SECTION 1E3
ENGINE ELECTRICAL - HFV6 3.2L
Caution : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
SPECIFICATIONS
Starter Specifications
Description | Unit | Standard |
Type | - | PG 260D |
Capacity | Kw | 1.4 |
Drive Pinion Speed (No Load Test at 12 volts Condition) | rpm | 2,600 MIN |
Brush Length | mm (in.) | 8.25 |
Armature Diameter | mm (in.) | 45.5 |
Armature Runout | mm (in.) | 0.08 |
Segment Home Depth | mm (in.) | 0.6~1.0 |
Generator Specifications
Description | Unit | Standard |
Type | - | AD237 |
Capacity | AH | 120 |
Regulator Type | - | Multi/Non RVC |
Regulator Voltage | V | 14.6 ± 0.25 at Tb=25°C, 6,000 rpm, 50% Load |
Brush | Length | mm (in.) | 18.8 |
Number | EA | 2 |
Minimum Length | mm (in.) | 8.0 |
Battery Specifications
Description | Unit | Standard |
Type | - | MF |
Capacity | AH | 70 |
Cold Cranking Amps (CCA) | CCA | 770 |
Minimum Reserve Capacity (RC) | min | 110 |
Load Test | amps | 380 |
Minimum Voltage: | . | . |
| 9.69.59.49.39.18.98.78.5 | 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) |
Spark Plug Specifications
Description | Unit | Standard |
Type | - | HR7MPP302 (BOSCH) |
Gap | mm (in.) | 1.1 (0.0433) |
Fastener Tightening Specifications
Application | N•m | Lb-Ft | Lb-In |
Accessory Drive Belt Idler Pulley-to-Generator Through Bolt | 58 | 43 | - |
Generator Upper Mounting Bolts | 50 | 37 | - |
Generator-to-Battery Lead Wire Retaining Nut | 15 | 11 | - |
Starter Assembly Mounting Bolts | 45 | 33 | - |
Starter Solenoid-to-Battery Lead Wire Retaining Nut | 15 | 11 | - |
Starter Solenoid-to-Engine Main Harness Lead Wire Retaining Nut | 10 | - | 89 |
Battery Tray Retaining Bolts | 10 | - | 89 |
Engine Fuse Block Lower Cover Bolts | 10 | - | 89 |
Engine Fuse Block Retaining Bolts | 3 | - | 27 |
Battery Hold-Down Bar Bracket Retaining Nuts | 10 | - | 89 |
SCHEMATIC AND ROUTING DIAGRAMS
Starting System
Charging System
DIAGNOSIS
General Diagnosis
No Crank
Checks | Action |
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 Ef2 is blown. | Replace the ignition switch or fuse Ef2. |
Ground short | Repair the ground short. |
Crank OK, But Too Slow
Checks | Action |
Low battery voltage | . |
- Battery
- Battery cables is loose, corroded, or damaged
| Charging the battery or replace the battery. Repair or replace the battery cable. |
Faulty starter motor | Repair or replace the starter motor. |
Starter Motor Does Not Stop
Checks | Action |
Faulty starter motor | Repair or replace the starter motor. |
Faulty ignition switch | Replace the ignition switch. |
Starter Motor Running But Not Cranking
Checks | Action |
Broken clutch pinion gear or faulty starter motor | Replace the starter motor. |
Broken flywheel ring gear. | Replace the flywheel. |
Connected circuit is open. | Repair the open circuit. |
Overcharging Battery
Checks | Action |
Faulty IC regulator | Replace the IC regulator. |
Battery Discharge
Checks | Action |
Loosen the generator drive belt. | Adjust the belt tension or replace the belt. |
The circuit is open or shorted. | Repair the open or shorted 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 is ON – Engine Does Not Work
Checks | Action |
Fault IC regulator | Replace the IC regulator. |
Charging indicator lamp is blown or fuse is blown. | Repair or replace the charging indicator lamp/fuse. |
Faulty ignition switch | Replace the ignition switch. |
Generator ground circuit is open or shorted. | Repair the circuit. |
Charging Indicator Lamp Does Not Put Out Lights After Starting the Engine
Checks | Action |
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. |
Hard to Start the Engine
Checks | Action |
Faulty ignition coil | Replace the ignition coil. |
Faulty spark plug | Replace the spark plug or adjust the gap. |
Poor ignition timing | Reset the valve timing. |
Engine Idling State is Unstable
Checks | Action |
Faulty spark plug | Replace the spark plug or adjust the gap. |
Faulty ignition coil | Replace the ignition coil. |
Poor ignition timing | Reset the valve timing. |
Poor ignition timing | Reset the valve timing. |
Poor Engine Accelerating
Checks | Action |
Poor ignition timing | Reset the valve timing. |
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 |
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.
- 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 personal 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.
- 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 A 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 A load.
Important : The battery temperature must be estimated by touch and by the temperature condition the battery has been exposed 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.
- 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.
Genrator Output Test
- Perform the generator system test. Refer to "Generator System Check"in this section.
- Perform the generator system test. Refer to "Generator System Check"in this section.
- Replace the generator if it fails that test. Refer to "Generator" in the On-Vehicle Service portion of this section. If it passes the test, perform the on-vehicle output check which follows.
Important : Always check the generator for output before assuming that a grounded "L" terminal circuit has damaged the regulator.
- Attach a digital multimeter, an ammeter, and a carbon pile load to the vehicle.
- Attach a digital multimeter, an ammeter, and a carbon pile load to 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.
- With the ignition switch in the OFF position, check and record the battery voltage.
- Remove the harness connector from the generator.
- Turn the ignition to RUN 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 V. 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 13 V, but less than 16 V. If the reading is over 16 V or below the previous reading, replace the generator. Refer to "Generator" in the On-Vehicle Service section.
- Run the engine at a moderate idle, and measure the generator amperage output.
- Turn on the carbon pile, and adjust it to obtain the maximum amps while maintaining the battery voltage above 13 V.
- If the reading is within 15 amps of the generator’s rating noted on the generator, the generator is good. If not, replace the generator. Refer to "Generator" in the On-Vehicle Service section.
- With the generator operating at the maximum output, measure the voltage between the generator housing and the battery negative terminal. The voltage drop should be 0.5 V or less. If the voltage drop is more than 0.5 V, check the ground path from the generator housing to the negative battery cable.
- Check, clean, tighten, and recheck all of the ground connections.
Generator System Check
When operating normally, the generator indicator lamp will come on when the ignition is in RUN 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 a glove box lamp, to stay on.
Diagnose the generator with the following procedure:
- Visually check the belt and the wiring.
- With the ignition in the ON position and the engine stopped, the charge indicator lamp should be ON. If not, detach the harness at the generator and ground the "L" terminal in the harness with a 5 A jumper lead.
- If the lamp lights, replace the generator. Refer to "Generator" 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 generator. Refer to "Generator" 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 generator for output before assuming that a grounded "L" terminal circuit has damaged the regulator. Refer to "Generator" in the Unit Repair section. 
