Service Manual2009 Aveo

SECTION

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE

Generator - 1.2 DOHC - B12D -

Removal Procedure

Disconnect the negative battery cable.
Lift up the vehicle.
Remove the accessory belt. Refer to Section 1C1, Accessory Belt.

Disconnect the harness connector.

Remove the battery harness connector nut to disconnect the battery positive connector.
Disconnect the generator harness connector.

Remove the generator retaining bolts/nuts.
Remove the generator.

Installation Procedure

Install the generator.
Install the generator retaining bolt/nut.
Install the battery harness connector nut to connect the battery positive connector.

Tighten

Tighten the generator retaining bolt/nut : 25 N•m (18.4 lb-ft).

Connect the harness connector.

Install the accessory belt. Refer to Section 1C1, Accessory Belt.
Lift down the vehicle.
Connect the negative battery cable.

Generator - 1.4 DOHC - G14D -

Removal Procedure

Disconnect the negative battery cable.
Lift up the vehicle.
Remove the accessory belt. Refer to Section 1C2, Accessory Belt.

Disconnect the harness connector.

Remove the battery harness connector nut to disconnect the battery positive connector.
Disconnect the generator harness connector.

Remove the generator retaining bolts.
Remove the generator.

Installation Procedure

Install the generator.
Install the generator retaining bolts.

Tighten

Tighten the generator retaining bolt to 35 N•m (25.8 lb-ft).

Install the battery harness connector nut to connect the battery positive connector.
Connect the harness connector.

Install the accessory belt. Refer to Section 1C2, Accessory Belt.
Lift down the vehicle.
Connect the negative battery cable.

Starter - 1.2 DOHC - B12D -

Removal Procedure

Disconnect the negative battery cable.
Lift up the vehicle.
Remove the starter solenoid nut to disconnect the starter harness.
Remove the starter solenoid nut to disconnect the battery positive connector.
Remove the ground bolt from the engine block.

Remove the starter retaining stud blots.
Remove the starter.

Installation Procedure

Install the starter.
Install the starter retaining stud blots.

Tighten

Tighten the starter mounting blot : 23 N•m (16.9 lb-ft).

Install the ground bolt from the engine block.
Install the starter solenoid nut to connect the battery positive connector.
Install the starter solenoid nut to connect the starter harness.

Tighten

Tighten the engine ground bolt : 38 N•m (28.0 lb-ft).
Tighten the starter solenoid harness connector nut : 10.5 N•m (7.7 lb-ft).
Tighten the starter solenoid battery positive connector nut : 10.5 N•m (7.7 lb-ft).

Lift down the vehicle.
Connect the negative battery cable.

Starter - 1.4 DOHC - G14D -

Removal Procedure

Disconnect the negative battery cable.
Lift up the vehicle.
Remove the starter solenoid nut to disconnect the starter harness.
Remove the starter solenoid nut to disconnect the battery positive connector.
Remove the ground bolt from the engine block.

Remove the starter mounting bolts.
Remove the starter.

Installation Procedure

Install the starter.
Install the starter mounting bolts.

Tighten

Tighten the starter mounting bolt : 25 N•m (18.4 lb-ft).

Install the ground bolt from the engine block.
Install the starter solenoid nut to connect the battery positive connector.
Install the starter solenoid nut to connect the starter harness.

Tighten

Tighten the engine ground bolt : 38 N•m (28.0 lb-ft).
Tighten the starter solenoid harness connector nut : 10.5 N•m (7.7 lb-ft).
Tighten the starter solenoid battery positive connector nut : 10.5 N•m (7.7 lb-ft).

Lift down the vehicle.
Connect the negative battery cable.

Battery/Battery Tray

Removal Procedure

Disconnect the negative battery cable and then disconnect the positive battery cable.
Remove the nuts from the battery rods that fasten the battery hold-down bar clamp.

Check the battery carrier tray for obvious cracks or damage. Detach the carrier tray if necessary by removing the upper and the lower bolts.

Installation Procedure

Install the battery carrier by fastening the carrier tray upper and lower bolts.

Tighten

Tighten the battery carrier tray upper and the lower bolts to 20 N•m (15 lb-ft).

Install the battery into the tray.
Fasten the bar clamp to the battery by loosely attaching the battery rods from the battery tray cutouts through the bar clamp holes, and loosely tightening the nuts.

Tighten

Tighten the battery retainer clamp-to-battery rod nuts to 4 N•m (35 lb-in).

Connect the negative battery cables.

Tighten

Tighten the battery cable nuts to 4.5 N•m (40 lb-in).

UNIT REPAIR

Generator - 1.2L DOHC/KDAC -

Disassembly Procedure

Remove the generator. Refer to "Generator"in this section.
Remove the generator rear cover retaining nut.
Remove the generator rear cover.

Remove the generator pulley retaining nut.
Remove the generator pulley.
Remove the generator pulley bushing.

Remove the through-bolt(4 EA).
Disconnect the generator front cover.

Caution : Do not force to handle the generator rotor because the generator rotor is pressed with the bearing. Do use a rubber hammer when removing.

Notice : The generator rear cover assembly consists of the brush, rectifier, regulator and stator and they are one assembly.

Remove the generator rotor bushing.
Remove the generator rotor fan.
Remove the generator rotor from the generator rear cover assembly.

Inspection / Measurement

Caution : The standard of all tests are used by digitalmeter.

Inspect the rotor assembly.

Test the rotor for an open circuit. Replace the rotor if necessary.

2) Test the slip-ring each other for an open circuit. Replace the rotor if necessary.

3) Test the rotor coil, slip-ring, and core for open or ground circuit. Replace them if necessary.

Brush Inspection.

Inspect the brush. If the brush is broken or have a wear, replace the generator rear cover assembly.
Open the brush cap and inspect for breaking. If breaked, replace the generator rear cover assembly.

Inspect trio(-) diodes.

Set the digitalmeter for measuring diode voltage.
Connect the digitalmeter positive connector to the cover.
Connect the digitalmeter negative connector to the negative diode and inspect for open or ground circuit.
If the measured spec. is under 200~600mV, replace the generator rear cover assembly.

Inspect trio(+) diodes.

Set the digitalmeter for measuring diode voltage.
Connect the digitalmeter negative connector to the cover.
Connect the digitalmeter positive connector to the positive diode and inspect for open or ground circuit.
If the measured spec. is under 200~600mV, replace the generator rear cover assembly.

Assembly Procedure

Install the generator rotor to the generator rear cover assembly.
Install the generator rotor fan.
Install the generator rotor bushing.

Install the generator front cover.
Install the through-bolt(4 EA).

Tighten

Tighten the generator through-bolt (T4): 4.75 N•m (3.5 lb-ft).

Install the generator pulley bushing.
Install the generator pulley.
Install the generator pulley retaining nut.

Tighten

Tighten the generator pulley retaining nut: 95 N•m (70 lb-ft).

Install the generator rear cover.
Install the generator rear cover retaining nut.

Tighten

Tighten the generator rear cover retaining nut: 16.5 N•m (12.1 lb-ft).

Install the generator.

Generator - 1.4L DOHC/KDAC -

Disassembly Procedure

Remove the generator. Refer to "Generator"in this section.
Remove the generator rear cover retaining nut.
Remove the generator rear cover.

Remove the generator pulley retaining nut.
Remove the generator pulley.
Remove the generator pulley bushing.

Remove the through-bolt(4 EA).
Disconnect the generator front cover.

Caution : Do not force to handle the generator rotor because the generator rotor is pressed with the bearing. Do use a rubber hammer when removing.

Notice : The generator rear cover assembly consists of the brush, rectifier, regulator and stator and they are one assembly.

Remove the generator rotor bushing.
Remove the generator rotor fan.
Remove the generator rotor from the generator rear cover assembly.

Inspection / Measurement

Caution : The standard of all tests are used by digitalmeter.

Inspect the rotor assembly.

Test the rotor for an open circuit. Replace the rotor if necessary.

2) Test the slip-ring each other for an open circuit. Replace the rotor if necessary.

3) Test the rotor coil, slip-ring, and core for open or ground circuit. Replace them if necessary.

Brush Inspection.

Inspect the brush. If the brush is broken or have a wear, replace the generator rear cover assembly.
Open the brush cap and inspect for breaking. If breaked, replace the generator rear cover assembly.

Inspect trio(-) diodes.

Set the digitalmeter for measuring diode voltage.
Connect the digitalmeter positive connector to the cover.
Connect the digitalmeter negative connector to the negative diode and inspect for open or ground circuit.
If the measured spec. is under 200~600mV, replace the generator rear cover assembly.

Inspect trio(+) diodes.

Set the digitalmeter for measuring diode voltage.
Connect the digitalmeter negative connector to the cover.
Connect the digitalmeter positive connector to the positive diode and inspect for open or ground circuit.
If the measured spec. is under 200~600mV, replace the generator rear cover assembly.

Assembly Procedure

Install the generator rotor to the generator rear cover assembly.
Install the generator rotor fan.
Install the generator rotor bushing.

Install the generator front cover.
Install the through-bolt(4 EA).

Tighten

Tighten the generator through-bolt (G14D): 4.75 N•m (3.5 lb-ft).

Install the generator pulley bushing.
Install the generator pulley.
Install the generator pulley retaining nut.

Tighten

Tighten the generator pulley retaining nut: 95 N•m (70 lb-ft).

Install the generator rear cover.
Install the generator rear cover retaining nut.

Tighten

Tighten the generator rear cover retaining nut: 18.5 N•m (13.6 lb-ft).

Install the generator.

GENERAL DESCRIPTION AND SYSTEM OPERATION

Battery

The battery has three major functions in the electrical system. First, the battery provides a source of energy for cranking the engine. Second, the battery acts as a voltage stabilizer for the electrical system. Finally, the battery can, for a limited time, provide energy when the electrical demand exceeds the output of the generator.

The sealed battery is standard on all cars. There are no vent plugs in the cover. The battery is completely sealed, except for two small vent holes in the sides. These vent holes allow the small amount of gas produced in the battery to escape.

The sealed battery has the following advantages over conventional batteries:

No water need be added for the life of the battery.
It is protected against overcharge. If too much voltage is applied to the battery, it will not accept as much current as a conventional battery. In a conventional battery, the excess voltage will still try to charge the battery, leading to gassing, which causes liquid loss.
It is not as liable to self-discharge as a conventional battery. This is particularly important when a battery is left standing for long periods of time.
It has more power available in a lighter and a smaller case.

Ratings

A battery has two ratings: (1) a reserve capacity rating designated at 27°C (80°F), which is the time a fully charged battery will provide 25 amperes current flow at or above 10.5 volts; (2) A cold cranking amp rating determined under testing at -18°C (0°F), which indicates the cranking load capacity.

Reserve Capacity

The reserve capacity is the maximum length of time it is possible to travel at night with the minimum electrical load and no generator output. Expressed in minutes, Reserve Capacity (or RC rating) is the time required for a fully charged battery, at a temperature of 27°C (81°F) and being discharged at a current of 25 amperes, to reach a terminal voltage of 10.5 volts.

Cold Cranking Amperage

The cold cranking amperage test is expressed at a battery temperature of -18°C (0°F). The current rating is the minimum amperage, which must be maintained by the battery for 30 seconds at the specified temperature, while meeting a minimum voltage requirement of 7.2 volts. This rating is a measure of cold cranking capacity.

The battery is not designed to last indefinitely. However, with proper care, the battery will provide many years of service.

If the battery tests well, but fails to perform satisfactorily in service for no apparent reason, the following factors may point to the cause of the trouble:

Vehicle accessories are left on overnight.
Slow average driving speeds are used for short periods.
The vehicle’s electrical load is more than the generator output, particularly with the addition of aftermarket equipment.
There are defects in the charging system, such as electrical shorts, a slipping generator belt, a faulty generator, or a faulty voltage regulator.
There has been battery abuse, including failure to keep the battery cable terminals clean and tight, or a loose battery hold-down.
There are mechanical problems in the electrical system, such as shorted or pinched wires.

Built - In Hydrometer

The sealed battery has a built-in, temperature-compensated hydrometer in the top of the battery. This hydrometer is to be used with the following diagnostic procedure:

When observing the hydrometer, make sure that the battery has a clean top.
Under normal operation, two indications can be observed:

GREEN DOT VISIBLE - Any green appearance is interpreted as a "green dot," meaning the battery is ready for testing.
DARK GREEN DOT IS NOT VISIBLE - If there is a cranking complaint, the battery should be tested. The charging and electrical systems should also be checked at this time.

Occasionally, a third condition may appear:
Occasionally, a third condition may appear:

CLEAR OR BRIGHT YELLOW - This means the fluid level is below the bottom of the hydrometer. This may have been caused by excessive or prolonged charging, a broken case, excessive tipping, or normal battery wear. Finding a battery in this condition may indicate high charging by a faulty charging system. Therefore, the charging and the electrical systems may need to be checked if a cranking complaint exists. If the cranking complaint is caused by the battery, replace the battery.

Charging Procedure

Batteries with the green dot showing do not require charging unless they have just been discharged, such as in cranking a vehicle.
When charging sealed-terminal batteries out of the vehicle, install the adapter kit. Make sure all the charger connections are clean and tight. For best results, batteries should be charged while the electrolyte and the plates are at room temperature. A battery that is extremely cold may not accept current for several hours after starting the charger.
Charge the battery until the green dot appears. The battery should be checked every half-hour while charging. Tipping or shaking the battery may be necessary to make the green dot appear.
After charging, the battery should be load tested. Refer to "Starter Motor" in this section.

Charging Time Required

The time required to charge a battery will vary depending upon the following factors:

Size of Battery - A completely discharged large heavy-duty battery requires more than twice the recharging as a completely discharged small passenger car battery.
Temperature - A longer time will be needed to charge any battery at -18°C (0°F) than at 27°C (81°F). When a fast charger is connected to a cold battery, the current accepted by the battery will be very low at first. The battery will accept a higher current rate as the battery warms.
Charger Capacity - A charger which can supply only 5 amperes will require a much longer charging period than a charger that can supply 30 amperes or more.
State-of-Charge - A completely discharged battery requires more than twice as much charge as a onehalf charged battery. Because the electrolyte is nearly pure water and a poor conductor in a completely discharged battery, the current accepted by the battery is very low at first. Later, as the charging current causes the electrolyte acid content to increase, the charging current will likewise increase.

Charging A Completely Discharged Battery - Off The Vehicle -

Unless this procedure is properly followed, a perfectly good battery may be needlessly replaced.

The following procedure should be used to recharge a completely discharged battery:

Measure the voltage at the battery terminals with an accurate voltmeter. If the reading is below 10 volts, the charge current will be very low, and it could take some time before the battery accepts the current in excess of a few milliamperes. Refer to "Charging Time Required" in this section, which focuses on the factors affecting both the charging time required and the rough estimates in the table below. Such low current may not be detectable on ammeters available in the field.
Set the battery charger on the high setting.

Important : Some chargers feature polarity protection circuitry, which prevents charging unless the charger leads are correctly connected to the battery terminals. A completely discharged battery may not have enough voltage to activate this circuitry, even though the leads are connected properly, making it appear that the battery will not accept charging current. Therefore, follow the specific charger manufacturer’s instruction for bypassing or overriding the circuitry so that the charger will turn on and charge a low-voltage battery.

Battery chargers vary in the amount of voltage and current provided. The time required for the battery to accept a measurable charger current at various voltages may be as follows:
Battery chargers vary in the amount of voltage and current provided. The time required for the battery to accept a measurable charger current at various voltages may be as follows:

Voltage	Hours
16.0 or more	Up to 4 hours
14.0-15.9	Up to 8 hours
13.9 or less	Up to 16 hours

If the charge current is not measurable at the end of the above charging times, the battery should be replaced.
If the charge current is measurable during the charging time, the battery is good, and charging should be completed in the normal manner.

Important : It is important to remember that a completely discharged battery must be recharged for a sufficient number of ampere hours (AH) to restore the battery to a usable state. As a general rule, using the reserve capacity (RC) rating as the number of ampere hours of charge usually brings the green dot into view.

If the charge current is still not measurable after using the charging time calculated by the above method, the battery should be replaced.
If the charge current is measurable during the charging time, the battery is good, and charging should be completed in the normal manner.

Jump Starting Procedure

Position the vehicle with the good(charged) battery so that the jumper cables will reach from the one battery to the other.
Turn off the ignition, all the lights, and all the electrical loads in both vehicles. Turn on the hazard flashers if jump starting where there is traffic. In addition, turn on any other lights needed for the work area.
In both vehicles, apply the parking brake firmly.

Notice : Make sure the cables are not on or near pulleys, fans, or other parts that will move when the engine starts, damaging the parts.

Shift an automatic transaxle to PARK, or a manual transaxle to NEUTRAL.
Shift an automatic transaxle to PARK, or a manual transaxle to NEUTRAL.

Caution : Do not use cables that have loose or missing insulation, or injury could result.

Clamp one end of the first jumper cable to the positive terminal on the battery. Make sure it does not touch any other metal parts. Clamp the other end of the same cable to the positive terminal on the other battery. Never connect the other end to the negative terminal of the discharged battery.
Clamp one end of the first jumper cable to the positive terminal on the battery. Make sure it does not touch any other metal parts. Clamp the other end of the same cable to the positive terminal on the other battery. Never connect the other end to the negative terminal of the discharged battery.

Caution : Do not attach the cable directly to the negative terminal of the discharged battery. Doing so could cause sparks and possible battery explosion.

Clamp one end of the second cable to the negative terminal of the booster battery. Make the final connection to a solid engine ground, such as the engine lift bracket, at least 450 millimeters (18 inches) from the discharged battery.
Clamp one end of the second cable to the negative terminal of the booster battery. Make the final connection to a solid engine ground, such as the engine lift bracket, at least 450 millimeters (18 inches) from the discharged battery.
Start the engine of the vehicle with the good battery. Run the engine at a moderate speed for several minutes. Then start the engine of the vehicle which has the discharged battery.
Remove the jumper cables by reversing the above sequence exactly. Remove the negative cable from the vehicle with the discharged battery first. While removing each clamp, take care that it does not touch any other metal while the other end remains attached.

Generator

The KDAC charging system has several models available, including the Ø114D (Valeo Mando) or CS121D. The number denotes the outer diameter in millimeters of the stator lamination.

CS generators are equipped with internal regulators. The Y connection (Valeo Mando) or Delta (KDAC) stator, a rectifier bridge, and a rotor with slip rings and brushes are electrically similar to earlier generators. A conventional pulley and fan are used. There is no test hole.

Unlike three-wire generators, the Ø114D (Valeo Mando) or CS121D (KDAC) may be used with only two connections: battery positive and an "L" terminal to the charge indicator lamp.

As with other charging systems, the charge indicator lamp lights when the ignition switch is turned to ON, and goes out when the engine is running. If the charge indicator is on with the engine running, a charging system defect is indicated.

The regulator voltage setting varies with temperature and limits the system voltage by controlling the rotor field current. The regulator switches rotor field current on and off. By varying the on-off time, correct average field current for proper system voltage control is obtained. At high speeds, the on-time may be 10 percent and the off-time 90 percent. At low speeds, with high electrical loads, on-time may be 90 percent and the off-time 10 percent.

The mono regulator having 2~3 pins in the terminal can be applied for generator. The regulator maintains the system voltage by controlling field current on-off without typically fixed freguency.

Charging System

The KDAC charging system has several models available, including the Ø114D (Valeo Mando) or CS121D. The number denotes the outer diameter in millimeters of the stator laminations.

CS generators use a new type of regulator that incorporates a diode trio. The Y connection (Valeo Mando) or Delta KDAC stator, a rectifier bridge, and a rotor with slip rings and brushes are electrically similar to earlier generators. A conventional pulley and fan are used. There is no test hole.

Starter

Wound field starter motors have pole pieces, arranged around the armature, which are energized by wound field coils.

Enclosed shift lever cranking motors have the shift lever mechanism and the solenoid plunger enclosed in the drive housing, protecting them from exposure to dirt, icy conditions, and splashes.

In the basic circuit, solenoid windings are energized when the switch is closed. The resulting plunger and shift lever movement causes the pinion to engage the engine flywheel ring gear. The solenoid main contacts close. Cranking then takes place.

When the engine starts, pinion overrun protects the armature from excessive speed until the switch is opened, at which time the return spring causes the pinion to disengage. To prevent excessive overrun, the switch should be released immediately after the engine starts.

Starting System

The engine electrical system includes the battery, the ignition, the starter, the generator, and all the related wiring. Diagnostic tables will aid in troubleshooting system faults. When a fault is traced to a particular component, refer to that component section of the service manual.

The starting system circuit consists of the battery, the starter motor, the ignition switch, and all the related electrical wiring. All of these components are connected electrically.