Hyundai Excel X2 1989-1998 Engine Electrical System

ENGINEELECTRICALSYSTEMReturn To Main Table of ContentsGENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

GENERAL

GENERAL

SPECIFICATIONS

Distributor MPI FBC

Type Contact pointless typeAdvance mechanism Controlled by electronic control unit

Firing order 1 - 3 - 4 - 2

Centrifugal and vacuum type

Ignition coilMPI FBC

TypePrimary coil resistanceSecondary coil resistanceIdentification No.

DiamondPoong SungDae Joon

Mold single-coil0.8 0.08 CI12.1 1.8 Kfi

F -088PC88DSA-117

1.2 0.12D13.7 2.1 Kfl

-

PN22C-

Spark plug (MPI, FBC)

TypeNGK

Champion

Plug gap

BUR6EA-11BPR6ES-11RN9YC41.0-1.1 mm (0.039-0.043 in.)

2 7 - 2

GENERAL

Starter motor (MPI, FBC)

TypeRated outputRated timeNo-load characteristics

Terminal voltageAmperageMaximum speed

No. of pinion teethPinion gap

A/T, Power SteeringDirect drive type12V 0.9 KW

30 sec

11.5V60A or less6,600 rpm or more

80.0197-0.079 in. (0.5-2 mm)

M / T

l2V 0.7 KW

6,500 rpm or more

AlternatorMPI FBC

TypeRated outputVoltage regulator typeRegulator setting voltageTemperature compensationIdentification No.

MelcoMando

Battery voltage sensing12V 75A (13.5V in case of Mando products)Electronic built-in type14.4 0.3V-10 3 mV/C

A2T09493AB175015

13.5V 65A

14.7 0.3V-7 3 mV/C

-

AB165014

Battery (MPI, FBC)

Type MF 60AH-B (Maintenance-free battery)Ampere hours (5HR) 48 Ah or more

(20HR) 60 Ah or more

Cold cranking [at -17.8C (0F)] 420 A or more

Reserve capacity 92 min.

Specific gravity [at 25C (77F)] 1.270 0.01

NOTECOLD CRANK AMPERAGE is the amperage a battery can deliver for 30 seconds and maintain a terminalvoltage of 7.2 or greater at a specified temperature.RESERVE CAPACITY RATING is the amount of time a battery can deliver 25A and maintain a minimumterminal voltage of 10.5 at 26.7C (80F).

2 7 - 3

IGNITION SYSTEM (MPI)

IGNITION SYSTEM

GENERAL INFORMATION

Ignition timing is controlled by the electronic control ignitiontiming system. The standard reference ignition timing data forthe engine operation conditions are programmed in the memoryof the electronic control unit (ECU).The engine conditions (rpm, load, warm-up condition, etc.) aredetected by the various sensors. Based upon these sensorsignals and the ignition timing data, signals to interrupt theprimary current are sent to the power transistor. The ignition coilis activated, and timing is controlled this way.

TROUBLESHOOTING

Probable condition Probable cause

Engine will not start or is Incorrect ignition timing

Remedy

Adjust ignition timing

hard to start. (Cranks OK)Ignition coil faulty Inspect ignition coil

Power transistor faulty

Distributor faulty

Inspect power transistor

Inspect distributor

High tension cable faulty

Spark plugs faulty

Inspect high tension cable

Replace plugs

Ignition wiring disconnected or broken Inspect wiring

Rough idle or stalls Spark plugs faulty Replace plugs

Ignition wiring faulty

Incorrect ignition timing

Inspect wiring


Ignition coil faulty Inspect ignition coil

Power transistor faulty

High tension cord faulty

Spark plugs faulty

Ignition wiring faulty


Spark plugs faulty



Inspect power transistor

Inspect high tension cord

Replace plugs

Inspect wiring

Adjust timing

Replace plugs



Engine hesitates/pooracceleration

Poor mileage

Engine overheats

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IGNITION TIMING

Adjustment conditions:Coolant temperature: 80-95C (170-205F)Lamps, cooling fan, and all accessories: OffTransaxle: Neutral (N or P for A/T)Parking brake: On

Adjustment Procedures

1.2.

3.

4.5.

6.

7.

Connect timing light.Start engine and run at curb idle speed.

Curb idle speed: 700 100 rpm

With the engine stopped, connect a lead wire with alligatorclips to the terminal for ignition-timing adjustment (locatedin the engine compartment), and ground it.

Start and run the engine at curb idle speed.Check basic ignition timing and adjust if necessary.

Basic ignition timing: 5 2BTDC

If the timing is incorrect, loosen the distributor mounting nut,and rotate the distributor until the timing is correct.

NOTEThe ignition timing will be advanced if the distributor isturned to the left and retarded if it is turned to the right.

After adjustment, securely tighten the mounting nut.

Tightening torque: 10-13 Nm (100-130 kg.cm, 7-9 lb.ft)

CAUTIONBe careful, when tightening the nut, that the distributordoes not move.

8. Stop the engine.9. Disconnect the lead wire connected at step 3.

10. Start and run the engine at curb idle speed.11. Check to be sure that the idling ignition timing is the correct

timing.

Actual ignition timing: 10BTDC

2 7 - 5


CHECKING IGNITION COILS

1. Measurement of the primary coil resistance.Measure the resistance of the positive (+) terminal andnegative (-) terminal of the ignition coil.

Standard value: 0.8 0.08 n

2. Measurement of the secondary coil resistance.Measure the resistance between the ignition coils positive(+) terminal and the high-voltage terminal.

Standard value: 12.1 1.8 KR

POWER TRANSISTOR

1. Connect the negative (-) terminal of the 3V power supplyto terminal 2 of the power transistor; then check whetherthere is continuity between terminal 3 and terminal 2 whenterminal 1 and the positive (+) terminal are connected anddisconnected.

Terminal 1 and (+) terminal Terminal 3 and terminal 2

Connected Continuity

Disconnected No continuity

2. Replace the power transistor if there is a malfunction.

CHECKING SPARK PLUG

Inspection and Cleaning

1. Disconnect the spark plug cable from the spark plug.

NOTEPull on the spark plug cable boot when removing the sparkplug cable, not the cable, as it may be damaged.

2. Using a plug spark wrench, remove all of the spark plugsfrom the cylinder head.

CAUTIONTake care not to allow contaminants to enter through thespark plug holes.

3. Check the spark plugs for the following:1) Broken insulator2) Worn electrode3) Carbon deposits4) Damaged or broken gasket5) Condition of the porcelain insulator at the tip of the spark

plug

2 7 - 6


4. Check the spark plug gap using a wire gap gauge, and adjustif necessary.

Standard value: 1.0-1.1 mm (0.039-0.043 in.)

5. Re-insert the spark plug and tighten to the specified torque.If it is overtorqued, damage to the threaded portion ofcylinder head might result.

Spark plug: 20-30 Nm (204-306 kg.cm, 15-21 lb.ft)

Analyzing Spark Plug

Engine conditions can be analyzed by the tip deposits near theelectrode.

Condition Dark deposits White deposits

Description o Too rich a fuel o Too lean a fuel mixturemixture o Advanced ignition timing

o Low air intake o Insufficient plug tightening

2 7 - 7


SPARK PLUG TEST(When engine can be cranked)

Connect the spark plug to the high tension cable. Ground theouter electrode (main body), and crank the engine. In theatmosphere, only short sparks are produced because of the smalldischarge gap. If the spark plug is good, however, sparks willoccur in the discharge gap (between the electrodes). In adefective spark plug, no sparks will occur because of a leakthrough the insulation.

CHECKING SPARK PLUG CABLES

1. Check the cap and outer shell for cracks.2. Measure the resistance.

Unit: KO

No.1 No.2 No.3 No.4

Resistance 10.1 11.8 11.8 14.2

NOTEResistance should not be higher than 10,000~ per footof cable. If resistance is higher, replace the cable.

2 7 - 8


REMOVAL AND INSTALLATION OF COMPONENTS

TORQUE Nm (kg.cm, lb.ft)

DISTRIBUTOR

Removal

1. Disconnect the battery ground cable.2. Remove the two distributor cap retaining clips and move cap

to one side.3. Disconnect the lead wire connector.4. Remove the distributor mounting nut and remove the

distributor assembly.

Installation

1. Turn the crankshaft so that No.1 piston cylinder is at topdead center.

2. Align the distributor housing and gear mating marks.3. Install the distributor in to the engine while aligning the fine

cut groove (or protection) of the distributors installationflange with the center of the distributor installation stud.

DISASSEMBLY AND ASSEMBLY OF DISTRIBUTOR

DISASSEMBLY

1. Lightly clamp the distributor in a vise equipped with softjaws.

2. Pull off the rotor from the rotor shaft.3. Remove the packing rubber.4. Lift off the cover.5. Remove the rotor shaft by using a driver.

6. Remove the disc and spacer.7. Disconnect the lead wire connector.8. Lift off the plate and unit by removing the three mounting

screws.

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9.10.

11.

12.

Remove the shaft bearing tightening screws.Make a position identification mark (for the driven gear) onthe distributor shaft.Place the driven gear on a soft base (wooden block) toprevent damaged.Punch out the roll pin by using a pin punch.

INSPECTION OF CAP & ROTOR

After checking the following, repair or replace if a problem isfound.1. There must be no cracking in the cap.2. There must be no damage to the caps electrode or the

rotors electrode.3. There must be no carbon tracking.4. Clean away any dirt from the cap and rotor.

REASSEMBLY

Distributor Shaft

After coating the shaft with a small amount of engine oil insertit into the housing.

CAUTIONDo not use solvent or similar products.

Driven Gear

1. Align the driven gear with the mark made at the time ofdisassembly, and install the gear to the distributor shaft.

2. When aligning the driven gears mating mark and thehousings mating mark, make sure that notch A at theshaft end is at the position shown in the figure, and thenalign the roll pin hole and drive in a new roll pin.

CAUTIONDrive in the roll pin so that the slits are at a right anglerelative to the shaft.

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Disc

Insert the disc into the sensor part of the pick up unit and installin alignment with the spacer.

CAUTIONThe discs slits must not be restricted.

Cover

Install the cover so that the covers indentation A is alignedwith the housings notch B.

2 7 - 1 2

IGNITION SYSTEM (FBC)

IGNITION TIMING

Adjustment conditions:Coolant temperature: 80-95C (170-205F)Lamps and all accessories: OffTransmission: Neutral (N or P for A/T)Parking brake: On

Adjustment Procedures

1. Connect tachometer and timing light.2. Start engine and run at curb idle speed.

Curb idle speed : 700 50 rpm

3. Check basic ignition timing and adjust if necessary.

Basic ignition timing : 5 1oBTDC

4. To adjust ignition timing, loosen the distributor mounting nutand rotate the distributor until the timing is correct.

5. After adjustment, securely tighten the mounting nut.

CHECKING SPARK PLUG

Inspection and Cleaning

1.

2.

3.

Disconnect the spark plug cable from the spark plug.

NOTE:Pull on the spark plug cable boot when removing the sparkplug cable, not the cable, as it may be damaged.

Using a plug spark wrench, remove all of the spark plugsfrom the cylinder head.

CAUTION:Take care not to allow contaminants to enter through thespark plug holes.

Check the spark plugs for the follows:1) Broken insulator2) Worn electrode3) Carbon deposits4) Damaged or broken gasket5) Condition of the porcelain insulator at the tip of the spark

plug.

2 7 - 1 3


SPARK PLUG TEST(when engine can be cranked)

Connect the spark plug to the high tension cable. Ground theouter electrode (main body), and crank the engine. Inatmosphere, only short sparks are produced because of the smalldischarge gap. If the spark plug is good, however, sparks willoccur in the discharge gap (between the electrodes). In adefective spark plug, no sparks will occur because of a leakthrough the insulation.

CHECKING SPARK PLUG CABLES

1. Check the cap and outer shell for cracks.2. Measure the resistance.

No.1 No.2 No.3 No.4

Resistance 10.1 11.8 11.8 14.2

NOTE:Resistance should not be higher than 10,000~ per foot ofcable. If resistance is higher, replace the cable.

2 7 - 1 4


4. Check the spark plug gap using a wire gap gauge, and adjustif necessary.

Standard value : 1.0-1.1 mm (0.039-0.043 in.)

5. Re-insert the spark plug and tighten to the specified torque.If it is overtorqued, damage to the threaded portion ofcylinder head might result.

Spark plug : 20-30 Nm (204-306 kg.cm, 15-21 Ib.ft)

Analyzing Spark Plug

Engine conditions can be analyzed by the tip deposits near theelectrode.

Condition Dark deposits White deposits

Description o Too rich a fuel o Too lean a fuel mixturemixture o Advanced ignition timing

o Low air intake o Insufficient plugtightening

2 7 - 1 5


DISTRIBUTOR

COMPONENTS

1. Breather2. Cap3. Contact carbon4. Rotor5. Cable assembly6. Ground wire7. Igniter8. Spring pin9. Signal rotor

10. Breaker base11. Vacuum controller-Dual diaphragm type12. Rotor shaft

13. Spring retainer14. Governor spring15. Governor weight16. Distributor shaft17. Oil seal18. Packing19. Housing20. O-ring21. Washer22. Driven gear23. Pin

2 7 - 1 6


REMOVAL

1. Disconnect battery ground cable.2. Disconnect high tension cable and spark plug cables from

distributor.

3. Disconnect wiring harness from the distributor lead wire.4. Disconnect vacuum hoses from vacuum controller.5. Remove distributor mounting nut and remove distributor

assembly from engine cylinder head.

DISASSEMBLY

1.2.

3.4.5.

Lightly clamp distributor in a vise equipped with soft jaws.Remove retaining clips and lift off distributor cap and sealring.Pull off rotor from rotor shaft.Remove two vacuum controller attaching screws.Remove link of controller from pin on the breaker base, thenremove vacuum controller.

6. Remove two screws and remove igniter.7. Remove lead wire (black).

8. Remove signal rotor shaft tightening screw and two breakerplate retaining screws.

9. Remove signal rotor shaft and breaker plate assembly.

2 7 - 1 7


10. Remove signal rotor shaft from signal rotor.

11. Remove two spring retainers with pliers and then removetwo governor spring.

12. Remove two governor weights.

13. Mark location of drive gear on distributor shaft.14. Place drive gear on soft base (wood block) so that roll pin

can be removed.15. Using a pin punch, remove roll pin.16. Remove drive gear and washer.17. Remove distributor shaft from housing.

REASSEMBLY

1. Clean and inspect all parts.2. Install shaft into housing.3. Install drive gear into distributor shaft at previously marked

location. Then install new roll pin.

2 7 - 1 8


4. Install governor weights on the governor plate.5. Install governor springs and spring retainer.

6. Install signal rotor shaft into distributor shaft.7. Install breaker plate to housing. Fit the breaker plate so that

the projection (A) fits into the groove (8).8. Tighten two breaker plate retaining screw.

9. Install signal rotor to rotor shaft. Fit the signal rotor so thatthe spring pin fits on the rotor shaft.

10. Install ignition to breaker plate and install two screws.11. Connect one end of lead wire to igniter attaching screw and

other end to breaker plate.

2 7 - 1 9


12. Adjust air gap between signal rotor and pick-up of igniter.

Air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 mm (0.03 in.)

13. Connect vacuum control link to breaker plate and tighten twovacuum controller screws.

14. Install rotor to rotor shaft.15. Install seal ring and distributor cap to housing and set the

retaining clips.

IGNITION COIL

Inspection

1. Using a circuit tester, measure resistance. An open or shortcircuited coil should be replaced.

[Standard value]Primary coil resistance . . . . . . . . . . . . . . . . . . . . . . . . . .1.2 n

Secondary coil resistance. . . . . . . . . . . . . . . . . . . . .13.7 K0External resistor resistance. . . . . . . . . . . . . . . . . . . . 1.35 a

2 7 - 2 0

CHARGING SYSTEM

CHARGING SYSTEM

GENERAL INFORMATION

The charging system includes a battery, an alternator with abuilt-in regulator, and the charging indicator light and wires. Thealternator has six built-in diodes (three positive and three

negative), each rectifying AC current to DC current. Therefore,DC current appears at alternator B terminal.In addition, the charging voltage of this alternator is regulatedby the battery voltage detection system. The main componentsof the alternator are the rotor, stator, rectifier, capacitor, brushes,bearings and V-ribbed belt pulley. The brush holder contains abuilt-in electronic voltage regulator.

TROUBLESHOOTING

Symptom Probable cause Remedy

Charging warningindicator does notlight with ignitionswitch ON andengine off.

Fuse blown.

Light burned out.

Wiring connection loose.

Electronic voltage regulator faulty.

Charging warningindicator does notgo out with enginerunning.(Battery requiresfrequent recharging).

Discharge battery.

Drive belt loose or worn.

Battery cables loose, corroded or worn.

Fuse blown.

Fusible link blown.

Electronic voltage regulator or alternatorfaulty.

Wiring faulty.

Drive belt loose or worn.

Wiring connection loose or open circuit.

Fusible link blown.

Poor grounding.

Electronic voltage regulator or alternatorfaulty.

Battery life.

Check fuses.

Replace light.

Tighten loose connections.

Replace voltage regulator.

Adjust tension or replace drive belt.

Repair or replace cables.

Check fuses.

Replace fusible link.

Test alternator.

Repair wiring.

Adjust tension or replace drive belt.

Tighten loose connection or repairwiring.

Replace fusible link.

Repair.

Test alternator.

Replace battery.

Overcharge Electronic voltage regulator faulty. Replace voltage regulator.

Voltage sensing wire faulty. Repair wire.

2 7 - 2 1

CHARGING SYSTEM

INSPECTION OF CHARGING SYSTEM

VOLTAGE DROP TEST OF ALTERNATOR OUTPUTWIRE

This test determines whether or not the wiring between thealternator B terminal and the battery (+) terminal is good bythe voltage drop method.

Preparation1. Turn the ignition switch to OFF.2. Disconnect the battery ground cable.3. Disconnect the alternator output lead from the alternator B

terminal.4. Connect a DC ammeter (0 to 100A) in series to the B

terminal and disconnected the output lead. Connect the (+)lead of the ammeter to the B terminal and the. (-) leadto the disconnected output wire.

NOTEUse a clamp type ammeter that can measure currentwithout disconnecting the harness. The reason is thatwhen checking a vehicle that has a low output current dueto poor connection of the alternator B terminal, such apoor connection is corrected as the B terminal isloosened and a test ammeter is connected in its place. Asa result, causes for the trouble may not be determined.

5. Connect a digital voltmeter between the alternator Bterminal and battery (+) terminal. Connect the (+) lead wireof the voltmeter to the B terminal and the (-) lead wireto the battery (+) terminal.

6. Connect the battery ground cable.7. Leave the hood open.

Test1. Start the engine.2. Turn on the headlamps and adjust the engine speed so that

the ammeter reads 20A and read the voltmeter under thiscondition.

Result1. It is okay if the voltmeter indicates the standard value.

Standard value: 0.2V max.

2. If the voltmeter indicates a value that is larger than thestandard value, poor wiring is suspected. In this case checkthe wiring from the alternator B terminal to the fusible linkto the battery (+) terminal. Check for loose connections, colorchange due to an overheated harness, etc. Correct thembefore testing again.

2 7 - 2 2

CHARGING SYSTEM

3. Upon completion of the test, set the engine speed at idle.Turn off the head lamps and the ignition switch.

4. Disconnect the battery ground cable.5. Disconnect the ammeter and voltmeter that have been

connected for testing.6. Connect the alternator output wire to the alternator B

terminal.7. Connect the battery ground cable.

OUTPUT CURRENT TEST

This test judges whether or not the alternator gives an outputcurrent that is equivalent to the nominal output.

Preparation

1. Prior to the test, check the following items and correct asnecessary.1) Check the battery installed in the vehicle to ensure that

it is in good condition*. The battery checking method isdescribed in BATTERY.

NOTE*The battery that is used to test the output current

should be one that has been partially discharged. Witha fully charged battery, the test may not be conductedcorrectly due to an insufficient load.

2) Check the tension of the alternator drive belt. The belttension check method is described in the sectionCOOLING.

2.3.4.

Turn off the ignition switch.Disconnect the battery ground cable.Disconnect the alternator output wire form the alternator Bterminal.

5. Connect a DC ammeter (0 to 100A) in series between theB terminal and the disconnected output wire. Be sure toconnect the (-) lead wire of the ammeter to thedisconnected output wire.

NOTETighten each connection securely, as a heavy current willflow. Do not rely on clips.

6.

7.

Connect a voltmeter (0 to 20V) between the B terminal andground. Connect the (+) lead wire to the alternator Bterminal and (-) lead wire to a good ground.Attach an engine tachometer and connect the battery groundcable.

8. Leave the engine hood open.

2 7 - 2 3

CHARGING SYSTEM

Test

1. Check to see that the voltmeter reads the same value as thebattery voltage.If the voltmeter reads 0V, and open circuit in the wirebetween the alternator B terminal and battery (-)terminal, a blown fusible link or poor grounding is suspected.

2. Start the engine and turn on the headlights.3. Set the headlights to high beam and the heater blower

switch to HIGH, quickly increase the engine speed to 2,500rpm and read the maximum output current value indicatedby the ammeter.

NOTEAfter the engine startup, the charging current quicklydrops. Therefore, the above operation must be donequickly to read the maximum current value correctly.

Result

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

Limit value:52.5 A min . . . . . . . . . . . . . . . . . . . . . . 75A alternator (MPI)45A min. . . . . . . . . . . . . . .. ....65A alternator (FBC)

NOTE1) The nominal output current value is shown on the

nameplate affixed to the alternator body.2) The output current value changes with the electrical

load and the temperature of the alternator itself.Therefore, the nominal output current may not beobtained. If such is the case, keep the headlights onto cause discharge of the battery, or use the lights ofanother vehicle to increase the electrical load.The nominal output current may not be obtained if thetemperature of the alternator itself or ambienttemperature is too high.In such a case, reduce the temperature before testingagain.

2. Upon completion of the output current test, lower the enginespeed 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


2 7 - 2 4

REGULATED VOLTAGE TEST

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

Preparation

1.

2.3.4.

5.

6.

7.

Prior to the test, check the following items and correct ifnecessary.1) Check the battery installed on the vehicle to see that it

is fully charged. For battery checking method, seeBATTERY.

2) Check the alternator drive belt tension. For belt tensioncheck, see section, COOLING.

Turn ignition switch to OFF.Disconnect the battery ground cable.Connect a digital voltmeter between the S(L) terminal ofthe alternator and ground. Connect the (+) lead of thevoltmeter to the S(L) terminal of the alternator. Connectthe (-) lead to good ground or the battery (-) terminal.Disconnect the alternator output wire from the alternator Bterminal.

Connect a DC ammeter (0 to 100A) in series between theB terminal and the disconnected output wire. Connect the(-) lead wire of the ammeter to the disconnected outputwire.Attach the engine tachometer and connect the batteryground cable.

Test

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

Voltage: Battery voltage

If it reads 0V, there is an open circuit in the wire betweenthe alternator S(L) terminal and the battery (+), or thefusible link is blown.

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 10Aor less.

2 7 - 2 5

CHARGING SYSTEM

Result

1. If the voltmeter reading. agrees with the value listed in theRegulating Voltage Table below, the voltage regulator isfunctioning correctly. If the reading is other than thestandard value, the voltage regulator or the alternator isfaulty.

Regulating Voltage Table

Voltage regulator ambient Regulating voltage V

temperature C (F) 75A alternator 65A alternator

-20 (-4) 14.2-15.4 14.4-15.620 (68) 13.9-14.9 14.2-15.260 (140) 13.4-14.6 13.8-15.180 (176) 13.1-14.5 13.6-15.0

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


2 7 - 2 6

CHARGING SYSTEM

ALTERNATOR

REMOVAL AND INSTALLATION

TORQUE : Nm (kg.cm, lb.ft)

1. Disconnect the negative terminal from the battery.2. Loosen the belt tension and remove the belt.3. Raise the vehicle.

4. Remove the mud guard-LH.5. Disconnect the alternator B+ terminal wire.6. Remove the alternator assembly.7. Installation is the reverse order of removal.

2 7 - 2 7

CHARGING SYSTEM

COMPONENTS (75A)

1. Pulley2. Seal3. Rotor assembly4. Rear bearing5. Bearing retainer6. Front bearing7. Front bracket8. Stator9. Plate

10. Voltage regulator and brush holder11. Brush12. Brush spring13. Slinger14. Rectifier15. Rear bracket

2 7 - 2 8

CHARGING SYSTEM

COMPONENTS (65A)

1. Pulley2. Seal3. Rotor assembly4. Rear bearing5. Bearing retainer6. Front bearing7. Front bracket8. Stator

9. Terminal10. Plate11. Brush12. Brush spring13. Slinger14. Rectifier assembly15. Rear bracket

2 7 - 2 9

DISASSEMBLY

1. Remove the three through bolts.2. Insert a flat screwdriver between the front bracket and stator

core, and pry downward.

CAUTION1) Do not insert the screwdriver too deeply, as there is

a danger of damaging the stator coil.

2) The rear cover may be hard to remove because a ringis used to lock the outer race of the rear bearing. Tofacilitate removal of rear cover, heat just the bearingbox section with a 200-watt soldering iron.Do not use a heat gun, as it may damage the diodeassembly.

3. Secure the rotor in a vise with the pulley side up.

CAUTIONBe careful that the vise jaws do not damage the rotor.

4. Remove the pulley nut, then remove the spring washer, thenthe pulley, and then the spacer.

5. Remove the front bracket and two seals.6. Remove the rotor from the vise.7. Remove the brush holder screws, the rectifier screws, and

the nut from the B terminal.8. Remove the stator assembly from the rear bracket.9. Detach the slinger from the brush holder.10. When the stator is to be removed, unsolder the three stator

leads to the main diodes on the rectifier.

CAUTION1) When soldering or unsoldering, use care to make sure

that heat of soldering iron is not transmitted to thediodes for a long period.

2) Use care that excessive force is not exerted on theleads of the diodes.

11. When separating the rectifier from the brush holder,unsolder the two plates soldered to the rectifier.

2 7 - 3 0

CHARGING SYSTEM

INSPECTION

Rotor

1. Check the rotor coil for continuity. Check to make sure thatthere is continuity between the slip rings.If resistance is extremely low, it means that there is a short.If there is no continuity or if there is a short circuit, replacethe rotor assembly.

Resistance value: Approx. 3.1 fl

2. Check the rotor coil for ground. Check to make sure that thereis no continuity between slip the ring and the core.If there is continuity, replace rotor assembly.

Stator

1. Make a continuity check on the stator coil. Check to makesure that there is continuity between the coil leads.If there is no continuity, replace stator assembly.

2. Check the coil for grounding. Check to make sure that thereis no continuity between the coil and the core.If there is continuity, replace the stator assembly.

2 7 - 3 1

CHARGING SYSTEM

Rectifiers

Positive rectifier test

Check for continuity between the positive rectifier and stator coillead connection terminal with an ohmmeter. The ohmmetershould read continuity in only one direction. If there is continuityin both directions, a diode is shorted.Replace the rectifier assembly.

Negative rectifier test

Check for continuity between the negative rectifier and the statorcoil lead connection terminal. The ohmmeter should readcontinuity in only one direction. If there is continuity in bothdirections, a diode is shorted, and the rectifier assembly mustbe replaced.

Diode trio test

Check the three diodes for continuity by connecting an ohmmeterto both ends of each diode. Each diode should have continuityin only one direction.If continuity is present in both directions, a diode is defective andthe heatsink assembly must be replaced.

BRUSH REPLACEMENT

Replace the brushes if they are worn to limit line.

2 7 - 3 2

CHARGING SYSTEM

1. Unsolder the pigtail and remove the old brush and spring.

2. Install the brush spring and a new brush in the brush holder,3. Insert the brush to where there is a space 2 to 3 mm (0.079

to 0.118 in.) between the limit line and the end of the brushholder.

4. Solder the pigtail to the brush holder.

REASSEMBLY

Perform reassembly in the reverse procedure of disassembly. Payattention to the following:Before the rotor is attached to the rear bracket, insert a wirethrough the small hole in the rear bracket to lock the brush. Afterthe rotor has been installed, the wire can be removed.

INSTALLATION

1.

2.

3.

Position the alternator and insert the support bolt. (Do notattach the nut.)Push the alternator forward and determine how manyspacers (thickness: 0.198 mm) should be inserted betweenthe front leg of the alternator and the front case (space Ain the illustration). (There should be enough spacers so thatthey do not fall out when you let go of them.)Insert the spacers (space A in the illustration), attach the nut,and complete the installation.

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BATTERY (MAINTENANCE FREE TYPE)

1. The maintenance-free battery is, as the name implies, totallymaintenance free and has no removable battery cell caps.

2. Water never needs to be added to the maintenance-freebattery.

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

4. The battery contains a visual inspection indicator.

BATTERY VISUAL INSPECTION (1)

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CHARGING SYSTEM

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CHARGING SYSTEM

SPECIFIC GRAVITY CHECK CHART

The specific gravity of battery electrolyte changes withtemperature. Heat thins the solution and lowers the specificgravity. Cold thickens the solution and raises the specific gravity.

A fully charged battery should have a specific gravity between1.260 and 1.280, with the electrolyte temperature at 80F, thespecific gravity reading must be corrected by adding 4 points(.004) for each 10o above 80F or subtracting 4 points for every10o below 80F.

For example : The hydrometer reading is 1.280, and theelectrolyte temperature reading is 10oF. By using the chart, thespecific gravity must be lowered by 0.028 points. The truecorrected reading is 1.252.

1.280 -0.028 = 1.252

You should never take a hydrometer reading immediately afterwater has been added. The water and electrolyte must be mixedby either charging for a few minutes at a low rate or by allowingthe battery to sit for an hour.

CAUTIONA difference of 50 points (0.050) or more between one ormore cells indicates a defective battery. It should be replaced.

BATTERY CHARGE RATE

Charge methodSpecific gravity

Below 1.100

1.100 - 1.130

1.130 - 1.160

1.160 - 1.190

1.190 - 1.220

Above 1.220

Slow charge (5A) Fast charge (20A)

14 hours 4 hours

12 hours 3 hours

10 hours 2.5 hours

8 hours 2.0 hours

6 hours 1.5 hours

4 hours 1.0 hours

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BATTERY VISUAL INSPECTION (2)

1. Make sure ignition switch is in the Off position and allaccessories are Off.

2. Disconnect the battery cables (negative first)3. Remove the battery from the vehicle.

CAUTIONCare should be taken in the event the battery case iscracked or leaking, to protect your skin from theelectrolyte. A suitable pair of rubber gloves (not householdtype) should be worn when removing the battery.

4. Inspect the battery carrier for damage caused by the loss ofacid from the battery. If acid damage is present, it will benecessary to clean the area with a solution of clean warm,water and baking soda. Scrub the area with a stiff bristlebrush and wipe off with a cloth moistened with baking sodaand water.

5. Clean the top of the battery with the same solution asdescribed in Step (4).

6. Inspect the battery case, and cover, for cracks. If cracks arepresent, the battery must be replaced.

7. Clean the battery posts with a suitable battery post cleaner.8. Clean the inside surface of the terminal clamps with a

suitable battery terminal cleaning tool. Replace damaged orfrayed cables and broken terminal clamps.

9. Install the battery in the vehicle.10. Connect the cable terminals to the battery post, making sure

the top of the terminals are flush with the top of the post.11. Tighten the terminal nut securely.12. Coat all connections with light mineral grease after

tightening.

CAUTIONWhen batteries are being charged, an explosive gas formsbeneath the cover of each cell. Do not smoke nearbatteries being charged or which have recently beencharged.Do not break live circuits at the terminals of the batteriesbeing charged. A spark will occur where the circuit isbroken.Keep all open flames away from the battery.

STARTING SYSTEM

GENERAL INFORMATION

The starting system includes the battery, starter motor, solenoidswitch, ignition switch, inhibitor switch (A/T only), connectionwires, and the battery cables.When the ignition key is turned to the start position, currentflows and energizes the coil of the starter motors solenoid.When this happens, the solenoid plunger and the clutch shiftlever 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 thestarter armature when the engine starts, the clutch pinion gearoverruns.

TROUBLESHOOTING

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STARTING SYSTEM

STARTER

REMOVAL AND INSTALLATION

1. Disconnect the battery ground cable.2. Remove the E.G.R. valve assembly (U.S.A. Cal. only).3. Remove the speed meter cable.4. Disconnect the starter motor connector and terminal.5. Remove the starter motor assembly.6. Installation is the reverse order of removal.

E.G.R. valve mounting bolt tightening torque:10-15 Nm (100-150 kg.cm, 7-11 lb . f t )

STARTING SYSTEM

STARTING SYSTEM

INSPECTION (After removal)

Pinion Gap Adjustment

1. Disconnect the wire from the M-terminal.2. Connect a 12V battery between the S-terminal and the

M-terminal.3. Set the switch to ON, and the the pinion will move out.

CAUTIONThis test must be performed quickly (in less than 10seconds) to prevent coil from burning.

4. Check the pinion to stopper clearance (pinion gap) with afeeler gauge.If the pinion gap is out of specification, adjust by adding orremoving washers between the solenoid and the frontbracket.

Pinion Gap: 0.5-2.0 mm (0.0197-0.079 in)

Solenoid Pull-in Test

1. Disconnect the connector from the M-terminal.2. Connect a 12V battery between the S-terminal and

M-terminal.

CAUTIONThis test must be performed quickly (in less than 10seconds) to prevent the coil from burning.

3. If the pinion moves out, the pull-in coil is good. If it doesnt,replace the solenoid.

Solenoid Hold-in Test

1. Disconnect the connector from the M-terminal.2. Connect a 12V battery between the S-terminal and the body.


3. If the pinion remains out, everything is in order. If the pinionmoves in, the hold-in circuit is open. Replace the magneticswitch.

STARTING SYSTEM

Solenoid Return Test

1. Disconnect the connector from the M-terminal.2. Connect a 12V battery between the M-terminal and the

body.


3. Pull out the pinion and then release it. If the pinion returnsquickly to its original position, everything is in order. If itdoesnt replace the solenoid.

Performance Test (No-load)

1. Make the no-load circuit test as shown.2. After adjusting the rheostat until the battery voltage shown

on the voltmeter reads 11.5 volts, confirm that the maximumamperage draw is within the specifications and that thestarter motor turns smoothly and freely.Current : 60A or less

DISASSEMBLY

To remove the overrunning clutch from the armature shaft, thestop ring must be removed.Move the stop ring toward the pinion and remove the snap ring,now the stop ring can be removed from shaft.

INSPECTION (After disassembly)

Armature Coil Ground Test

Using an ohmmeter, check to make sure that there is nocontinuity between the commutator and the armature coil core.If there is continuity, replace armature assembly.

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STARTING SYSTEM

Armature Coil Short-Circuit Test

Test the armature coil in a growler. Replace the coil if there aresigns of a short. If the blade attached to the core vibrates whilethe core is turned, the armature is shorted.

Armature Coil Open-Circuit Test

Using an ohmmeter, check for continuity between the

commutator segments. If there is no continuity, the commutatorsegments are open. Replace the armature assembly.

Field Coil Open-Circuit Test

Using an ohmmeter, check the field coil for continuity. If thereis no continuity, the field coil is open. Replace the field coilassembly.

Field Coil Ground Test

With the field coil mounted to the yoke, check for continuitybetween the field coil and the yoke using an ohmmeter. If thereis continuity, replace the field coil.

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STARTING SYSTEM

Brush

A brush worn down to the wear limit line should be replaced.

Brush Holder

Check for continuity between the (+) side brush holder and brushholder base. If there is continuity, replace the holder assembly.

Overrunning Clutch

Inspect the pinion and spline teeth for wear or damage. Replaceif damaged. Also inspect the flywheel ring gear for damage.Rotate the pinion. It should turn freely in a clockwise direction,and lock when turned counterclockwise.

BRUSH REPLACEMENT

1. Remove the worn brush while taking care not to damage thepigtail.

2. Sand the pigtail end with sandpaper to ensure a goodsoldering, joint.

3. Solder the end of the pigtail.

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STARTING SYSTEM

REAR BRACKET BUSHING REPLACEMENT

1. Before the bushing is removed, measure and record thepressed-in position (depth) of the bushing.

2. The bushing can be removed by the use of a puller as shownin the illustration.

3. Press a new bushing in, up to the position recorded underStep. 1.

REASSEMBLY

1. Install the overrunning clutch to the front end of thearmature shaft.

2. Install the stop ring and the snap ring from the front endof the armature shaft. Push the stop ring all the way towardthe snap ring.

3. When the lever is mounted to the front bracket, pay attentionto its direction. If it is mounted in a reverse direction, thepinion will remain in an outward position and fail to operateproperly.

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STARTING SYSTEM

INSPECTION OF CLUTCH START SYSTEM(IGNITION LOCK SYSTEM)

Check clutch pedal

Check that pedal height, pedal freeplay and clutch pedal clevispin play are correct. (Refer to clutch group)

Check starter relay

Remove the starter relay and check continuity between theterminals. If the continuity is not as specified, replace the relay.

Check ignition lock switch

1. Check for continuity between terminals when the switch isON (pushed).

2. Check for no continuity between terminals when the switchis OFF (free).

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Date post:	21-Nov-2015
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Hyundai Excel X2 1989-1998 Engine Electrical System

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