Kia Carnival 2009 General Information Manual
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Kia Carnival 2009 General Information Manual

Engine electrical system
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Engine Electrical System
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Engine
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Summary of Contents for Kia Carnival 2009

  • Page 1 Engine Electrical System General Information Engine cal System...

  • Page 2: Battery Test Procedure

    2009 > G 2.7 DOHC > THE MICRO 570 ANALYZER The MICRO 570 Analyzer provides the ability to test the charging and starting systems, including the battery, starter and generator. Because of the possibility of personal injury, always use extreme caution and appropriate eye protection when working with batteries.
  • Page 3 2. The tester will ask if the battery is connected "IN A VEHICLE" or "OUT OF A VEHICLE". Make your selection by pressing the arrow buttons; then press ENTER. 3. Choose either CCA or CCP and press the ENTER button. •...
  • Page 4 The battery ratings (CCA) displayed on the tester must be identical to the ratings marked on battery label. 6. To conduct starter test, press ENTER. BATTERY TEST RESULTS RESULT ON PRINTER REMEDY Good battery No action is required Battery is in a good state Good recharge Recharge the battery and use Battery is not charged properly...
  • Page 5 2. After pressing ENTER key, start the engine. 3. Cranking voltage and starter test results will be displayed on the screen. Take a relevant action according to the test results by referring to the starter test results as given below. 4.
  • Page 6 2. ENTER button is pressed, the tester displays the actual voltage of generator. Press ENTER to test the charging system. 3. The MICRO 570 will prompt you to rev the engine until the rev detected. It will then collect the data. 4.
  • Page 7 6. The MICRO 570 will detect the amount of ripple from the charging system to the battery. Excessive ripple usually means the stator is damaged or that one or more generator diodes have failed. 7. The MICRO 570 will prompt you to turn on accessary loads. It will then test at idle and prompt you to rev the engine.
  • Page 8 CHARGING SYSTEM TEST RESULTS RESULT ON PRINTER REMEDY Charging system normal/Diode ripple normal Charging system is normal Generator does not supply charging current to battery No charging voltage => Check belts, connection between generator and battery Replace belts or cable or generator as necessary Generator does not supply charging current to battery and electrical Low charging voltage load to system fully...

  • Page 9: Special Service Tool

    2009 > G 2.7 DOHC > SPECIAL SERVICE TOOL Tool (Number and name) Illustration Alternator pulley remover wrench Removal and installation of alternator (09373-27000) pulley REFERENCE SERVICE TOOLS Tool (Number and name) Illustration - Check the battery condition Micro-570 - Check the charging and starting Battery checker system...

  • Page 10: Troubleshooting

    2009 > G 2.7 DOHC > TROUBLE SHOOTING IGNITION SYSTEM Symptom Suspect area Remedy Engine will not start or Ignition lock switch Inspect ignition lock switch, or replace as required is hard to start Ignition coil Inspect ignition coil, or replace as required (Cranks OK) Spark plugs Inspect spark plugs, or replace as required...
  • Page 11 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 Repair or replace cables worn out Starter motor faulty Replace Starter keeps running Starter motor Replace Ignition switch...

  • Page 12: Specification

    2009 > G 2.7 DOHC > SPECIFICATION IGNITION SYSTEM Items Specification Primary resistance 0.715 ± 0.015 ! Ignition coil Secondary resistance Spark plugs ILFR5B11 Plugs Gap 1.0 ~ 1.1 mm (0.0394 ~ 0.0433 in) STARTING SYSTEM Items Specification Rated voltage 12 V, 1.2 kW No.
  • Page 13 Engine Electrical System Ignition System Engine Electrical System...
  • Page 14 2009 > G 2.7 DOHC > DESCRITION Ignition timing is controlled by the electronic control ignition timing system. The standard reference ignition timing data for the engine operating conditions are preprogrammed in the memory of the ECM (Engine Control Module). The engine operating conditions (speed, load, warm-up condition, etc.) are detected by the various sensors.

  • Page 15: Ignition Coil

    2009 > G 2.7 DOHC > REMOVAL IGNITION COIL 1. Remove the engine cover. 2. Remove the ignition coil (A). 3. Remove the ignition coil. 4. Installation is the reverse of removal. REPLACEMENT SPARK PLUG 1. Remove the ignition coil connector(A). 2.

  • Page 16: On-Vehicle Inspection

    A. [U2.7] L nleaded : ILFR5B11 Leaded : LFR5A ON-VEHICLE INSPECTION SPARK TEST 1. Remove the ignition coil connector(A). Disconnect the iguition coil connector while pulling up tre connector lock. 2. Remove the ignition coil. 3. Using a spark plug socket, remove the spark plug. 4.

  • Page 17: Inspect Spark Plug

    INSPECT SPARK PLUG 1. Inspect the electrodes(A) an ceramic insulator(B). INSPECTION OF ELECTRODES Condition Dark deposits White deposits - Fuel mixture too lean - Fuel mixture too rich Description - Advanced ignition timing - Low air intake - Insufficient plug tightening torque 2.
  • Page 18 INSPECT IGNITION COIL Standard : 0.0715 ± 0.015! Mesure the resistance between the terminals No.1 and No.3.
  • Page 19 Engine Electrical System Charging System Engine cal System...
  • Page 20 2009 > G 2.7 DOHC > DESCRIPTION The charging system included a battery, an alternator with a built-in regulator, and the charging indicator light and wire. The Alternator has 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.

  • Page 21: Check Battery Voltage

    2009 > G 2.7 DOHC > 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.

  • Page 22: Output Current Test

    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.
  • Page 23 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.

  • Page 24: Regulated Voltage Test

    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.
  • Page 25 -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.
  • Page 26 Engine Electrical System Charging System - Alternator Engine cal System...
  • Page 27 2009 > G 2.7 DOHC > COMPONENT...
  • Page 28 2009 > G 2.7 DOHC > REMOVAL 1. Disconnect the battery negative terminal first, then the positive terminal. 2. Disconnect the alternator connector, and remove the cable from alternator "B" terminal. 3. Remove the drive belt. 4. Pull out the through bolt and then remove the alternator(A). 5.
  • Page 29 5. Remove the nut, pulley(A) and spacer. 6. Loosen the 4 through bolts(A). 7. Disconnect the rotor(A) and cover(B). 8. Reassembly is the reverse order of disassembly. INSPECTION INSPECT ROTOR 1. Check that there is continuity between the slip rings (A).
  • Page 30 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.
  • Page 31 Engine Electrical System Charging System - Battery Engine cal System...
  • Page 32 2009 > G 2.7 DOHC > 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.
  • Page 33 2009 > G 2.7 DOHC > 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:...
  • Page 34 (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.
  • Page 35 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.
  • Page 36 Engine Electrical System Starting System Engine cal System...
  • Page 37 2009 > G 2.7 DOHC > 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.

  • Page 38: Starter Circuit Troubleshooting

    2009 > G 2.7 DOHC > STARTER CIRCUIT TROUBLESHOOTING The battery must be in good condition and fully charged. 1. Remove the fuel pump relay(A) 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.
  • Page 39 4. Disconnect the battery also from the body. If the pinion retracts immediately, it is working properly. To avoid damaging the starter, do not leave the battery connected for more than 10 seconds. 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.
  • Page 40 Engine Electrical System Starting System - Starter Engine cal System...
  • Page 41 2009 > G 2.7 DOHC > COMPONENT...
  • Page 42 2009 > G 2.7 DOHC > REMOVAL STATATER 1. Disconnect the battery negative cable. 2. Disconnect the starter cable (A) from the B terminal (B) on the solenoid (C), then disconnect the connector (D) from the S terminal (E). 3. Remove the 2 bolts holding the starter, then remove the starter. 4.
  • Page 43 5. Remove the shield (A) and packing (B). 6. Remove the lever plate (A) and lever 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).
  • Page 44 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.
  • Page 45 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. 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.
  • Page 46 replace the armature. 8. 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 1.
  • Page 47 3. Install the armature in the housing, and install the brush holder. Next, pry back each brush spring again, and push the brush down until it seats against the commutator, then release the spring against the end of the brush. To seat new brushes, slip a strip of #500 or #600 sandpaper, with the grit side up, between the commutator and each brush, and smoothly rotate the armature.
  • Page 48 Engine Electrical System Starting System - Starter Relay Engine Electrical System...
  • Page 49 2009 > G 2.7 DOHC > INSPECTION 1. Remove the fuse box cover. 2. Remove the starter relay. 3. Using an ohmmeter, check that there is continuity between each terminal. Terminal Continuity 30 - 87 85 - 86 4. Apply 12V to terminal 85 and ground to terminal 86. Check for continuity between terminals 30 and 87.

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