Kia G 3.8 DOHC Manual Download Page 53 | Manualshive

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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. Do not immerse parts in cleaning solvent. Immersing the yoke assembly and/or armature will damage the

insulation. Wipe these parts with a cloth only.

2. Do not immerse the drive unit in cleaning solvent. The overrun clutch is pre-lubricated at the factory and solvent

will wash lubrication from the clutch.

3. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.

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Summary of Contents for G 3.8 DOHC

Page 1: ...Engine Electrical System General Information Engine SLJ YPcal System...

Page 2: ...e running Battery requires frequent recharging Drive belt loose or worn Battery cable loose corroded or worn Electronic voltage regulator or alternator Wiring Adjust belt tension or replace belt Inspe...

Page 3: ...nition switch Replace Starter spins but engine will not crank Short in wiring Pinion gear teeth broken or starter motor Ring gear teeth broken Repair wiring Replace Replace fly wheel or torque convert...

Page 4: ...ARGING SYSTEM Items Specification Alternator Rate voltage 13 5 V 130A Speed in use 1 000 18 000 rpm Voltage regulator IC regulator built in type Regulator setting voltage 14 2 14 8 V 500 RPM 10A 25 C...

Page 5: ...Engine Electrical System Ignition System Engine Electrical System...

Page 6: ...e operating conditions are preprogrammed in the memory of the PCM Power Control Module The engine operating conditions speed load warm up condition etc are detected by the various sensors Based on the...

Page 7: ...2007 G 3 8 DOHC COMPONENTS...

Page 8: ...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 4 Installation is the reverse of removal ON VEHICLE INSPECTION...

Page 9: ...s 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 Crank the engine for no more than 5 10 se...

Page 10: ...SPARK PLUG 1 Remove the ignition coil connector A...

Page 11: ...park plug Be careful that no contaminates enter through the spark plug holes 4 Inspect the electrodes A and ceramic insulator B INSPECTION OF ELECTRODES Condition Dark deposits White deposits Descript...

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: ...ach 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 T...

Page 15: ...n 2 Check that there is no abnormal noise from the alternator while the engine is running CHECK DISCHARGE WARNING LIGHT CIRCUIT 1 Warm up the engine and then turn it off 2 Turn off all accessories 3 T...

Page 16: ...and correct as necessary Check the battery installed in the vehicle to ensure that it is in good condition The battery checking method is described in the section Battery The battery that is used to...

Page 17: ...e vehicle and test it Limit value 65A min The nominal output current value is shown on the nameplate affixed to the alternator body The output current value changes with the electrical load and the te...

Page 18: ...Turn on the ignition switch and check to see that the voltmeter indicates the following value Voltage Battery voltage If it reads 0V there is an open circuit in the wire between the alternator B term...

Page 19: ...Engine Electrical System Charging System Alternator Engine Electrical System...

Page 20: ...2007 G 3 8 DOHC COMPONENTS...

Page 21: ...the cable from alternator B terminal 3 Remove the drive belt 4 Pull out the through bolt and then remove the alternator A 5 Installation is the reverse of removal DISASSEMBLY 1 If the front bearing n...

Page 22: ...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 a...

Page 23: ...ion between the B terminal A and P terminals B between the E terminal C and P terminals B of each diode pair All diodes should have continuity in only one direction Because the rectifier diodes are de...

Page 24: ...careful 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...

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: ...Engine Electrical System Charging System Battery Engine Electrical System...

Page 28: ...ce 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 seale...

Page 29: ...solution as described above 6 Inspect the battery case and cover for cracks If cracks are present the battery must be replaced 7 Clean the battery posts with a suitable battery post tool 8 Clean the...

Page 30: ...INSPECTION BATTERY DIAGNOSTIC FLOW...

Page 31: ...low 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 3 Read the voltage after the load h...

Page 32: ...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 t...

Page 33: ...Engine Electrical System Starting System Engine Electrical System...

Page 34: ...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 t...

Page 35: ...e problem The starting system is now OK If the starter still does not crank the engine go to next step 4 Disconnect the connector from the S terminal of solenoid Connect a jumper wire from the B termi...

Page 36: ...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...

Page 37: ...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 sta...

Page 38: ...Engine Electrical System Starting System Starter Engine Electrical System...

Page 39: ...2007 G 3 8 DOHC COMPONENTS...

Page 40: ...er E TROQUE 49 0 63 7 Nm 5 0 6 5 kgf m 36 2 47 0 Ib ft starter mounting D 3 Installation is the reverse of removal 4 Connect the battery negative cable to the battery DISASSEMBLY 1 Disconnect the M te...

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: ...top 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...

Page 43: ...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 Loosen the through bolts A...

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: ...top 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...

Page 46: ...he armature 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 Mea...

Page 47: ...row or v shaped D Commutator mica depth Standard New 0 5 mm 0 0197 in Limit 0 2mm 0 0079 in 7 Check for continuity between the segments of the commutator If an open circuit exists between any segments...

Page 48: ...R 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 p...

Page 49: ...ong the shaft Replace it if does not slide smoothly 2 Rotate the overrunning clutch both ways Does it lock in one direction and rotate smoothly in reverse If it does not lock in either direction or it...

Page 50: ...ust or brass chips between the segments B If the commutator run out is not within the service limit replace the armature Commutator runout Standard New 0 02mm 0 0008in max Service limit 0 05mm 0 0020i...

Page 51: ...ny 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 If continuity exis...

Page 52: ...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 commuta...

Page 53: ...damaged CLEANING 1 Do not immerse parts in cleaning solvent Immersing the yoke assembly and or armature will damage the insulation Wipe these parts with a cloth only 2 Do not immerse the drive unit i...

Page 54: ...Engine Electrical System Starting System Starter Relay Engine Electrical System...

Page 55: ...check that there is continuity between each terminal Terminal Continuity 30 87 NO 85 86 YES 4 Apply 12V to terminal 85 and ground to terminal 86 Check for continuity between terminals 30 and 87 5 If t...

Page 56: ...Engine Electrical System Cruise Control System Engine Electrical System...

Page 57: ...l signals to PCM Brake pedal switch Transaxle range switch A T Clutch switch M T ETS motor Regulates the throttle valve to the set opening by PCM ETS Electronic Throttle System CRUISE CONTROL Cruise c...

Page 58: ...s slowed to required cruise speed releasing COAST SET switch will re engage system at new selected speed The tab down To lower vehicle speed cruise must be engaged and operating Tab down is done by qu...

Page 59: ...varies greatly upward or downward Surging repeated alternating acceleration and deceleration occurs after setting Malfunction of the vehicle speed sensor circuit Repair the vehicle speed sensor syste...

Page 60: ...arness or replace the SET switch Malfunction of the PCM signals Check input and output signals at PCM TROUBLE SYMPTOM 6 Trouble symptom Probable cause Remedy Cannot accelerate or resume speed by using...

Page 61: ...Engine Electrical System Cruise Control System Cruise Control Switch Engine Electrical System...

Page 62: ...2007 G 3 8 DOHC CIRCUIT DIAGRAM...

Page 63: ...the control switch 2 Measure resistance between terminals on the control switch when each function switch is ON switch is depressed Function switch Terminal Resistance Cruise Main 7 8 3 9k 1 Cancel 8...

Page 64: ...Cruise Main 7 8 Cancel 8 2 0 0V 0 22V Set Coast 8 2 1 5V 0 22V Resume Accel 8 2 3 0V 0 22V 3 If not within specification replace switch...

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