Charging System - 2.0L: Other Kia Optima III

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.

On-Vehicle Inspection

Check The Battery Terminals And Fuses

1. Check that the battery terminals are not loose or corroded.
2. Check the fuses for continuity.

Check Discharge Warning Light Circuit

1. Warm up the engine and then turn it off.
2. Turn off all accessories.
3. Turn the ignition switch "ON". Check that the discharge warning light is lit.
4. Start the engine and Check that the light goes off. If the light does not go off as specified, troubleshoot the discharge light circuit.

Preparation

1. Turn the ignition switch to "OFF".
2. Disconnect the output wire from the alternator "B" terminal. Connect the (+) lead wire of ammeter to the "B" terminal of alternator and the (-) lead wire of ammeter to the output wire. Connect the (+) lead wire of voltmeter to the "B" terminal of alternator and the (-) lead wire of voltmeter to the (+) terminal of battery.

Scheme 36

Result

1. The voltmeter may indicate the standard value. Standard value: 0.2V max
2. If the value of the voltmeter is higher than expected (above 0.2V max.), poor wiring is suspected. In this case check the wiring from the alternator "B" terminal to the battery (+) terminal. Check for loose connections, color change due to an over-heated harness, etc. Correct them before testing again.
3. Upon completion of the test, set the engine speed at idle.

Turn off the headlamps, blower motor and the ignition switch.

1. Prior to the test, check the following items and correct as necessary. Check the battery installed in the vehicle to ensure that it is in good condition. The battery checking method is described in the "Battery" service information. The battery that is used to test the output current should be one that has been partially discharged. With a fully charged battery, the test may not be conducted correctly due to an insufficient load. Check the tension of the alternator drive belt. The belt tension check method is described in the "Inspect drive belt" service information.
2. Turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Disconnect the alternator output wire from the alternator "B" terminal.
5. Connect a DC ammeter (0 to 150A) in series between the "B" terminal and the disconnected output wire. Be sure to connect the (-) lead wire of the ammeter to the disconnected output wire. NOTE: Tighten each connection securely, as a heavy current will flow. Do not rely on clips.
6. Connect a voltmeter (0 to 20V) between the "B" terminal and ground. Connect the (+) lead wire to the alternator "B" terminal and (-) lead wire to a good ground.
7. Attach an engine tachometer and connect the battery ground cable.
8. Leave the engine hood open.

Scheme 37

1. The ammeter reading must be higher than the limit value. If it is lower but the alternator output wire is in good condition, remove the alternator from the vehicle and test it. Limit value : 60% of the rate voltage NOTE: The output current value changes with the electrical load and the temperature of the alternator itself. Due to temperature the maximum output current may not be obtained. If such is the case, keep the headlamps on to increase the electrical load. The nominal output current may not be obtained if the temperature of the alternator itself or ambient temperature is too high. In such a case, reduce the temperature before testing again.
2. Upon completion of the output current test, lower the engine speed to idle and turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Remove the ammeter and voltmeter and the engine tachometer.
5. Connect the alternator output wire to the alternator "B" terminal.
6. Connect the battery ground cable.

1. Prior to the test, check the following items and correct if necessary. Check that the battery installed on the vehicle is fully charged. The battery checking method is described in the "Battery" service information. Check the alternator drive belt tension. The belt tension check method is described in the "Inspect drive belt" service information.
2. Turn ignition switch to "OFF".
3. Disconnect the battery ground cable.
4. Connect a digital voltmeter between the "B" terminal of the alternator and ground. Connect the (+) lead of the voltmeter to the "B" terminal of the alternator. Connect the (-) lead to good ground or the battery (-) terminal.
5. Disconnect the alternator output wire from the alternator "B" terminal.
6. Connect a DC ammeter (0 to 150A) in series between the "B" terminal and the disconnected output wire. Connect the (-) lead wire of the ammeter to the disconnected output wire.
7. Attach the engine tachometer and connect the battery ground cable.

Scheme 38

1. If the voltmeter reading agrees with the value listed in the regulating voltage table below, the voltage regulator is functioning correctly. If the reading is other than the standard value, the voltage regulator or the alternator is faulty.
2. Upon completion of the test, reduce the engine speed to idle, and turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Remove the voltmeter and ammeter and the engine tachometer.
5. Connect the alternator output wire to the alternator "B" terminal.
6. Connect the battery ground cable.

Regulating Voltage Table (Internal mode)

REGULATING VOLTAGE CHART

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1. Disconnect the battery negative terminal first, then the positive terminal. Tightening torque: (+) terminal : 7.8 ~ 9.8 N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2 lb-ft) (-) terminal : 4.0 ~ 6.0 N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4 lb-ft)
2. Disconnect the A/C compressor switch connector (A) the alternator connector (B), and the cable from alternator "B" terminal (C).
3. Remove the drive belt (A) after turning the drive belt tensioner (B) counterclockwise.
4. Pull out the through bolt and then remove the alternator (A). Tightening torque: 49.0 ~ 63.7 N.m (5.0 ~ 6.5kgf.m, 36.2 ~ 47.0 lb-ft)
5. Installation is the reverse order of removal.

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1. Remove the alternator cover (A) using a screw driver after loosening the nuts (B).
2. Remove the slip ring guide (A) and then loosen the mounting bolts and disconnect the brush holder assembly (B).
3. Remove the pulley (A) using the SST (09373-27000) (B).
4. Loosen the 4 through bolts (A).
5. Disconnect the rotor (A) and cover (B).
6. Reassembly is the reverse order of disassembly.

Scheme 49

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.

Scheme 50

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.

Scheme 51

1. The maintenance-free battery is, as the name implies, totally maintenance free and has no removable battery cell caps.
2. Water never needs to be added to the maintenance-free battery.
3. The battery is completely sealed, except for small vent holes in the cover. NOTE: After disconnecting then reconnecting the battery negative cable, reset some parts that require the reset procedures. Refer to «BATTERY RESET»(ref-429542-S08550118682011101500000) .

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1. Disconnect the terminals from the battery. Tightening torque: (+) terminal (A) : 7.8 ~ 9.8 N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2 lb-ft) (-) terminal (B) : 4.0 ~ 6.0 N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4 lb-ft)
2. Remove the battery insulation pad (A).
3. Remove the battery mounting bracket (B) by loosening the mounting bolt and then remove the battery (C). Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7 lb-ft)
4. Remove the battery tray (A). Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7 lb-ft)
5. Installation is the reverse order of removal. CAUTION: When installing the battery, fix the mounting bracket on the tray correctly.

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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. Disconnect the hood switch connector. Close the trunk lid. Close the doors or remove the door switches.
3. Wait a few minutes until the vehicle's electrical systems go to sleep mode. NOTE: 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. CAUTION: 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, Connect a jump cable between the battery (-) terminal and the ground cable. Disconnect the ground cable from the battery (-) terminal. Connect an ammeter between the battery (-) terminal and the ground cable. 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. Check the parasitic current again, and search for suspected unit by removing a unit connected with the abnormal circuit one by one. Limit value (after 10~20 min.) : Below 50 mA

Scheme 58

1. Make sure 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. CAUTION: 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. CAUTION: 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.