Engine Electrical System GENERAL STARTING SYSTEM SRoustestoornS fet GieouT OMesANFoR STARTING Pec seroice root fE-8 See Swe Mtoe Sr Ne fey STARTER GRGAT TROUBLESHOOTING” EE 88 IGNITION SYSTEM ONAL fe7 CHARGING SYSTEM STANEPECTION.. Graproncanironeianané ~~ """ —— cRuIse CONTROL SYSTEM Cuvee Weer aa Syerews.occoacran fea Couns eE28 cece ao Sisasseueey fer REMOVAL est INSPECTION FeaEE ENGINE ELECTRICAL SYSTEM GENERAL SPECIFICATION ssn: anon sysrem Teme ‘Specification ‘gmon con Primary ressanee 082 = 107% (0) _" Secondary resistancs 70% 15% (st) NOK BRASES Leaded CHAMPION ROTO cap (08~ 0S mm (0515 OaRs4 mR) Spark lige = pak ee NGK ‘BERSES-T1 | neaced ‘CHAMPION RCIOVEA ‘Gap 0~ 1 mim (00588 — 00H) STARTING SYSTEM ems Speciation Fated votage 1212 KW (Na. of pion tot 2 Starr ‘ota Tsv toed Coes “Ampere 908, MAX ‘Speed 72500 rpm, MNGENERAL EE-3 (CHARGING SYSTEM ————— heme ‘Speciation Tipe Bator votage sensing ste votage 185 v 1108 — Spood in vse 1,000 = 18,000 rer ‘Votage regulator locron bultn ype Fogultor sting wotape 1455 +02 V Temperaure compensation B5at mvs Wee TAF BAH ater ‘God erankng amperage al -1e°OC0.7F 800 A Reserve caparty 110 min [Sesser at 20°06 1280 + ot a + RESERVECAPACITY RATING 6 ameunte tine 1 bata can Sovar 254 and maintain 2 min. + COLD CRANKING AMPERAGE the amporage ‘mum tominal tage ot 1053128." 180}. {bate can dave 30 scons ancmaintan ‘terminal votageof72V orgraser aa spectied temperature ‘AUTO CRUISE CONTROL SYSTEM ems ‘Specioation Seting ener Wii = 1.Skrvh on lve oad Vote speed memory vain Ne valaon ES ‘Seting tie C— 0908 max esuring tine 0600 max Minimum operating speed 20 = 2k ‘Cancel peed range 35 = 2K Masini memorized speed 180 = akrah Puling oe T2TNCSKD Main sich sora eit valve Boks = 16 (Command suitch sari eitene value SET meh 2000 = 18 FESUME swech = 100+ 1ses eine eLEeTRICAL SYSTEM TROUBLE SHOOTING cam vawmon svete San eo ena) Ee wat aaron wih Tape a bk whan seed sree sat | nen con ‘ofec ate ok sess tng’ Gana 00 |S pe efector ps, orc ied (Be wiadecmnesertekn_| Rear win or pce ee aah eaten weg apa ig, pea outed =o Pepe soresae Soonted Erg asso] Spake ad oa cates | pet papa ee, one a Ged eieas | ae vg Boe me orion seine | Fear esgo | Sa san at Dg ae [rept pt is ent wi ad ‘CHARGING SYSTEM ‘Syston Supa Renedy ‘Charging warning Fuse Bown ‘Choa has Indestor dose not ght | Light burned out Pepin ign tain gion ewazn ON" | Weng someon foee ‘Tigh loose connection nd eng of Eloctone vtage regular Replace votage regulator Charging warning | Oro bet oceo oF worn “A al tension oF epics bat fndestor doesnot go | Baber ctl lease, corded or worm | Inspect cable conection, repair ‘ut th engine ening or rapisco cae {Bator requis requ | election vatage regulator or atsmator | Repco wotagoroultr or alerator recharge) Weng . Reps or pace wing ‘Overharoe tectonic vltage equtor Replice vtag regulior Votage sensng wie Repel or ropiace Weng Dacha ‘Dre bat bees oF worn “Ast bl enon or replace Bak Wing connection ge or short cxeut | Inepect ling connect, repair ‘erepice suing Election votage regulator or atanator | Repleevotage regulator or alerator Poor grounding Inspect ground or par L Worn tory Feplsce battyGENERAL SsTaRTING SYSTEM: Syroion ‘Suspect aa Remedy Engin wit notcrank | Bary are lw ‘Charge or replace battery Batry ean ose, coved or worn out Rapa or place cables TTaneaso range swich (Veh Wit somatic Waneaxt on) Florio TR group auomati rans nga wil not rank Fuse Bown Popaoe fuse | Starr motor fauty Fopiace | Ignition ste aly epics Engine cranks sowy | Baty charge low ‘charge or replace batory Batory cabs lose, cored or worn out opal or ropsce cables Stror motor uy enlace ‘Slane Faape ening | Starter motor Igniton en ‘Sao spine ba Short in wing opal witha ion goa teeth broken or ster motor Fpl ‘ing ger tou bokon 08 Ty whoa oF oque convertorcE ENGINE ELECTRICAL SYSTEM SPECIAL SERVICE TOOL ena ool (amber and name) tuatation te ‘Aerator ple emaver wrench Removal and stataion of terete pullyGENERAL ‘THE MICRO 570 ANALYZER sense KEYPAD ‘The MICRO 570 Analyzer provides the ably fo test ThelICROS7O bston onthe kay padprovdehefolowng ‘he charging ae staring syst, ncuaing he atry, _funetons A caunow = terest pony rennin as ((( ‘ways use extrome caution and appropriate eye | SSS [Gp || 2 Poste muTentoen iat ees || text ese Eee =FES ENGINE ELECTRICAL SYSTEM BATTERY TEST PROCEDURE. 8. Choose ether COA o CCP and poss the ENTER 1 Conneat he ato t th btn. + "'Red damp to batty postive (termina Back clamp to batry negative () termi 2. Thotasor il ask he battery is omected NA VE- HOLE" or ‘OUT OF A VEMIGLE®, Make your ela ‘ion by proaing the srw buona thon prose EN TER [seuectiveur +: | * COA: Cot/eranking amps isan SAE specoa- ton te cranking ated at OF (18°) + COP: Got erankng amps 1s an SAE specoa- fon fr korean maniacs or esnkng bat- tered at (18). Settho cA vibe dpiayod onto seroonto the CCA ‘ale marked on tne ator label by pressing up and ‘own buton and poss ENTER, eran Tho batry ratgs( CCA) splyedan tho tester must ‘be identical ote tings mare an bao Ibe.GENERAL EE-9 ‘5. The tesor(ler0570) splays ator test ests in ude wotago an batty ratings ‘Arora action must be gen according to ho test ‘ooute by releringtothe ater et eauleas chown Gore Tho bate ratings (OCA) aspayed on the restr ‘must be tenia to tho ratings markod on batory ‘etd Dow BATTERY TEST RESULTS ( coovsarenr { abe. 8. To conduct starter ts, coninuousy press ENTER, ‘RESULT ON PRINTER REMEDY (Good batery No ection 6 requed Baton & i good sale Good charge Feenrge the baer and use ‘Batley snot charged propery charge & Retest | = Charge and tet tha battery again (Faire to charge the battery {uy mey esd neoreet mossurement vale) “> Roplace btiory and recheck ho charging estan. (improper cowacion rl [etwoen Bata end vohise oeblea ray catpe “REPLACE BATTERY ‘eatery eta the Oatery after romoving eblee andeonnacng the fstr tthe batty tring! cect of replacing th baler) ‘ov covcepiece | 7 Sse end ees he bat. And thn, at reals may cause "REPLACE BATTERY” replace batry and ochock th charging sytem @ warwne ‘Whenever fing a claim for battery, the printout of oh ‘the battery toot results must be oHef STARTER TEST PROCEDURE ‘Ar the beter tt, ress ENTER immediatly for 1 ‘he star tot CIR —<—$——<—) PRESS ENTER FOR ENGINE ELECTRICAL SYSTEM 3. Cran wovage and tater test oss wil be e- plsjed on tne screen. “ako a relevant acon according to th ot resus by reloing tte sare tos ross 2 gen baw 4 Tocontrue charging syst ts, press ENTER.GENERAL STARTER TEST RESULTS EE -11 ‘RESULT ON PRINTER REMEDY ‘ranking votage normal ‘System shows normal Sareea Cranking wotage low ‘ranking votage i tower han normal ee Check starr “he stato of baey charge I fo low toto (Chango bttry cnarge the Sater and retst = Replace battery > I th vehi I nt started though th bar condton ot Replace bat | Sood and tly charged” displayed. piace battery "Shack wing for open creve ata cate connection, stator i apa or ropiaoo as ncossary. Sire engine does crank, check fuel gsiem.f ENGINE ELECTRICAL SYSTEM (CHARGING SYSTEM TEST PROCEDURE 4 Press ENTER 1. Press ENTER to bogin charging system es (_@uvunor — | BEeseee_|| | e — 5. The MICRO 570 analyzer charging systom ouput at lee tor compara o ater readings 22. ENTER buon pressed he ster depays te ac tual otage of alloratr, Prose ENTER tooo ne charging sytem, 6. Ta a eleva action ancortng otha tat reut by tern wo be tao below fer shstng of he on seme gh ani lsconeat he test camps From th Bat 3. Tumotallctsaload andar engine for seconds wih pressing tne accelerator palGENERAL EE-13 (CHARGING SYSTEM TEST RESULTS RESULT ON PRINTER REMEDY ‘Ghargng sytem normalDiede pple noel ‘Charging sytem is norma No charging wotage “Romar doos nl supply earghg curent 0 baton eNchek bate, connecton bebwan aloratr an Dllory Fepiace bots or cabo of aera necessary Low charging voteg= “Atenator coos not suplychargng caren o baton and ‘eatea load fo system ay Check bate and aerator and rplace ae necessary High charging votape “Te vege from alate fo batlory fe igher han een Sit dug voting repiting ‘Check connection and ground and pice regulter as necessary = Check eco level nthe batery Excess ripple cetected ‘he or more odes nthe akerstor eno nstoning propery ‘SGheck tomar mounting and bots ond vplace ea necsssarycE-14 IGNITION SYSTEM DESCRITION. see lontiontiing corre he electronic contagion timingayetem. Te standad‘slrenos gion ting deta forthe engine operating consons are peprograriaa "he memory of he ECM (Engine Control Mosul), “Te engine operating condtons (epee os, warm-ap Condor, ta} a doloted by tho vareus senso. Based on tose sensor signals and the inten trang Gata. signas to ntrupt the primary curent are sant to te ECM. The iption cose actvaed, ana ming I ‘ontrole ENGINE ELECTRICAL SYSTEM ON-VEHICLE INSPECTION ema SPARK TEST 1. Remove he gntin col connector. 2 9. Using a somh pi shel rove te spk vn 4. na he spark pg to theron colIGNITION SYSTEM. EE-15 ‘5. Ground the spark gto the engine 8. Check s spark occurs while engine being cranked Drore To proven fal bala ected fom Iectors we he engin i ang craked, ramore tefl pune) [ay om io ase box ‘Crank the engine fer no more than 5-10 seconds. 7. Inspect the spark pugs, 8. Using a sparkplug soca, instal ho spark log. 8. Insta heft oo 10, Rocannect he igrtlon col connect.EE-16 ENGINE ELECTRICAL SYSTEM ‘Sparkes BAD (Check conection a grton cot connaetor |] ——>| Connect sary 0K BAD, (Check heighten eat | Fepace te pion co 0K AD ‘Check power aupoirtoignten cot [>| Check wrngbetwaon nition smitch and "Tom niin atch 1 ON, Ignten cot 2. Chaok hat thor etary votage at ‘gon col postive (+) trial ox ‘Chackihecamsha postion sonsor | BAD [Replace te camena poston sensor (Pair to FL grou) rl (Peter FL group) OK ‘Checkiheeankahat patton sansor | BAD” Replace tho srankshat postion sensor (Porto FL sro) (Bator FL grup) OK ‘heck ton signa tem ecm | BAD, [chock wing between ECM andignten co, (RtertoFL grou) ‘ang hon ty anaer ECM 0K Try anather inten eoIGNITION SYSTEM INSPECT SPARK PLUG 1. Remove the into coi connector 2, Remove the ignton eos (Grore When removing the igniten col connector, pl ho lock pin) ara pus 0c). a7 8 Using ipa socket renovate pa up. Ay caution Be careful tno contaminates eter through the ook pug oto, 4 spat ne derode (A andcrenic nest). ‘ap n> INSPECTION OF ELECTRODES Conaton | Dark deposi [White doposts | [Fuel mire two ean Fuolmire |= Aevanoad Deccrpten |” too sar ‘gntion ring Cowairinake |= nautient ug tinting 5. Check he obevede ot (kt ‘Sanaars Uneadod 1.0 1.1 mm (0994 ~ 0453 a) Leaded 08 = 09 rem (00815 - 0.0354).EE -18 INE ELECTRICAL SYSTEM INSPECT IGNITION con. REMOVAL exec 1. Meseue te primary col resistance between tsi IGNITION COIL fats (and) 1. Remove he engine cover 2. Remove theipnon col (A ‘Standard value 0620 = 10% am Gore When remain the fnton coi connector, pil he Jack pig) ara push be ct). 2. Instalaton iethe roves of emo(CHARGING sysTEM CHARGING SYSTEM DESCRIPTION sass ‘Th enwong system ncudd a batery an aerator with "bate regulon, snd the chergngIndatr ht and ‘The Atemstornas busin odes, sch etiyng AC cu font to OC curent “mertere, OC etn! appears a aerator" erin. Inaaaten the cmarging osaga ol his allonatr ap led bythe Batlory votage detection sytem. ‘Tha alrato is egulsd by the batary vege detec ton system, Tho mal components of he atoratr are th ter, stator, ocr, capes brushes, bean Visited bet pute. Te bru elder cniins& alton acroni votage roglatrE20 ENGINE ELECTRICAL SYSTEM CIRCUIT DIAGRAM FOR CHARGING SYSTEM sn(CHARGING SYSTEM ON-VEHICLE INPECTION sina: B) cavmon + Chock thatthe tater eabies are connected to the comect terminal, + Disconnect the battory cables when tho bat- tory Is guen a gulck charge. + Never disconnect the battery while the engine leruning. (CHECK BATTERY VOLTAGE 1H 20 minutes nee not passod ince th angie was "oppad tum th ignition siwieh ON ara turn on the ‘ecteal sytem (Roacamp, Hower ott, fer de Tagger et) tr 60 seconds to remove be suaco charge. 2. Tuntheignionswich OFF and uno the sete! «tons. 3. Moasure he bateryvltage between the nage () ‘ana postin ()trminals fo ator. Slandad votaga 25 OV at 20167) 11 he votage sles tan specication, charge the bat. (CHECK THE BATTERY TERMINALS AND FUSES 1. Chock hat he batry terminals rena 03 ocr 2. Cheok the fuse for contin E21 INSPECT DRIVE BELT frayed cords any dtet has bon ound replace the cive bet wore Cracks on nb side of bat are considered accept. fbi ithe bot has chunks mising rom thei, ‘Should be reclaced VISUALLY CHECK ALTERNATOR WIRING AND LISTEN FoR ABNORMAL NOES 1 Chock tate wing isn goo eoncton 2. Check hat thre ino storm noes rom he aie stor whe the engine running. (CHECK DISCHARGE WARNING LIGHT cIRCUFT 1. Warm up te engine and hen tun ot. 2. Tum ota eccesores charge warming lg 4 Statne engno. Check hat he gt "be ght dass not goof as opocie,toxslashoot the discharge int ereE22 ENGINE ELECTRICAL SYSTEM eee ENGINE ELECTRICAL SYSTEM INSPECT CHARGING SYSTEM RESULT OUTAGE DROP TEST OF ALTERNATOR OUTPUT 1. Tha volmetermay ndate the standard value, nae “Tistest determines ether ornate wingbotwventne Stand value: C2 meq Shomatr"6 terminal nthe batey (2) rman gees he wotage op method 2, We veo he vlna higher han expected ee {atove Onc), por wrng i aurpeted nis PREPARATION {Se acs wing wom he ors aril tothe bay) tormina. Cheek fe laose cone: Yona, color tangs due fo an overated harness, 2. Djscennec he ouput wit om the aerator "Bt 2, Corac thm before testing again. ‘Beemina ef atte andre) ead we of are compen fh tat, at he engine sped et Psimina of ator anatns (jie oem Sonam oe 1. Tam he ignition sth 0 “OFF io ieter tote auteurs, Cornet he (a eae! gn gt na hvadlanps bowser anh ton {onmeter to fhe Borin of tamer andihe ¢) Ta * ° Jead wire of voter tothe) rma of bate. 1. Start ne engine 2, Tumonthehoscamps and blower meter and sot ho ge sped unl the ammeter indatos 20 ‘and then, eadie volmetr as tno.CHARGING SYSTEM (OUTPUT CURRENT TEST “This tat determines hater or not he atalor shes an 2upat curant als equivalent othe normal ouput PREPARATION 1. Proto test, check he fotowing items and comet Check te batery stale in the vehicle to ensure Inuit good conto, The bar checing mathes ‘screrbed in na section “atoy ‘Th itor tat ie ved fo tet the ouput cuent shoua be one that hea Been party discharged. ‘Wiha ly chargod bates hotest may not be cor Ccted aorecy cue to an heuitln! oua. {Chace th tron 9 the aorntor dive bok. The Sottonston shock motto ia desorbed the secon spect ane ba 2 Tum ot he ition te, Disconnect te battery ground cable, 4 Disconnect he atrnator output om the ater ator" rma 5. Conpcta DC ammear (001504) in series betwean ‘ha"B tema andve eoconnaced out re, Be suretocomect be (led eof e ammeter oe ‘deconnecig out wie. Grore Tighten each connection sacucy s a heavy curont iil ow. Do et ron eps {8 Comet avotneter (9 20¥) betas ho Berm: alenaground. Connect na(.)losd wir lo be ar. ‘str"6" terminal and (nad wre oa Good round. 7. tach an engine tachometer and connet he batory ‘oune eae wen BL wl {S$ aroun E23 vest 1. hook osu thal the votmetar ads a he same ‘value asthe ate vege. ine vlna ends, andi open rcutin heirs between alternator 8 ‘erminl and baary () erin or poor grounding suspected 2. Sarthe engine andtur on he heasamos 3. Sol tho hetdlamps t high beam and the nestor Bower oven HIGH, qucky foresee the ening Speedo 2.500 rpm and read the mmum ouput Sent vai incoated bythe ammater ‘Ata the erin tar up the daring current quickly trops. ‘Thortore, te above oprain must be done quickly toed te maximum comer value const.