Engine Electrical System

Engine Electrical System

General Information
 2009 > D 1.6 TCI-U >

TROUBLE SHOOTING
CHARGING SYSTEM

Symptom Suspect area Remedy

Charging warning Fuse blown Check fuses
indicator does not light Light burned out Replace light
with ignition switch "ON" Wiring connection loose Tighten loose connection
and engine off. Electronic voltage regulator Replace voltage regulator
Charging warning Drive belt loose or worn Adjust belt tension or replace belt
indicator does not go out Battery cable loose, corroded or worn Inspect cable connection, repair or replace
with engine running. Electronic voltage regulator or cable
(Battery requires frequent alternator Replace voltage regulator or alternator
recharging) 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 Inspect wiring connection, repair or replace
circuit wiring
Electronic voltage regulator or Replace voltage regulator or alternator
alternator Inspect ground or repair
Poor grounding Replace battery
Worn battery

STARTING SYSTEM

Symptom Suspect area Remedy

Engine will not crank Battery charge low Charge or replace battery
Battery cables loose, corroded or Repair or replace cables
worn out Refer to TR group-automatic transaxle
Transaxle range switch (Vehicle with
automatic transaxle only) Replace fuse
Fuse blown Replace
Starter motor faulty Replace
Ignition switch faulty
Engine cranks slowly Battery charge low Charge or replace battery
Battery cables loose, corroded or Repair or replace cables
worn out Replace
Starter motor faulty
Starter keeps running Starter motor Replace
Ignition switch Replace
Starter spins but engine Short in wiring Repair wiring
will not crank Pinion gear teeth broken or starter Replace
motor Replace fly wheel or torque converter
Ring gear teeth broken
 2009 > D 1.6 TCI-U >

SPECIFICATION
STARTING SYSTEM

Items Specification
Rated voltage 12 V, 1.7 kW
No. of pinion teeth 8
Voltage 11 V
No-load
Ampere 90A, MAX
characteristics
Starter Speed 2,600 rpm, MIN

Commutator Standard 29.4 mm (1.1575in.)

diameter Limit 28.8 mm (1.1339in.)
Standard 0.5 mm (0.0197in.)
Under cut depth
Limit 0.2 mm (0.0079in.)

CHARGING SYSTEM
Items Specification
Type Battery voltage sensing
Rate voltage 12 V, 120A
Speed in use 1,000 ~ 18,000 rpm
Alternator
Voltage regulator Electronic built-in type
Regulator setting voltage 14.55 ± 0.2 V
Temperature compensation -7 ± 3 mV / °C
Type MF 60AH
Cold cranking amperage [at
550 A
Battery -18°C(-0.4°F)]
Reserve capacity 92 min
Specific gravity [at 20°C(68°F)] 1.280 ± 0.01

•• COLD CRANKING AMPERAGE is the amperage a battery can deliver for 30 seconds and maintain a
terminal voltage of 7.2V or greater at a specified temperature.
•• RESERVE CAPACITY RATING is amount of time a battery can deliver 25A and maintain a minimum
terminal voltage of 10.5V at 26.7°C(80.1°F).
 Engine Electrical System

Engine Electrical System

Charging System
 2009 > D 1.6 TCI-U >

DESCRIPTION
The charging system included a battery, an alternator with a built-in regulator, and the charging indicator light
and wire.
The Alternator has eight built-in diodes, each rectifying AC current to DC current.
Therefore, DC current appears at alternator "B" terminal.
In addition, the charging voltage of this alternator is regulated by the battery voltage detection system.
The alternator is regulated by the battery voltage detection system. The main components of the alternator are
the rotor, stator, rectifier, capacitor brushes, bearings and V-ribbed belt pulley. The brush holder contains a
built-in electronic voltage regulator.
 2009 > D 1.6 TCI-U >

ON-VEHICLE INPECTION

•• Check that the battery cables are connected to the correct terminals.
•• Disconnect the battery cables when the battery is given a quick charge.
•• Never disconnect the battery while the engine is running.

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 ~ 12.9V 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.

VISUALLY CHECK ALTERNATOR WIRING AND LISTEN FOR ABNORMAL NOISES

1. Check that the wiring is in good condition.
2. Check that there is no abnormal noise from the alternator while the engine is running.

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.

INSPECT CHARGING SYSTEM

VOLTAGE DROP TEST OF ALTERNATOR OUTPUT WIRE
This test determines whether or not the wiring between the alternator "B" terminal and the battery (+) terminal
is good by the voltage drop method.

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.
TEST
1. Start the engine.
2. Turn on the headlamps and blower motor, and set the engine speed until the ammeter indicates 20A.
And then, read the voltmeter at this time.

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 th e 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.

OUTPUT CURRENT TEST

This test determines whether or not the alternator gives an output current that is equivalent to the normal
output.

PREPARATION
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 good condition. The battery checking method is
described in the section "Battery".
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 section
"Inspect drive belt".
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.
 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.

TEST
1. Check to see that the voltmeter reads as the same value as the battery voltage. If the voltmeter reads 0V,
and the open circuit in the wire between alternator "B" terminal and battery (-) terminal or poor grounding is
suspected.
2. Start the engine and turn on the headlamps.
3. Set the headlamps to high beam and the heater blower switch to HIGH, quickly increase the engine speed
to 2,500 rpm and read the maximum output current value indicated by the ammeter.

After the engine start up, the charging current quickly drops. Therefore, the above operation must be
done quickly 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
good condition, remove the alternator from the vehicle and test it.

Limit value (120A alternator) : 84A min.

•• The nominal 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.
Therefore, the nominal output current may not be obtained. If such is the case, keep the headlamps
on the cause discharge of the battery, or use the lights of another vehicle 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.

REGULATED VOLTAGE TEST

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

PREPARATION
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 section "Battery".
Check the alternator drive belt tension. The belt tension check method is described in the section "Inspect
drive belt".
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.

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

Voltage: Battery voltage

If it reads 0V, there is an open circuit in the wire between the alternator "B" terminal and the battery and the
battery (-) terminal.
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 10A or less

RESULT
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

Voltage regulator ambient temperature °C (°F) Regulating voltage (V)

-20 (-4) 14.2 ~ 15.4
20 (68) 14.0 ~ 15.0
60 (140) 13.7 ~ 14.9
80 (176) 13.5 ~ 14.7

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.
 Engine Electrical System

Engine Electrical System

Charging System - Alternator
2009 > D 1.6 TCI-U >

COMPONENT
 2009 > D 1.6 TCI-U >

REPLACEMENT
1. Disconnect the battery negative terminal first, then the positive terminal.
2. Disconnect the alternator connector(A), and remove the cable(B) from alternator "B" terminal.

3. Remove the alternator(A).

Tightening torque :
38.2 ~ 58.8N.m (3.9 ~ 6.0kgf.m, 28.2 ~ 43.4lbf.ft)

4. Installation is the reverse order of removal.

DISASSEMBLY
1. Remove the B terminal mounting nut(A) and rear cover nut(B).

2. Remove the alternator cover(A) using a screw driver(B).

3. Loosen the mounting bolts(A) and disconnect the brush holder assembly(B).

4. Remove the slip ring guide(A).

5. Remove the pulley(A) using the special tool.

6. Unsolder the 3 stator leads(A).

7. Loosen the 4 through bolts(A).

8. Disconnect the rotor(A) and cover(B).

9. Reassembly is the reverse order of disassembly.

INSPECTION
INSPECT ROTOR
1. Check that there is continuity between the slip rings(A).
2. Check that there is no continuity between the slip rings and the rotor(B) or rotor shaft(C).
3. If the rotor fails either continuity check, replace the alternator.

INSPECT STATOR
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.
 Engine Electrical System

Engine Electrical System

Charging System - Battery
 2009 > D 1.6 TCI-U >

DESCRIPTION
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.
 2009 > D 1.6 TCI-U >

INSPECTION
BATTERY DIAGNOSTIC TEST (1)

CHECKING FLOW

LOAD TEST
1. Perform the following steps to complete the load test procedure for maintenance free batteries.
2. Connect the load tester clamps to the terminals and proceed with the test as follow:
(1) If the battery has been on charge, remove the surface charge by connect a 300ampere load for 15 seconds.
(2) Connect the voltmeter and apply the specified load.
(3) Read the voltage after the load has been applied for 15 seconds.
(4) Disconnect the load.
(5) Compare the voltage reading with the minimum and replace the battery if battery test voltage is below that shown
in the voltage table.
Voltage Temperature
9.6V 20°C (68.0°F) and above
9.5V 16°C (60.8°F)
9.4V 10°C (50.0°F)
 9.3V 4°C (39.2°F)
9.1V -1°C (30.2°F)
8.9V -7°C (19.4°F)
8.7V -12°C (10.4°F)
8.5V -18°C (-0.4°F)

- If the voltage is greater shown in the table, the battery is good.

- If the voltage is less than shown in the table, replace the battery.

BATTERY DIAGNOSTIC TEST (2)

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.

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.

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.
 Engine Electrical System

Engine Electrical System

Starting System
 2009 > D 1.6 TCI-U >

DESCRIPTION
The starting system includes the battery, starter, solenoid switch, ignition switch, inhibitor switch (A/T), ignition
lock switch, connection wires and the battery cable.
When the ignition key is turned to the start position, current flows and energizes the starter motor's solenoid
coil.
The solenoid plunger and clutch shift lever 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
the starter armature when the engine starts, the clutch pinion gear overruns.
 2009 > D 1.6 TCI-U >

STARTER CIRCUIT TROUBLESHOOTING

The battery must be in good condition and fully charged.

1. Remove the fuel pump relay from the fuse box.

2. With the shift lever in N or P (A/T) or clutch pedal pressed (M/T), turn the ignition switch to "START"
If the starter normally cranks the engine, starting system is OK. If the starter will not crank the engine at all,
go to next step.
If it won't disengage from the ring gear when you release key, check for the following until you find the
cause.
A. Solenoid plunger and switch malfunction.
B. Dirty pinion gear or damaged overrunning clutch.
3. Check the battery condition. Check electrical connections at the battery, battery negative cable connected to
the body, engine ground cables, and the starter for looseness and corrosion. Then try starting the engine
again.
If the starter cranks normally the engine, repairing the loose connection repaired the problem. The starting
system is now OK.
If the starter still does not crank the engine, go to next step.
4. Disconnect the connector from the S-terminal of solenoid. Connect a jumper wire from the B-terminal of
solenoid to the S-terminal of solenoid.
If the starter cranks the engine, go to next step.
If the starter still does not crank the engine, remove the starter, and repair or replace as necessary.
5. Check the following items in the order listed until you find the open circuit.
A. Check the wire and connectors between the driver's under-dash fuse/relay box and the ignition switch,
and between the driver's under-dash fuse/relay box and the starter.
B. Check the ignition switch (Refer to BE group - ignition system)
C. Check the transaxle range switch connector or ignition lock switch connector.
D. Inspect the starter relay.

STATER SOLENOID TEST

1. Disconnect the field coil wire from the M-terminal of solenoid switch.
2. Connect a 12V battery between S-terminal and the starter body.
3. Connect the field coil wire to the M-terminal.

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

4. If the pinion moves out, the pull-in coil of solenoid is working properly.
If the pinion does not move, replace the solenoid.
5. Diconnect the field coil wire from the M-terminal.
6. If the pinion has moved out, the hold-in coil of the solenoid is working properly.
If the pinion moves in, replace the solenoid.

FREE RUNNING TEST

1. Place the starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to
starter motor as follows.
2. Connect a test ammeter (100-ampere scale) and carbon pile rheostats shown is the illustration.
3. Connect a voltmeter (15-volt scale) across starter motor.

4. Rotate carbon pile to the off position.

5. Connect the battery cable from battery's negative post to the starter motor body.
6. Adjust until battery voltage shown on the voltmeter reads 11volts.
7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly
and freely.

Current : 90A max

Speed : 2,600 rpm
 Engine Electrical System

Engine Electrical System

Starting System - Starter
2009 > D 1.6 TCI-U >

COMPONENT
 2009 > D 1.6 TCI-U >

REPLACEMENT
1. Disconnect the battery negative cable.
2. Disconnect the starter cable(A) from the B terminal on the solenoid then disconnect the connector from the
S terminal.

3. Remove the 2 bolts holding the starter, then remove the starter.
4. Installation is the reverse of removal.
5. Connect the battery negative cable to the battery.

DISASSEMBLY
1. Disconnect the M-terminal(A) on the magnet switch assembly(B).

2. After loosening the 2 screws(A), detach the magnet switch assembly(B).

3. Loosen the brush holder mounting screw(A) and through bolts(B).

4. Remove the rear bracket(A) and brush holder assembly(B).

5. Remove the yoke(A) and armature(B).

6. Remove the lever plate(A) and planet shaft packing(B).

7. Disconnect the planet gear(A).

8. Disconnect the planet shaft assembly(A) and lever(B).

9. Press the stop ring(A) using a socket(B).

10. After removing the stopper(A) using stopper pliers(B).

11. Disconnect the stop ring(A), overrunning clutch(B), internal gear(C) and planet shaft(D).
12. Reassembly is the reverse of disassembly.

Using a suitable pulling tool(A), pull the overrunning clutch stop ring(B) over the stopper(C).

INSPECTION
ARMATURE INSPECTION AND TEST
1. Remove the starter.
2. Disassemble the starter as shown at the beginning of this procedure.
3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or
damage, replace the armature.

4. Check the commutator(A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within
the following specifications, or recondition with #500 or #600 sandpaper(B).
5. Check the commutator diameter. If the diameter is below the service limit, replace the armature.

Commutator diameter
Standard (New) : 29.4 mm (1.1575 in)
Service limit : 28.8 mm (1.1339 in)

6. Measure the commutator(A) runout.

A. If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips
between the segments.
B. If the commutator run out is not within the service limit, replace the armature.

Commutator runout
Standard (New) : 0.02mm (0.0008in.) max
Service limit : 0.05mm (0.0020in.)

7. Check the mica depth(A). If the mica is too high(B), undercut the mica with a hacksaw blade to the proper
depth. Cut away all the mica(C) between the commutator segments. The undercut should not be too
 shallow, too narrow, or v-shaped(D).

Commutator mica depth

Standard (New) : 0.5 mm (0.0197 in.)
Limit : 0.2mm (0.0079 in.)

8. Check for continuity between the segments of the commutator. If an open circuit exists between any
segments, replace the armature.

9. Check with an ohmmeter that no continuity exists between the commutator(A) and armature coil core(B),
and between the commutator and armature shaft(C). If continuity exists, replace the armature.

INSPECT STARTER BRUSH

Brushes that are worm out, or oil-soaked, should be replaced.
STARTER BRUSH HOLDER TEST
Check that there is no continuity between the (+) brush holder(A) and (-) brush holder(B). If there is no
continuity, replace the brush holder assembly.

INSPECT OVERRUNNING CLUTCH

1. Slide the overrunning clutch along the shaft.
Replace it if does not slide smoothly.
2. Rotate the overrunning clutch both ways.
Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction of it locks in
both directions, replace it.

3. If the starter drive gear is worn or damaged, replace the overrunning clutch assembly. (the gear is not
available separately)
Check the condition of the flywheel or torque converter ring gear if the starter drive gear teeth are damaged.
 Engine Electrical System

Engine Electrical System

Starting System - Starter9LSH`
 2009 > D 1.6 TCI-U >

INSPECTION
1. Remove the fuse box cover.
2. Remove the starter relay(A).

3. Using an ohmmeter, check that there is continuity between each terminal.

Terminal Continuity
30 - 87 NO
85 - 86 YES

4. Apply 12V to terminal 85 and ground to terminal 86.

Check for continuity between terminals 30 and 87.

5. If there is no continuity, replace the starter relay.

6. Install the starter relay.
7. Install the fuse box cover.
 Engine Electrical System

Engine Electrical System

Preheating System
2009 > D 1.6 TCI-U >

COMPONENT
 2009 > D 1.6 TCI-U >

INSPECT PREHEATING SYSTEM

Conditions before inspection :
Battery voltage : 12V
1. Connect voltmeter between glow plug plate and plug body (ground).
2. Check indicated value on voltmeter with ignition switch ON.
3. Check that preheat indication lamp lights for about 6 seconds and indicates battery voltage (about 9V or
over) for about 36 seconds immediately after ignition switch is turned on. [At cooling water temperature
20°C (68.0°F)]

Continuity time varies depending upon cooling water temperature.

4. After checking 3, set ignition switch at START position.

5. The system is normal if battery voltage (about 9V or over) is generated for about 6 seconds during engine
cranking and after start operation. [at cooling water temperature 20°C (68.0°F)]
6. When the voltage or continuity time is not normal, check the terminal voltage in glow control unit, and single
parts.

INSPECT GLOW PLUS

1. Check the continuity between the terminal and body as illustrated. Replace if discontinuity or with large
resistance.

Standard value : 0.25

Remove oil from plug before measuring as glowplug resistance is very small.

2. Check for rust on glow plug plate.

3. Check glow plug for damage.
INSPECT GLOW PLUG RELAY
1. Remove the glow plug relay.
2. Inspect the relay continuity.
A. Using an ohmmeter, check that there is continuity between terminals 2 and 4.
If there is no continuity, replace the relay.
B. Check that there is no continuity between terminals 1 and 5.
If there is continuity, replace the relay.

3. Inspect the relay operation.

A. Apply battery positive voltage across terminals 2 and 4.
B. Using an ohmmeter, check that there is continuity between terminals 1 and 5.
If there is no continuity, replace the relay.

4. Install the glow plug relay.