Service Manual2008 Captiva ENGINE ELECTRICAL

SECTION 1E1

ENGINE ELECTRICAL - 2.0 DIESEL

SPECIFICATIONS

Starter Specifications

Application	Unit	Description
Type	-	PG260NS
Output(Capacity)	Kw	1.8 KW
No load test at 12 volts condition	A	90 MAX
Drive Pinion Speed	rpm	2550rpm min

Alternator Specifications

Application	Unit	Description
Brushed length	mm	11.0 mm
Type	-	AD237
Output (Capacity)	KW	125A
Brushed length	mm	21.8

Battery Specifications

Application	Unit	Description
Type	-	Maintenance Free
Output (Capacity)	V-AH	12V-90AH
Cold Cranking	CCA	912CCA
Load Test	Amps	450
Minimum Voltage:	.	.
9.6 9.5 9.4 9.3 9.1 8.9 8.7 8.5	V V V V V V V V	70°F (21°C) and above 60°F (15.6°C) 50°F (10°C) 40°F (4.4°C) 30°F (-1.1°C) 20°F (-6.7°C) 10°F (-12.2°C) 0°F (-17.8°C)

Fastener Tightening Specifications

Application	N•m	Lb-Ft	Lb-In
Battery Ground Retaining Nut	10	-	88.5
Battery Hold–Down Bar Bracket Retaining Nut	4	-	35
Battery Terminal Nut	4.5	-	40
Battery Tray Bolts	10	-	88.5
Engien Fuse Block Ground Retaining Nut	10	-	88.5
Engine Fuse Block Lower Cover Retaining Nut	10	-	88.5
Engine Fuse Block Retaining Bolt	10	-	88.5
Generator B+ Wiring Harness Retaining Nut	25	18.4	-
Generator Bolt	30	22.1	-
Glow Plug Fuse Box Retaining Bolt	10	-	88.5
Glow Plug Module Retaining Nut	14	10.3	-
Starter Solenoid Terminal–to–Battery Lead Wire Nut	15	11.1	-
Starter–to–Engine Block Mounting Bolt	45	33.2	-

SCHEMATIC AND ROUTING DIAGRAMS

Starting System

Charging System

DIAGNOSIS

Electric System

Condition	Probable Cause	Correction
No Crank	Low battery voltage.	Charging the battery or Replace the battery.
	Battery cable is loose, corroded, or damaged.	Repair or Replace the battery cable.
	Faulty starter motor or starter motor circuit is open.	Repair or Replace the starter motor/starter motor circuit.
	Faulty ignition switch or fuse Ef5 or F12 is blown.	Replace the ignition switch or fuse Ef5 or Ef6.
	Ground short.	Repair the ground short.
Crank OK, But Too Slow	Low battery voltage.	Charging the battery or Replace the battery.
	Batter. Battery cables is loose, corroded, or damaged.	Repair or Replace the battery cable.
	Faulty starter motor.	Repair or Replace the starter motor.
Starter Motor Does Not Stop	Faulty starter motor.	Repair or Replace the starter motor.
Starter Motor Does Not Stop	Faulty ignition switch.	Replace the ignition switch.
Starter Motor Running, But Not Cranking	Broken the clutch pinion gear or faulty starter motor.	Replace the starter motor.
	Broken the flywheel ring gear.	Replace the flywheel.
	Connected circuit is open.	Repair the open circuit.
Overcharging Battery	Faulty the IC regulator.	Replace the IC regulator.
Battery Discharge	Loosen the generator drive belt.	Adjust the belt tension or Replace the belt.
	The circuit is open or a short.	Repair the open or a short circuit.
	Faulty IC regulator.	Replace the IC regulator.
	Battery run down.	Replace the battery.
	Open ground circuit.	Repair the open ground circuit.
Charging Indicator Lamp Does Not Work When the Ignition Switch ON (Engine Does Not Work)	Fault IC regulator.	Replace the IC regulator.
	Charging indicator lamp is blown or fuse F13 is blown.	Repair or Replace the charging indicator lamp/fuse F13.
	Faulty ignition switch.	Replace the ignition switch.
	Generator ground circuit is open or a short.	Repair the circuit.
Charging Indicator Lamp Does Not Put Out Lights After Starting the Engine	Faulty IC regulator.	Replace the IC regulator.
	Battery cable is corroded or damaged.	Repair or Replace the battery cable.
	Loosen the generator drive belt.	Adjust the belt tension or Replace the belt.
	Faulty wiring harness.	Repair the wiring harness.

Battery Load Test

Check the battery for obvious damage, such as a cracked or broken case or cover, which could permit the loss of electrolyte. If obvious damage is noted, replace the battery.

Caution : Do not charge the battery if the hydrometer is clear or light yellow. Instead, replace the battery. If the battery feels hot or if violent gassing or spewing of electrolyte through the vent hole occurs, discontinue charging or reduce the charging rate to avoid injury.

Check the hydrometer. If the green dot is visible, go to the load test procedure. If the indicator is dark but green is not visible, charge the battery. For charging a battery removed from the vehicle, refer to "Charging a Completely Discharged Battery" in this section.
Connect a voltmeter and a battery load tester across the battery terminals.
Apply a 300-ampere load for 15 seconds to remove any surface charge from the battery.
Remove the load.
Wait 15 seconds to let the battery recover, and apply a 270-ampere load.

Important : The battery temperature must be estimated by touch and by the temperature condition the battery has been exposed to for the preceding few hours.

If the voltage does not drop below the minimum listed, the battery is good and should be reinstalled. If the voltage is less than the minimum listed, replace the battery. Refer to "Battery Specifications" in this section.

Alternator Output Test

Perform the alternator system test. Refer to "Alternator System Check" in this section.
Replace the alternator if it fails that test. Refer to "Alternator" in the On-Vehicle Service section. If it passes the test, perform the on-vehicle output check which follows.

Important : Always check the alternator for output before assuming that a grounded "L" terminal circuit has damaged the regulator.

Attach a digital multimeter (a), an ammeter (b), and a carbon pile load (c) to the battery (d) and the alternator (e) of the vehicle.

Important : Be sure the vehicle battery is fully charged, and the carbon pile load is turned off.

With the ignition switch in the OFF position, check and record the battery voltage.
Remove the harness connector from the generator.
Turn the ignition switch to the ON position with the engine not running. Use a digital multimeter to check for voltage in the harness connector "L" terminal.
The reading should be near the specified battery voltage of 12 volts. If the voltage is too low, check the indicator "L" terminal circuits for open and grounded circuits causing voltage loss. Correct any open wires, terminal connections, etc., as necessary. Refer to "Charging System" in this section.
Attach the generator harness connector.
Run the engine at a moderate idle, and measure the voltage across the battery terminals. The reading should be above that recorded in Step 4 but less than 15 volts. If the reading is over 15 volts or below the previous reading, replace the alternator. Refer to "Alternator" in the On-Vehicle Service section.
Run the engine at a moderate idle, and measure the alternator amperage output.
Turn on the carbon pile, and adjust it to obtain the maximum amps while maintaining the battery voltage above 13 volts.
If the reading is within 15 amps of the alternator's rating noted on the alternator, the generator is good. If not, replace the alternator. Refer to "Alternator" in the On-Vehicle Service section.
With the alternator operating at the maximum output, measure the voltage between the alternator housing and the battery negative terminal. The voltage drop should be 0.5 volt or less. If the voltage drop is more than 0.5 volt, check the ground path from the alternator housing to the negative battery cable.
Check, clean, tighten, and recheck all of the ground connections.

Alternator System Check

When operating normally, the alternator indicator lamp will come on when the ignition switch is in the ON position and go out when the engine starts. If the lamp operates abnormally or if an undercharged or overcharged battery condition occurs, the following procedure may be used to diagnose the charging system. Remember that an undercharged battery is often caused by accessories being left on overnight or by a defective switch that allows a lamp, such as a trunk or glove box lamp, to stay on.

Diagnose the generator with the following procedure:

Visually check the belt and wiring.
With the ignition switch in the ON position and the engine stopped, the charge indicator lamp should be on. If not, detach the harness at the alternator and ground the "L" terminal in the harness with a fused, 5-ampere jumper lead.

If the lamp lights, replace the alternator. Refer to "Alternator" in the On-Vehicle Service section.
If the lamp does not light, locate the open circuit between the ignition switch and the harness connector. The indicator lamp bulb may be burned out.

With the ignition switch in the ON position and the engine running at moderate speed, the charge indicator lamp should be off. If not, detach the wiring harness at the generator.

If the lamp goes off, replace the alternator. Refer to "Alternator" in the On-Vehicle Service section.
If the lamp stays on, check for a short to ground in the harness between the connector and the indicator lamp.

Important : Always check the alternator for output before assuming that a grounded "L" terminal circuit has damaged the regulator. Refer to "Alternator" in the Unit Repair section.

Starter Motor Noise

Start the engine. If the starter does not operate normally, correction can be achieved as following procedures. Before start the procedures below ensure that the battery is fully charged, the battery cables are clean and tight and the grounds are clean, tight, and in the correct location.

Step	Action	Value(s)	Yes	No
1	Start the engine while listening to the starter motor turn. Is there a loud "whoop", it may sound like a siren if the engine is revved while the starter is engaged, after the engine starts, but while the starter is still held in the engaged position?	-	Go to Step 4	Go to Step 2
2	Do you hear a "rumble", a "growl", or, in some cases, a "knock" as the starter is coasting down to a stop after starting the engine?	-	Go to Step 5	Go to Step 3
3	Important : This is often diagnosed as a starter drive gear hang-in or a weak solenoid. When the engine is cranked, do you hear a high-pitched whine after the engine cranks and starts normally?	-	Go to Step 6	Go to Step 5
4	Inspect the flywheel ring gear for the following: Chipped gear teeth Missing gear teeth Milled teeth Is the flywheel bent, or does it have damaged teeth?	-	Go to Step 7	Go to Step 8
5	Remove the starter motor. Refer to "Starter" in this section. Inspect the starter motor bushings and clutch gear. Does the clutch gear have chipped or milled teeth or worn bushings?	-	Go to Step 8	Go to Step 7
6	Shim the starter motor away from the flywheel by adding shims between the starter motor and the engine block one at a time. Flywheel runout may make this noise appear to be intermittent. Did you complete the repair?	-	Go to Step 9	-
7	Replace the flywheel. Did you complete the replacement?	-	Go to Step 9	-
8	Replace the starter motor. Refer to "Starter" in this section. Did you complete the replacement?	-	Go to Step 9	-
9	Operate the system in order to verify the repair. Did you correct the condition?	-	System OK	Go to Step 1