Generators & Regulators: Diagnosis Kia Sedona I

TROUBLE SHOOTING

Note. See CHARGING SYSTEM - GENERAL TROUBLE SHOOTING article in GENERAL INFORMATION.

ON-VEHICLE TESTING

Note. When battery is disconnected, vehicle computer may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See appropriate COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

BATTERY LOAD TEST

1. When discharging the battery during 15 seconds at half currency of Cold Cranking Ampere (CCA), the voltage of the battery should be as shown below. REGULATING VOLTAGE Ambient Temperature Voltage Above 20 °C 9.6V ~ 18 °C 9.5V ~ 10 °C 9.4V ~ 4 °C 9.3V ~ -1 °C 9.1V ~ -7 °C 8.9V ~ -12°C 8.7V
2. When the voltage is not within specification, repeat the load test again, and re-charge battery.
3. If the battery is left alone for 2 hours after re-charging and its output is over 12.5V, and the voltage after a load test is over the standard value, the battery can be used.

Scheme 3

BATTERY VISUAL INSPECTION (2)

Scheme 4

Scheme 5

1. Make sure the ignition switch and all accessories are in the OFF position.
2. Disconnect the battery cables (negative first) (Scheme 4)
3. Remove the battery from the vehicle.
4. Inspect the battery carrier 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 in next step.
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 the 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.

GENERATOR OUTPUT LINE VOLTAGE DROP TEST

Note. Ensure battery is fully charged and load tested before testing. Verify drive belt tension is correct, electrical wiring, connectors and generator installation connections are in good condition and battery terminals are clean and tight. Inspect all fuses in both the engine compartment fuse box and the passenger compartment fuse box.

Note. This test determines condition of wiring from generator "B" terminal to battery positive terminal, including fusible link.

1. Ensure ignition is off. Disconnect negative battery cable. Disconnect generator output wire from generator "B" terminal. see scheme 2 Connect positive lead of ammeter with a range of 0-100 amps, to the "B" terminal and negative lead to disconnected output wire.
2. Connect positive lead of DVOM to "B" terminal and negative lead to battery positive cable. Reconnect negative battery cable. Connect a tachometer or scan tool to vehicle. Leave hood open. Start engine. With engine running at about 2500 RPM, turn headlights on and off to adjust generator load on ammeter slightly above 30 amps.
3. Decrease engine speed gradually until the value displayed on ammeter is 30 amps. Record reading on DVOM. Maximum voltage should be 0.3 volt. If voltage reading on DVOM is greater than maximum voltage, a malfunction in the generator output wire may exist. Check wiring between generator "B" terminal and positive battery terminal, including fusible link. If a terminal is not sufficiently tight or if harness has become discolored due to overheating, repair wiring, then retest.
4. After test is complete, run engine at idle. Turn off all lights and turn ignition off. Disconnect tachometer or scan tool. Disconnect negative battery cable. Remove ammeter and DVOM. Connect generator output wire to generator "B" terminal. Connect negative battery cable.

OUTPUT CURRENT TEST

Note. Ensure battery is fully charged and load tested before testing. Verify drive belt tension is correct, electrical wiring, connectors and generator installation connections are in good condition and battery terminals are clean and tight. Inspect all fuses in both the engine compartment fuse box and the passenger compartment fuse box.

Note. For the following test, battery should be slightly discharged. Load needed by a fully charged battery is insufficient for an accurate test. Ensure generator is cool prior to performing the following test.

1. Ensure ignition is off. Disconnect negative battery cable (Scheme 4) Disconnect generator output wire from generator "B" terminal. Connect positive lead of ammeter with a range of 0-100 amps, to the "B" terminal and negative lead to disconnected output wire.
2. Connect positive lead of voltmeter with a range of 0-20 volts, to the "B" terminal and ground negative lead. Connect negative battery cable. Connect a tachometer or scan tool to vehicle. Leave hood open. Ensure reading on voltmeter is equal to battery voltage.
3. Start engine and turn headlights on quickly. Switch headlights to high beam, turn heater blower switch to high, increase engine speed to about 2500 RPM, and read maximum current output displayed on ammeter. Current limit should be 70 percent of nominal (rated) output. For rated output, see «SPECIFICATIONS»(ref-153347-S02484564122003040200000).
4. Reading on ammeter should be above limit value. If reading is below limit value, and generator output wire is okay, remove and inspect generator.
5. After test is complete, run engine at idle. Turn ignition off. Disconnect tachometer or scan tool. Disconnect negative battery cable. Remove ammeter and voltmeter. Connect generator output wire to generator "B" terminal. Connect negative battery cable.

REGULATED VOLTAGE TEST

Note. Ensure battery is fully charged and load tested before testing. Verify drive belt tension is correct, electrical wiring, connectors and generator installation connections are in good condition and battery terminals are clean and tight. Inspect all fuses in both the engine compartment fuse box and the passenger compartment fuse box.

1. Ensure ignition is off. Disconnect negative battery cable (Scheme 4) Connect positive lead of voltmeter to the "S" terminal and ground negative lead. see scheme 2 Disconnect generator output wire from generator "B" terminal.
2. Connect positive lead of ammeter with a range of 0-100 amps, to the "B" terminal and negative lead to disconnected output wire. Reconnect negative battery cable. Connect a tachometer or scan tool to vehicle. Ensure reading on voltmeter is equal to battery voltage.
3. Ensure all lights and accessories are off. Start engine and increase engine speed to about 2500 RPM. Read voltmeter when current output by the generator becomes 10 amps or less. If voltage reading conforms to value in «VOLTAGE REGULATION»(ref-153347-S09301428102004050500000) table, voltage regulator is operating normal. If voltage reading does not confirm within standard value, a malfunction of the voltage regulator or generator exists. Repair or replace as necessary. VOLTAGE REGULATION Voltage Regulator Ambient Temperature °F (°C) Regulating Voltage (VE) -4 (-20) 14.2-15.4 68 (20) 13.9-14.9 140 (60) 13.4-14.6 176 (80) 13.1-14.5
4. Reduce engine speed to idle, then turn ignition off. Disconnect negative battery cable. Remove tachometer, scan tool, DVOM and ammeter. Connect generator output wire to generator "B" terminal. Connect negative battery cable.

DIODE TEST

Check the 3 diodes for continuity by connecting an ohmmeter to both ends of each diode. (Scheme 6) Each diode should have continuity in one direction only. If continuity is not as specified, replace complete assembly.

Scheme 6