Charging System - 2.0L: Other Kia Soul I рестайлинг

Alternator Management System (AMS)

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 lowers the charging rate when accelerating. Lowering the charging rate will allow more engine power for accelerating.

The system increases the charging rate when decelerating. The system uses the unused power of the decelerating engine and increases the charging rate.

Check Battery Voltage

1. If 20 minutes have not passed since the engine was stopped, turn the ignition switch ON and turn on the electrical system (headlamp, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge.
2. Turn the ignition switch OFF and turn off the electrical systems.
3. Measure the battery voltage between the negative (-) and positive (+) terminals of the battery. Standard voltage: 12.5 ~ 12.9 V at 20°C (68°F) If the voltage is less than specification, charge the battery.

Check The Battery Terminals And Fuses

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

Belt tension measurement

Measure the belt tension using a mechanical tension gauge or a sonic tension meter.

Belt tension

New belt

637.4 ~ 735.5 N (65 ~ 75 kgf, 143.3 ~ 165.3 lbf)

Used belt

441.3 ~ 539.4 N (45 ~ 55 kgf, 99.2 ~ 121.3 lbf)

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1. While pressing the handle (A) of the gauge, insert the belt (B) between pulley and pulley (or idler) into the gap between spindle (C) and hook (D).
2. After releasing the handle (A), read a value on the dial pointed by the indicator (B).

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1. Input the belt specifications into the tension meter (A). Belt type Location of measurement Input data M (Mass, g/m.rib) W (Width, rib) S (Span, mm) With A/C Crankshaft pulley to A/C compressor pulley 14.7 006.0 187 Without A/C Crankshaft pulley to alternator pulley 14.7 006.0 Actual measurement value NOTE: Measurement of S (Span): Caculate average value after measuring the distance 3~4 times.
2. Locate the micro phone (B) close to the center of belt span (A) and bounce the belt by finger 2~3 times. Read a value on the display. [With A/C] [Without A/C]

If adjustment is necessary

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1. Loosen the mounting bolts (A).
2. Tighten the adjusting bolt (B) counterclockwise in loose tension; fasten the bolt clockwise in high tension.
3. Recheck tension of the belt.
4. After adjusting tension, tighten the mounting bolts. Tightening torque M10 bolt: 29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 lb-ft) M8 bolt: 21.6 ~ 32.4 N.m (2.2 ~ 3.3 kgf.m, 15.9 ~ 23.9 lb-ft)

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. Check that the light is lit. If the light does not go off as specified, troubleshoot the discharge light circuit.

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. 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 voltage rate NOTE: The maximum output current value is shown on the nameplate affixed to the alternator body. 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 maximum 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. 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. REGULATING VOLTAGE TABLE (INTERNAL MODE) Voltage regulator ambient temperature °C (°F) Regulating voltage (V) -30 (-22) 13.4 ~ 14.7 25 (77) 13.5 ~ 14.4 135 (275) 12.9 ~ 14.3
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.

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1. Disconnect the battery negative terminal. Tightening torque: 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 3.0 ~ 4.4 lb-ft)
2. Remove the drive belt. Loosen the alternator mounting bolts (A). Loosen the tension by turning the tension adjusting bolt (B) counterclockwise. Remove the drive belt (C).
3. Disconnect the alternator connector (A) and the cable (B) from alternator "B" terminal. Tightening torque: 9.8 ~ 14.7 N.m (1.0 ~ 1.5 kgf.m, 7.2 ~ 10.8 lb-ft)
4. Pull out the through bolt and then remove the alternator (A). Tightening torque M10 bolt: 29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 lb-ft) M8 bolt: 21.6 ~ 32.4 N.m (2.2 ~ 3.3 kgf.m, 15.9 ~ 23.9 lb-ft)
5. Installation is the reverse order of removal.

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1. Loosen the nuts (B) and then remove the cover (A).
2. Loosen the mounting bolts (A) and remove the regulator assembly (B).
3. Remove the slip ring guide (A).
4. Using the SST (09373-27000), remove the pulley (A).
5. Loosen the 4 bolts (A) and then remove the rear housing (B).
6. Disconnect the rotor (A) and the housing (B).
7. Reassembly is the reverse order of disassembly.

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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.

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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.

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Note. In case of IGN 2 with connecting battery, input the signal 'ISG Start' then BY PASS RELAY will be ON, after boosting voltage (12±0.6V) of low battery, if the battery voltage is over 12±0.5V then BY PASS RELAY will be OFF. In the ISG mode, if the power of an audio system turns OFF by drawdown while "Auto Starting" or "Idle Starting" function operates, replace the DC/DC converter.

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1. Disconnect the battery negative terminal. Tightening torque: 4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb-ft)
2. Remove the glove box housing. (Refer to " «CRASH PAD»(ref-537227-S36224571332013032200000) ")
3. Disconnect the DC/DC converter connector (A) and then remove the DC/DC converter (B).
4. Installation is reverse order of removal. NOTE: After disconnecting then reconnecting the battery negative cable, the ISG function dose not operates until the system is stabilized, about 4 hours.

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1. Disconnect the battery negative terminal. Tightening torque: 4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb-ft)
2. Remove the rear seat. (Refer to " «REAR SEAT»(ref-537223-S26496345532013032200000) ")
3. Remove the RH luggage side trim. (Refer to " «INTERIOR TRIM»(ref-537227-S30621835772013032200000) ")
4. Disconnect the DC/DC converter connector (A) and then remove the DC/DC converter (B).
5. Installation is reverse order of removal. NOTE: After disconnecting then reconnecting the battery negative cable, the ISG function dose not operates until the system is stabilized, about 4 hours.

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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 " «GENERAL INFORMATION»(ref-537211-S33830081852013032200000) ")

[ISG Type]

AGM battery is used for especially heavy load on the vehicle network depending on equipment and requirements. AGM stands for Absorbent Glass Material Battery; that is absorbent glass fibre fleece. AGM batteries are fitted in models with electrical loads/consumers which have a high energy demand.

The constantly increasing energy demand of modern vehicle electrical systems calls for ever more powerful battery solutions.

The power consumption is considerable even when the vehicle is parked.

The somewhat higher price compared with a battery of similar size is fully balanced by the following benefits

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1. Significantly longer service life
2. Increased starting reliability at low temperatures
3. 100 % freedom from maintenance
4. Low risk in event of an accident (reduced risk to the environment)

Check the battery condition

The battery condition cannot be determined solely on the basis of the battery charge state. If there is a suspicion of a damaged battery, check the battery condition whit battery tester and investigate the cause by means of the test module. With a low battery charge state, recharge the battery.

Recharging the AGM battery

The battery may be charged using the battery chargers at a constant charge voltage of 14.8V.

If possible, the battery temperature during charging should be between 20°C and 30°C.

Only chargers with voltage clamping (IU or WU curve) may be used or chargers with IUoU curve which have a trickle.

IU or WU charging technique

Optimized charging voltage for IU or WU: 14.7V (at 20°C ~ 30°C) about 24 hours

Min. charging voltage at 20°C: 14.4V

Max. charging voltage at 20°C: 14.8V

10% of capacity is recommended as charging current (e.g. 60Ah: 10 = 6, 0A charging current).

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1. Disconnect the battery terminals (A). The negative terminal first. Tightening torque (+) terminal: 7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft) (-) terminal: 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 3.0 ~ 4.4 lb-ft)
2. Remove the air cleaner assembly. Remove the air duct (B). Disconnect the breather hose (C). Disconnect the air intake hose and then remove the air cleaner assembly (D). Tightening torque Hose clamp bolt: 2.9 ~ 4.9 N.m (0.3 ~ 0.5 kgf.m, 2.2 ~ 3.6 lb-ft) Air cleaner assembly bolts: 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft) NOTE: Install the air intake hose while the center of the mark of hose must be in line with the throttle body rib.
3. Disconnect the ECM connectors (A).
4. Remove the ECM & bracket (A). Tightening torque Bolts: 19.6 ~ 29.4N.m (2.0 ~ 3.0kgf.m, 14.5 ~ 21.7lb-ft) Nut: 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
5. Remove the battery insulation pad (A).
6. Remove the battery (B).
7. Remove the battery tray (A). Tightening torque: 8.8 ~ 13.7N.m (0.9 ~ 1.4kgf.m, 6.5 ~ 10.1lb-ft)
8. Installation is the reverse order of removal. CAUTION: When installing the battery, fix the ECM & bracket on the tray correctly. CAUTION: ISG (Idle stop & go) system equipped vehicle always use the AGM battery only. If flooded battery has installed, this can potentially lead to engine electrical trouble or ISG system error. Replace same capacity of the AGM battery. NOTE: Ensure the AGM battery is placed correctly on the battery tray. In all cases, an AGM battery must be installed and the battery sensor calibrated for the ISG system to function. After the battery has been changed or disconnected, the battery sensor must be recalibrated. After connecting the battery, start the engine at least once. Then park the car for at least 4 hours with the ignition off in the ignition switch OFF door closed, hood switch off state. After the 4 hours, the engine should be started two times. At this time the battery sensor will be recalibrated. (Refer to " «BATTERY SENSOR RECALIBRATION PROCEDURE»(ref-537292-S11118204202013032200000) " in FL group) But first 25 times, the ISG function can operates regardless of ISG system stability for ISG function operating check. WARNING: Do not open the AGM battery. The AGM battery must not be opened under any circumstances as the introduction of oxygen from the air will cause the battery to lose its chemical equilibrium and rendered non-operational.

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1. Turn all the 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. Reconnect the suspected parasitic current draw circuit fuse only and search for suspected unit by removing a component connected with the circuit one by one until the parasitic draw drops below limit value. Limit value (after 10~20 min.): Below 50 mA

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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.