alternator connector (A).
4.
Remove the cable nut (A) from the alternator "B" terminal.
Tightening torque :
18.6 - 24.5 N.m (1.9 - 2.5 kgf.m, 13.7 - 18.1 Ib-ft)

5.
Remove the alternator mounting bolts.
Tightening torque :
49.0 - 63.7 N.m (5.0 - 6.5 kgf.m, 36.2 - 47.0 Ib-ft)
6.
Remove the alternator (A).
Installation
1.
Install in the reverse order of removal.
Disassembly
1.
Remove the shaft cap (A).

  
•
When installing, replace with new shaft cap.
2.
Remove the OAP pulley (A).
3.
Remove the alternator cover (A) after loosening the mounting nut.
4.
Remove the regulator assembly (A).
5.
Remove the stator leads (A).
6.
Remove the 4 through bolts (A).
7.
Separate the rotor (A) and cover (B).
Reassembly
1.
Reassemble in the reverse order of disassembly.
  
•
When installing, replace with new shaft cap.
Inspection
Rotor
1.
Check that there is continuity between the slip rings (C).
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.
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.

Battery. Description and operation

Description
AGM Battery
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 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.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)
[AGM70L]

  
•
After disconnecting then reconnecting the battery negative cable, reset some parts that require the reset procedures.
(Refer to Body Electrical System - "General Information")
CMF Battery
The CMF (Closed Maintenance Free) battery is, as the name implies, totally maintenance free and has no removable battery cell caps.
The CMF (Closed Maintenance Free) battery does not require water replenishment for the repair.
The battery is completely sealed, except for small vent holes in the cover.
[CMF68L]

Battery. Troubleshooting

Troubleshooting

Battery. Specifications

Specification
â–· CMF68L-DIN
Item
Specification
Model type
 CMF68L-DIN
Capacity [20HR/5HR] (AH)
 68 / 54
Cold Cranking Amperage (A)
 600
Reserve Capacity (Min)
 110
Specific Gravity
1.25 - 1.31 [25°C (77°F)]
Voltage (V)
12

â–· AGM70L-DIN
Item
Specification
Model type
 AGM70L-DIN
Capacity [20HR/5HR] (AH)
 70 / 56
Cold Cranking Amperage (A)
 760 (SAE) / 760 (EN)
Reserve Capacity (Min)
 120
Specific Gravity
1.30 ~ 1.32 [25°C (77°F)]
Voltage (V)
12

  
•
Model type description
•
Cold Cranking Ampere (CCA) : 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) : 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.
  
BCI Type
Capacity
(5HR/20HR)
Length
Width
Height
Total Height
L (mm)
W (mm)
T (mm)
TH (mm)
28/35
 188 - 192
 126 - 130
 198 - 202
 218 - 222
32/40
 194 - 198
 133 - 137
 199 - 203
 223 - 227
36/45
 203 - 207
 173 - 177
 200 - 204
 221 - 225
44/55
 213 - 217
 173 - 177
 198 - 202
 218 - 222
48/60
 228 - 232
 173 - 177
 200 - 204
 221 - 225
54/68
 258 - 262
 173 - 177
 198 - 202
 220 - 224
56/70
 258 - 262
 173 - 177
 198 - 202
 223 - 227
64/80
 274 - 278
 170 - 174
 198 - 202
 221 - 225
70/88
 349 - 353
 172 - 176
 186 - 200
 183 - 187
72/90
 300 - 304
 170 - 174
 200 - 204
 221 - 225
76/95
 294 - 298
 172 - 176
 198 - 202
 220 - 224
80/100
 326 - 330
 170 - 174
 203 - 207
 225 - 229

[DIN Type]
Capacity
(5HR/20HR)
Length
Width
Height
Total Height
L (mm)
W (mm)
T (mm)
TH (mm)
36/45
 205 - 207
 173 - 175
 164 - 168
 188 - 190
48/60
 205 - 207
 173 - 175
 164 - 168
 188 - 190
54/68
 205 - 207
 173 - 175
 164 - 168
 188 - 190
64/80
 205 - 207
 173 - 175
 164 - 168
 188 - 190
72/90
 205 - 207
 173 - 175
 164 - 168
 188 - 190
80/100
 205 - 207
 173 - 175
 164 - 168
 188 - 190
88/110
 205 - 207
 173 - 175
 164 - 168
 188 - 190

[AGM DIN Type]
Capacity
(5HR/20HR)
Length
Width
Height
Total Height
L (mm)
W (mm)
T (mm)
TH (mm)
40/50
 205 - 207
 173 - 175
 164 - 168
 188 - 190
48/60
 227 - 229
 173 - 175
 164 - 168
 188 - 190
56/70
 276 - 278
 173 - 175
 164 - 168
 188 - 190
64/80
 312 - 314
 173 - 175
 164 - 168
 188 - 190
72/90
 351 - 353
 173 - 175
 164 - 168
 188 - 190
84/105
 392 - 394
 173 - 175
 164 - 168
 188 - 190

Battery. Repair procedures

Removal
Battery
1.
Turn the ignition switch OFF and disconnect the battery (-) terminal (A).
Tightening torque :
7.8 - 9.8 N.m (0.8 - 1.0 kgf.m, 5.8 - 7.2 Ib-ft)

2.
Disconnect the battery (+) terminal (A).
Tightening torque :
7.8 - 9.8 N.m (0.8 - 1.0 kgf.m, 5.8 - 7.2 Ib-ft)

3.
Remove the battery mouting bracket.
Tightening torque :
7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.8 - 8.7 Ib-ft)
4.
Remove the battery (A).
Battery Tray
1.
Remove the battery.
2.
Remove the air cleaner assembly.
(Refer to Engine Mechanical System - "Air Cleaner")
3.
Remove the engine control module (ECM).
(Refer to Engine Control / Fuel System - "Engine Control Module (ECM)")
4.
Remove the battery tray (A).
Tightening torque :
7.8 - 10.8 N.m (0.8 - 1.1 kgf.m, 5.8 - 8.0 Ib-ft)

Installation
1.
Install in the reverse order of removal.
  
•
When installing the battery, fix the mounting bracket on the tray correctly.
  
•
After disconnecting then reconnecting the battery negative cable, reset some parts that require the reset procedures.
(Refer to Body Electrical System - "General Information")
  
•
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.
  
•
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 non-operational.
Inspection
Battery Condition
Check the battery for damage or deformation. If severe damage, deformation or leakage is found, replace the battery.
Vehicle parasitic current inspection
[Using the Ammeter]
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.
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 electrical 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.
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.

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 checking the parasitic current.
•
Reconnect the suspected parasitic currentdraw circuit fuse only and search for suspectedunit by removing the component connected with thecircuit one by one until the parasitic draw dropsbelow limit value.
Limit value (after 10 - 20 min.) : Below 50 mA
[Using the Clamp type Ammeter]
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.
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 electrical 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.
Install the clamp type ammerter on battery negative (-) terminal.
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 checking the parasitic current.
•
Reconnect the suspected parasitic currentdraw circuit fuse only and search for suspectedunit by removing the component connected with thecircuit one by one until the parasitic draw dropsbelow limit value.
Limit value (after 10 - 20 min.) : Below 50 mA
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)
Keypad
The Micro 570 button on the key pad provide the following functions :

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

  
•
Connect clamps securely. If "CHECK CONNECTION" message is displayed on the screen, reconnect clamps securely.
2.
The tester will ask if the battery is connected "IN-VEHICLE" or "OUT-OF-VEHICLE". Make your selection by pressing the arrow buttons; then press ENTER.
3.
Select CCA and press the ENTER button.

  
•
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.

  
•
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.
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.

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.)
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 CELL-REPLACE
 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.
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.
  
•
Whenever filing a claim for battery, the print out of the battery test results must be attached.
Starter Test Procedure
7.
After the battery test, press ENTER immediately for the starter test.
8.
Start the engine.
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
Result On Printer
Remedy
CRANKING VOLTAGE NORMAL
 System shows a normal starter draw.
CRANKING VOLTAGE LOW
 Cranking voltage is lower than normal level.
–
Check starter.
CHARGE BATTERY
 The state of battery charge is too low to test.
–
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.

  
•
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.
11.
The tester displays the actual voltage of alternator.
Press ENTER to continue.
12.
Turn off all electrical load and rev engine for 5 seconds with pressing the accelerator pedal. (Follow the instructions on the screen)
13.
The message that engine RPM is detected will be displayed on the screen. Press ENTER to continue.
14.
If the engine RPM is not detected, press ENTER after revving engine.
15.
The tester will conduct charging system test during loads off.
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.
18.
Rev engine for 5 seconds with pressing the accelerator pedal. (Follow the instructions on the screen)
19.
The message that engine RPM is detected will be displayed on the screen. Press ENTER to continue.
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.
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.

Charging System Test Results
Result On Printer
Remedy
CHARGING SYSTEM NORMAL / DIODE RIPPLE NORMAL
 Charging system is normal.
NO CHARGING VOLTAGE
 Alternator does not supply charging current to battery.
–
Check belts, connection between alternator and battery and replace belts or 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 DETECTED
 One or more diodes in the alternator is not functioning properly.
–
Check alternator mounting and belts and replace as necessary.

The MDX-670P Analyzer
The MDX-670P 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 built-in printer to provide a copy of the results.

  
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 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.
  
•
For a proper connection, rock the clamps back and forth. The tester requires 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.

  
•
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.

  
•
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.

–
CCA : Cold Cranking Amps, as specified by SAE. The most common rating for cranking batteries at 0°F (-17.8 °C).
–
EN : Europe-Norm
–
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.
6.
Press ENTER to start test.

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.

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.)
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 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.
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.
  
•
For an in-vehicle 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.
9.
Start the engine when prompted.
10.
The tester displays the decision on the starter system, cranking voltage, and cranking time in milliseconds.

Starter Test Results
Result On Printer
Remedy
CRANKING VOLTAGE NORMAL
 System shows a normal starter draw.
CRANKING VOLTAGE LOW
 Cranking voltage is lower than normal level.
–
Check starter.
CHARGE BATTERY
 The state of battery charge is too low to test.
–
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 in-vehicle 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.
12.
Rev the engine with loads off. (Following the on-screen prompts)
13.
The message that engine RPM is detected will be displayed on the screen, idle the engine.
14.
Turn on electrical loads (air conditioner, lamps, audio and etc). Press ENTER to continue.
15.
Turn on electrical loads (air conditioner, lamps, audio and etc). Press ENTER to continue.
16.
The message that engine RPM is detected will be displayed on the screen, idle the engine.
17.
Turn off loads and engine.
18.
The Charging System decision is displayed at the end of the procedure.

Result On Printer
Remedy
NO PROBLEMS
 System is showing normal output from the alternator.
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 corroded, clean or replace the cable and retest.
–
If the belts and connections are in good working condition, replace the alternator. (Older vehicles use external voltage regulators, which may require only replacement of the voltage regulator.)
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.
Cleaning
1.
Make sure that the ignition switch and all accessories are in the OFF position.
2.
Disconnect the battery cables (negative first).
3.
Remove the battery from the vehicle.
  
•
Care should be taken in the event the battery case is cracked or leaking, to protect your skin from the electrolyte.
Heavy rubber gloves (not the household type) should be 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.
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.

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 various sensors. It is important to provide a stable power supply as these sensors bring diverse 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.

Battery Sensor. Repair procedures

Removal
1.
Turn the ignition switch OFF and disconnect the battery (-) terminal.
2.
Disconnect the battery sensor connector (A).
3.
Remove the battery sensor (A).
Tightening torque :
26.5 - 32.4 N.m (2.7 - 3.3 kgf.m, 19.5 - 23.9 Ib-ft)

Installation
1.
Install in the reverse order of removal.
  
•
For the vehicle equipped with a battery sensor, be careful not to damage the battery sensor when the battery is replaced or recharged.
1)
When replacing the battery, the new battery should be of the same type, capacity and brand with the previous one. If a battery of a different type is replaced, the battery sensor may recognize the battery to be abnormal.
2)
When installing the ground cable on the negative post of battery, tighten the clamp to the specified torque. An excessive tightening can damage the PCB internal circuit and the battery terminal.
3)
When recharging the battery, ground the negative terminal of the booster battery to the vehicle body.
Adjustment
Battery Sensor Recalibration Procedure
After reconnecting the battery negative cable, AMS function does not operate until the system is stabilized, for about 4 hours. If disconnecting the negative (-) battery cable from the battery during repair work for the vehicle equipped with AMS function, Battery sensor recalibration procedure should be performed after finishing the repair work.
1.
Turn the Iginition switch ON and OFF.
2.
Park the vehicle for about 4 hours with the hood and all doors closed.

DC DC converter

Description and operation

Description
Due to the considerably more frequent occurrence of starting operations, the electrical load that occurs often leads to voltage dips in the vehicle network.In order to stabilize the power supply for certain voltage-sensitive electrical components, a DC/DC converter is used in conjunction with the ISG function.The DC DC converter supplies the relay with a voltage that also remains constant during the starting operation.
The DC/DC converter is fitted at the behind of the glove box.Via the test leads for input voltage and the start relay , the electronics decide whether the power is supplied to the output via the bypass or the DC/DC converter.In the bypass mode, the on-board supply voltage is not fed across the DC/DC converter, rather is transferred directly to the outputs. In the booster phase, the vehicle voltage is adapted.

Components and components location

Components Location

1. DC/DC Converter [200W, 450W]

Specifications

Specifications
[200W]
Type

Specifications
Switching mode
 Input voltage range
 7 - 16
Battery powered (B+) output voltage
 11.4 - 12.6 [Max 15A, Max power 200W]
ACC output voltage
 11 - 13 [Max 3 A]
Time (sec)
 Max 1

[450W]
Type

Specifications
Switching mode
 Input voltage range
 7 - 16
Battery powered (B+) output voltage
 11.4 - 12.6 [Max 30A, Max power 450W]
ACC output voltage
 11 - 13 [Max 3 A]
Time (sec)
 Max 1

Schematic diagrams

Circuit Diagram
[200W]

[450W]

Terminal Function
[200W]

PIn
Description
1
 Battery power (B+) input
2
 Battery power (B+) output
3
 IGN1 input
4
 ISG signal input
5
 ACC input
6
 ACC output
7
 Ground

[450W]

PIn
Description
PIn
Description
1
 Ground
 6
 IGN1 input
2
 Ground
 7
 ISG signal input
3
 Battery power (B+) output
 8
 ACC input
4
 Battery power (B+) input
 9
 ACC output
5
 Battery power (B+) input [Current Cut Off]
 10
 Battery power (B+) output [AMP]

Repair procedures

Removal
1.
Turn the ignition switch OFF and disconnect the battery (-) terminal.
2.
Remove the heater & A/C control unit.
(Refer to Heating, Ventilation and Air Conditioning - "Heater & A/C Control Unit")
3.
Disconnect the DC/DC converter connector (A).
4.
Remove the DC/DC converter (B).
Installation
  
•
After reconnecting the battery negative cable, ISG function does not operates until the system is stabilized, about 4 hours. If disconnecting the negative (-) battery cable from the battery during repair work for the vehicle equipped with AMS function, Battery sensor recalibration procedure should be performed after finishing the repair work.
1.
Install in the reverse order of removal.
Specifications
Service Data Ignition System Ignition Coil Item Specification Rated Voltage (V) 13.5V Secondary Coil [Engine 1000RPM standard] Input voltage (V) 13.5V Dwell Time (ms) 4.0 - 4.6 Spark current (mA) Min. ...

Starting System
Description and operation Description The starting system includes the battery, starter, solenoid switch, ignition switch, ignition lock switch, connection wires and the battery cable. When the ignition ...

See also:

Steering wheel
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Components and components location Component Location 1. Windshield wiper arm & blade 2. Wiper & washer switch 3. Windshield washer hose 4. Windshield wiper motor & linkage 5. Washer motor ...

Thermostat. Troubleshooting
Troubleshooting Symptoms Possible Causes Remedy Coolant leakage • From the thermostat gasket Check the mounting bolts • Check the torque of the mounting bolts • Retighten the bolts and check leakage ...