Ignition System
| Items | Specification | |
|---|---|---|
| Ignition coil | Primary resistance | 0.75 ± 15% (ohms) |
| Secondary resistance | ||
| Spark plugs (Unleaded) | NGK | BKR5ES-11 |
| CHAMPION | RC10YC4 | |
| Gap | 1.0 ~ 1.1 mm (0.0394 ~ 0.0433 in.) | |
IGNITION SYSTEM SPECIFICATIONS
Starting System
| Items | Specification | ||
|---|---|---|---|
| Starter | Rated voltage | 12 V, 0.9 KW | |
| No. of pinion teeth | 8 | ||
| No-load characteristics | Voltage | 11.5 V | |
| Ampere | 60A, MAX | ||
| Speed | 5000 RPM, MIN | ||
| Commutator diameter | Standard | 33 mm | |
| Under cut depth | Standard | 0.4 ~ 1.0 mm (0.0157 ~ 0.0394 in.) | |
| Limit | 0.2 mm (0.0079 in.) | ||
STARTING SYSTEM SPECIFICATIONS
Charging System
| Items | Specification | |
|---|---|---|
| Alternator | Type | I.C. regulator built-in |
| Rate voltage | 13.5 V, 90A | |
| Speed in use | 1,000 ~ 18,000 RPM | |
| Voltage regulator | Electronic built-in type | |
| Regulator setting voltage | 14.4 ± 0.1 V | |
| Temperature compensation | 3.5 ± 2 mV/°C | |
| Battery | Type | 44-21GL |
| Cold cranking amperage [at -18 °C (-0.4 °F)] | 500 A | |
| Reserve capacity | 85 min | |
| Specific gravity [at 20 °C (68 °F)] | 1.280 ± 0.01 | |
CHARGING SYSTEM SPECIFICATIONS
Scheme 1
| Symptom | Suspect area | Remedy |
|---|---|---|
| Engine will not start or is hard to start (Cranks OK) | Ignition lock switch | Inspect ignition lock switch, or replace as required |
| Ignition coil | Inspect ignition coil, or replace as required | |
| Spark plugs | Inspect spark plugs, or replace as required | |
| Ignition wiring disconnected or broken | Repair wiring, or replace as required | |
| Rough idle or stalls | Ignition wiring | Repair wiring, or replace as required |
| Ignition coil | Inspect ignition coil, or replace as required | |
| Engine hesitates/poor acceleration | Spark plugs | Inspect spark plugs or replace as required |
| Ignition wiring | Repair wiring, or replace as required | |
| Poor mileage | Spark plugs | Inspect spark plugs or replace as required |
IGNITION SYSTEM TROUBLESHOOTING CHART
| Symptom | Suspect area | Remedy |
|---|---|---|
| Charging warning indicator does not light with ignition switch "ON" and engine off. | Fuse blown | Check fuses |
| Light burned out | Replace light | |
| Wiring connection loose | Tighten loose connection | |
| Electronic voltage regulator | Replace voltage regulator | |
| Charging warning indicator does not go out with engine running. (Battery requires frequent recharging) | Drive belt loose or worn | Adjust belt tension or replace belt |
| Battery cable loose, corroded or worn | Inspect cable connection, repair or replace cable | |
| Electronic voltage regulator or alternator | Replace voltage regulator or alternator | |
| Wiring | Repair or replace wiring | |
| Overcharge | Electronic voltage regulator | Replace voltage regulator |
| Voltage sensing wire | Repair or replace wiring | |
| Discharge | Drive belt loose or worn | Adjust belt tension or replace belt |
| Wiring connection loose or short circuit | Inspect wiring connection, repair or replace wiring | |
| Electronic voltage regulator or alternator | Replace voltage regulator or alternator | |
| Poor grounding | Inspect ground or repair | |
| Worn battery | Replace battery |
CHARGING SYSTEM TROUBLESHOOTING CHART
| Symptom | Suspect area | Remedy |
|---|---|---|
| Engine will not crank | Battery charge low | Charge or replace battery |
| Battery cables loose, corroded or worn out | Repair or replace cables | |
| Transaxle range switch (Vehicle with automatic transaxle only) | Refer to AUTOMATIC TRANSAXLE . | |
| Fuse blown | Replace fuse | |
| Starter motor faulty | Replace | |
| Ignition switch faulty | Replace | |
| Engine cranks slowly | Battery charge low | Charge or replace battery |
| Battery cables loose, corroded or worn out | Repair or replace cables | |
| Starter motor faulty | Replace | |
| Starter keeps running | Starter motor | Replace |
| Ignition switch | Replace | |
| Starter spins but engine will not crank | Short in wiring | Repair wiring |
| Pinion gear teeth broken or starter motor | Replace | |
| Ring gear teeth broken | Replace fly wheel or torque converter |
STARTING SYSTEM TROUBLESHOOTING CHART
The Micro 570 Analyzer
The Micro 570 Analyzer provides the ability to test the charging and starting systems, including the battery, starter and alternator.
| CAUTION | Because of the possibility of personal injury, always use extreme caution and appropriate eye protection when working with batteries. |
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Keypad
The Micro 570 button on the key pad provide the following functions
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- Connect the tester to the battery. Red clamp to battery positive (+) terminal. Black clamp to battery negative (-) terminal. CAUTION: Connect clamps securely. If "CHECK CONNECTION" message is displayed on the screen, reconnect clamps securely.
- 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.
- Select CCA and press the ENTER button. NOTE: CCA : Cold cranking amps, is an SAE specification for cranking batteries at -0.4 °F (-18 °C).
- 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. NOTE: The battery ratings (CCA) displayed on the tester must be identical to the ratings marked on battery label.
- The tester will conduct battery test.
- 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 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 CHARGE & RETEST Battery is not charged properly Charge and test the battery again. (Failure to charge the battery fully may read incorrect measurement value) 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. WARNING: Whenever filing a claim for battery, the print out of the battery test results must be attached. Starter Test Procedure
- After the battery test, press ENTER immediately for the starter test.
- Start the engine.
- 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 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. NOTE: 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
- Press ENTER to begin charging system test.
- The tester displays the actual voltage of alternator. Press ENTER to continue.
- Turn off all electrical load and rev engine for 5 seconds with pressing the accelerator pedal. (Follow the instructions on the screen)
- The message that engine RPM is detected will be displayed on the screen. Press ENTER to continue.
- If the engine RPM is not detected, press ENTER after revving engine.
- The tester will conduct charging system test during loads off.
- Turn on electrical loads (air conditioner, lamps, audio and etc.). Press ENTER to continue.
- The tester will conduct charging system test during loads on.
- Rev engine for 5 seconds with pressing the accelerator pedal. (Follow the instructions on the screen)
- The message that engine RPM is detected will be displayed on the screen. Press ENTER to continue.
- If the engine RPM is not detected, press ENTER after revving engine.
- Turn off electrical loads (air conditioner, lamps, audio and etc.). Turn the engine off.
- 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 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