Kia G 3.8 DOHC Manual
  1. Manuals
  2. Brands
  3. Kia Manuals
  4. Engine
  5. G 3.8 DOHC
  6. Manual
Kia G 3.8 DOHC Manual

Kia G 3.8 DOHC Manual

Electrical system
Hide thumbs
Table of Contents

Advertisement

Quick Links

Engine Electrical System
General Information
Engine
cal System

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the G 3.8 DOHC and is the answer not in the manual?

Questions and answers

Related Manuals for Kia G 3.8 DOHC

Summary of Contents for Kia G 3.8 DOHC

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

  • Page 2: Troubleshooting

    2007 > G 3.8 DOHC > TROUBLESHOOTING 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...
  • Page 3 Ignition switch Replace Starter spins but Short in wiring Repair wiring engine will not crank Pinion gear teeth broken or starter motor Replace Ring gear teeth broken Replace fly wheel or torque converter...

  • Page 4: Specifications

    2007 > G 3.8 DOHC > SPECIFICATIONS IGNITION SYSTEM Items Specification Primary resistance 0.62 ± 10 % Ignition coil Secondary resistance 7.0k! ± 15 % IFR5G-11 Unleaded 1.0 ~ 1.1 mm (0.0394 ~ 0.0433 in.) Spark plugs BKR5ES Leaed 0.8 ~ 0.9 mm (0.0315 ~ 0.0354 in)

  • Page 5: Engine Electrical System

    Engine Electrical System Ignition System Engine Electrical System...
  • Page 6 2007 > G 3.8 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 PCM (Power Control Module).
  • Page 7 2007 > G 3.8 DOHC > COMPONENTS...

  • Page 8: Ignition Coil

    2007 > G 3.8 DOHC > REMOVAL IGNITION COIL 1. Remove the engine cover. 2. Disconnect the ignition coil connector(A). When removing the ignition coil connector, pull the lock pin(A) and push the clip(B). 3. Remove the ignition coil (B).
  • Page 9 3. Using a spark plug socket, remove the spark plug. 4. Install the spark plug to the ignition coil. 5. Ground the spark plug to the engine. 6. Check if spark occurs while engine is being cranked. To prevent fuel being injected from injectors while the engine is being cranked, remove the fuel pump(A) relay from the fuse box.

  • Page 10: Spark Plug

    SPARK PLUG 1. Remove the ignition coil connector(A).
  • Page 11 When removing the ignition coil connector, pull the lock pin(A) and push the clip(B). 2. Remove the ignition coil(B). 3. Using a spark plug socket, remove the spark plug. Be careful that no contaminates enter through the spark plug holes. 4.
  • Page 12 Standard : 1.0 ~ 1.1 mm (0.0394 ~ 0.0433 in.) - Unleaded 0.8 ~ 0.9 mm (0.0315 ~ 0.0354 in) - Leaded IGNITION COIL 1. Measure the primary coil resistance between terminals (+) and (-). Standard value: 0.62! ± 10%...
  • Page 13 Engine Electrical System Charging System Engine Electrical System...
  • Page 14 2007 > G 3.8 DOHC > DESCRIPTION The charging system includes 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.
  • Page 15 2007 > G 3.8 DOHC > ON-VEHICLE INSPECTION • 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.

  • Page 16: Output Current Test

    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.
  • Page 17 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"...
  • Page 18 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".

  • Page 19: Charging System - Alternator

    Engine Electrical System Charging System - Alternator Engine Electrical System...
  • Page 20 2007 > G 3.8 DOHC > COMPONENTS...
  • Page 21 2007 > G 3.8 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).
  • Page 22 4. Remove the four screws, the rectifier(B) and the rubber seal(C). 5. Remove the four nuts(A) and insulators(B). 6. Remvoe the rear bracket assembly(A) and washer(B). 7. Remove the rotor(A) fron the stator and front frame assembly(B).
  • Page 23 INSPECTION ROTOR 1. Check that there is continuity between the slip rings(A). If there is no continuity, replace the generator. STATOR 1. Check that there is continuity between each pair of leads(A). If there is no continuity, repalce the generator. RECTIFIER 1.
  • Page 24 REASSEMBLY Becareful not to get any grease or oil on the slip rings. 1. Insert the rotor(A) in the stator and front frame assembly(B). 2. Install the washer(B) and the rear bracket assembly(A) 3. Tighten the four nuts and insulators(B).
  • Page 25 4. Install the rectifier(B) and the rubber seal(C) by tightening the four screws(A), 5. Install the brush holder(A). 6. Install the generator cover(A) by tightening the three nuts(B).
  • Page 26 7. Install the pulley with a hexagonal wrench.

  • Page 27: Charging System - Battery

    Engine Electrical System Charging System - Battery Engine Electrical System...
  • Page 28 2007 > G 3.8 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 29 2007 > G 3.8 DOHC > CLEANING 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.
  • Page 30 INSPECTION BATTERY DIAGNOSTIC FLOW...
  • Page 31 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 connecting a 300ampere load for 15 seconds. (2) Connect the voltmeter and apply the specified load.
  • Page 32 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 than shown in the table, the battery is good. - If the voltage is less than shown in the table, replace the battery.

  • Page 33: Starting System

    Engine Electrical System Starting System Engine Electrical System...
  • Page 34 2007 > G 3.8 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.

  • Page 35: Starter Circuit

    2007 > G 3.8 DOHC > TROUBLESHOOTING STARTER CIRCUIT 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"...
  • Page 36 3. Disconnect the battery from the M terminal. If the pinion does not retract, the hold-in coil is working properly. To avoid damaging the starter, do not leave the battery connected for more than 10 seconds. 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.
  • Page 37 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.

  • Page 38: Starting System - Starter

    Engine Electrical System Starting System - Starter Engine Electrical System...
  • Page 39 2007 > G 3.8 DOHC > COMPONENTS...
  • Page 40 2007 > G 3.8 DOHC > REMOVAL 1. Disconnect the starter cable from the B terminal on the solenoid, and the connector from the S terminal. 2. Remove the 2 bolts (D) holding the starter, then remove the starter (E).
  • Page 41 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).
  • Page 42 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.
  • Page 43 Using a suitable pulling tool (A), pull the overrunning clutch stop ring (B) over the stopper (C). DISASSEMBLY 1. Disconnect the M-terminal on the magnet switch assembly. 2. After loosening the 3 screws (A), detach the magnet switch assembly (B). 3.
  • Page 44 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).
  • Page 45 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.
  • Page 46 Using a suitable pulling tool (A), pull the overrunning clutch stop ring (B) over the stopper (C). INSPECTION ARMATURE 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.
  • Page 47 6. 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).
  • Page 48 STARTER BRUSH Brushes that are worm out, or oil-soaked, should be replaced. STARTER BRUSH HOLDER 1. 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. 2.

  • Page 49: Overrunning Clutch

    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 50 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 51 7. Check for continuity between the segments of the commutator. If an open circuit exists between any segments, 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).
  • Page 52 STARTER BRUSH HOLDER 1. 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. 2. Pry back each brush spring (A) with a screwdriver, then position the brush (B) about halfway out of its holder, and release the spring to hold it there.
  • Page 53 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. CLEANING 1.

  • Page 54: Engine Electrical System

    Engine Electrical System Starting System - Starter Relay Engine Electrical System...
  • Page 55 2007 > G 3.8 DOHC > 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 85 - 86 4. Apply 12V to terminal 85 and ground to terminal 86.

  • Page 56: Cruise Control System

    Engine Electrical System Cruise Control System Engine Electrical System...

  • Page 57: System Block Diagram

    2007 > G 3.8 DOHC > SYSTEM BLOCK DIAGRAM COMPONENT PARTS AND FUNCTION OUTLINE Component part Function Vehicle-speed sensor Converts vehicle speed to pulse. Power control module (PCM) Receives signals from sensor and control switches; Cruise control indicator Illuminate when CRUISE main switch is ON (Built into...
  • Page 58 vehicle speed sensor, ECM and ETS motor that connect throttle body. PCM contains a low speed limit which will prevent system engagement below a minimum speed of 40km/h (25mph). The operation of the controller is controlled by mode control switches located on steering wheel. Transaxle range switch and brake switch are provided to disengage the cruise control system.
  • Page 59 2007 > G 3.8 DOHC > TROUBLE SYMPTOM CHARTS TROUBLE SYMPTOM 1 TROUBLE SYMPTOM 2 Trouble symptom Probable cause Remedy The set vehicle speed varies greatly Malfunction of the vehicle speed Repair the vehicle speed sensor upward or downward sensor circuit system, or replace the part "Surging"...
  • Page 60 Damaged or disconnected wiring of Repair the harness or replace the the brake pedal switch brake pedal switch The CC system is not canceled when the brake pedal is depressed Check input and output signals at Malfunction of the PCM signals TROUBLE SYMPTOM 4 Trouble symptom Probable cause...
  • Page 61 Engine Electrical System Cruise Control System - Cruise Control Switch Engine Electrical System...

  • Page 62: Circuit Diagram

    2007 > G 3.8 DOHC > CIRCUIT DIAGRAM...

  • Page 63: Measuring Resistance

    2007 > G 3.8 DOHC > REMOVAL 1. Disconnect the battery (-) terminal. 2. Remove the driver side air bag module. 3. Disconnect the cruise control switch connector and then remove the cruise control switch with two screws. 4. Installation is the reverse of removal.
  • Page 64 Cruise Main Cancel 0.0V ± 0.22V Set/Coast 1.5V ± 0.22V Resume/Accel 3.0V ± 0.22V 3. If not within specification, replace switch.

Table of Contents