Ch 2 Engine Electrical

8/14/2019 Ch 2 Engine Electrical

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DISTRIBUTOR IGNITION SYSTEMGENERALINFORMATION2-2DIAGNOSISANDTESTING 2-2SECONDARYSPARKTEST2-2CYLINDERDROPTEST 2-2ADJUSTMENTS 2-3IGNITIONCOIL 2-3TESTING 2-3REMOVAL&INSTALLATION 2-3POWERTRANSISTOR(Ignition Module) 2-4REMOVAL&INSTALLATION 2-4DISTRIBUTOR 2-4REMOVAL&INSTALLATION 2-4

2-2

INSTALLATION 2-4CRANKSHAFTANDCAMSHAFTPOSITIONSENSORS 2-5DISTRIBUTORLESS IGNITIONSYSTEM 2-5GENERALINFORMATION2-5DIAGNOSISANDTESTING 2-5ADJUSTMENTS 2-5IGNITIONCOIL(s) 2-5TESTING 2-5REMOVAL&INSTALLATION 2-6POWERTRANSISTOR


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.~ P.X I_ - , . - I . -. , IS .~. I . r2-2 ENGINE LECTRICALnn

ity and rouble: hootingelectrical circuits,please refer to Section6 of this manual. I

The gnition ystem n he1.5L, 993-96 .8L,2.OL OHC, 994-98 .4LSOHC,.OL OHC,nd3.5L nginesses pointlessypedistributor,hoseadvance echanisms controlledy heEngine on-trol Unit ECU). n he1.5L, .8L, .4L nd3.5L n-gines,hedistributorouses built n gnition oiland gnition owerransistor.he .8LSOHC nd3.OL OHC ngines tilize separateoil and ran-sister ssemblv.Whenhe gnition witchs urnedON,batteryvoltages appliedo he gnition oil primary inding.As he haft f hedistributorotates,ignals retransmittedrom heoowertrainontrolmoduleo he

Fig. 1 This spark tester looks iust like a Fiu. 2 This spark tester has an aspark plug, attach the clip to ground and air-gap for measuring spark strecrank the engine o check or spark testing different voltage ignition s.ignition owerrarsistor. heseignals ctivatehepowerransistoro causegnition oil primary ind-ingcurrentlow rom he gnition oil negativeermi-

nal hroughhepowerransistoro groundepeatedly.This nterruptionnducesigh oltagen he gnitioncoilsecondarvindinas, hichs divertedhrouahthedistributor,park lug able nd park lugground,hus ausinggnitionn each ylinder.


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ENGINEELECTR

Fig. 9. . . note he idle speedandacteristics of the engine. The cwith the least drag is the non-ccyltnder(s) -

There renoadjustmentso thedistributorgnitionsystem ther han he gnitioniming djustment.e-fer o section or ignitioniming djustment.

2. Measurehe esistancef hesecondarygni-

desired pecificationsf:

tioncoilas ollows:a. Insert neof the est eadsnto hesec-ondarygnition oil erminal n op of thedis-tributor ap.b. Touchhesecondest ead o terminal orterminal of thedistributoronnector.c. Measurehe esistancendcomnareo the

2.

desired pecificationsf:

Measurehe esistancef hesectioncoilas ollows:a. Insert neof the est eadsntoondarygnition oil erminal n opotributor ap.b. Touchhesecondest ead o terminal of thedistributoronnecc. Measurehe esistancendco


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2-4 ENGINEELECTRICAL2. Installhedistributorn heengineis aligned ith hematchmarkn hehouhousings aligned ith hematchmarkn

4. Removehe etainingcrews nd oil romen-gine.5. Installations he eversef he emoval roce-dure.

Beforeemovinghedistributor,osition o.1cylinder tTopDead enterTDC) n hecompres-sionstroke ndalign he imingmarks.1. Disconnecthenegativeattery able.2. Removehe gnition irecover,f equipped.3. Detachhedistributor arnessonnector.4. Removehedistributorapwithall gnition iresstillconnected.emovehe oilwire, f necessary.5. Matchmarkhe otor o hedistributorousingand hedistributorousingo heengine.6. Removehehold-downut.7. Carefullyemovehedistributorrom heengine.

INSTALLATION6 See Figures 19 and 2gTiming Not Disturbed

1, Install new istributorousing -ring nd

4. Attachhedistributorarnessonn5. Installhedistributorap.6. Connecthenegativeattery able7. Adjusthe gnitioniming nd ightdown ut o 6 t. bs. 11Nm).Timing Dlsturbed

1. Install newdistributorousing -lubricate ithclean il.2. Positionheengine o heNo.1 pisTopDead enterTDC) f itscompressand hemark n he ibration ampers a

REMOVALS&NSTALLATION lubricate ithclean il.

0 on he imingndicator.3. Align hedistributorousing ndgmarks.nstallhedistributorn heenginor groove f hedistributorsnstallationlwith hedistributornstallationtud n heblock.Be ure hedistributors ullyseatalignmentf hedistributorotormakingtnr ic dinnnd with thn qn,c$nn of the Nn

ISL, 1AIL, 2.4L, and 3.5L Engines


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ENGlNEELECTRl

Fig. 19 Adjusting he distributor-1.5L en-gine shown, others similar

4. Install he hold-downnut.5. Attach he distributorharness onn6. Install he distributorcap.7. Connect he negativebatterycable8. Adjust he gn ition iming and ightdown nut o 8 ft. Ibs. (11 Nm).

For procedures n the position sensofer to Section4 in this manual.

The gnition system oundon the 1.6L, 1997-601.8L, 2.OLDOHC,1999-00 2.4L SOHC,2.4L DOHC,and 3.OLDOHCengines s a distributorless ype.The advanceof this system, ike the distributor ypeignition, is controlledby the EngineControl Unit(ECU)or PowertrainControl Module (PCM). Thedistributorless gnition systemcontainsa crankan-gle/position sensorwhich detects he crank angleor

TESTING1.6L and 19902.OLDOHCEngines6 See Figures21 and 22

1. Disconnect he negativebattery ableand gni-

b. Compare eading o the desrrecoil resistanceof 0.77-0.95 ohms.3. Measure he coil secondary esistalows:c. Detach he connector rom the d. Measure he resistancebetweevoltage erminals or the No. 1 and Nders, and between he h igh-voltage ethe No. 2 and No. 3 cylinders.e. Compare he measured esista


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2-6 ENGINEELECTRICAL

Fig. 26 Measuring ignition coil secondaryresistance-1997-00 1.8L and 1994-002.4L SOHCengines1. Disconnecthenegativeattery able nd gni-tioncoil harnessonnector.

89572g13Fig. 28 Measure he primary coil resistance Fig. 27 Measure the secondary resbetween the connector terminals-2.4L between he towers of the coil-2.4LDOHC naine engine

3. Tocheckhesecondaryoil resistance,er-. .term he ollowmg:a. Taganddisconnecthespark lugwiresfrom he gnition oil.b. Measurehesecondaryesistancef thecoil betweenhe owers f each ndividualoil.c. If the esistances notbetween0.1-27.3kilo-ohms,eplacehe gnition oil.

2. Measureheprimary oil resistances ollows:a. Measurehe esistanceetweenerminals3 and2 (coilsat heNo.1 andNo.4 cylindersides) f the gnition oil,andbetweenerminals3 and1 (coilsat heNo.2 andNo.3 cylindersides).b. Compareeadingo thedesired rimarycoil resistancef 0.70-0.86 hms.3. Measurehecoilsecondaryesistances ol-lows: 3.OLDOHCEnginec. Detachheconnectorrom he gnition oil.d. Measurehe esistanceetweenhehigh-voltageerminalsor theNo.1 andNo.4 cylin-ders, ndbetweenhehigh-voltageerminalsor6 See Figures 28 and 29

1. Measurehe esistancef heprimarygnitioncoilas ollows:

d. If themeasuredalue s within tlowance,here reno broken iresor scuits.2. Measurehe esistancef hesecontioncoilas ollows:3. Inserthe ead f heohmmeteretwpack ylindererminals:l Betweenoil erminals-4 for Cl Betweenoil erminals-5 for Cl Betweenoil erminals-6 for Ce. Measurehe esistancendcomdesired pecificationsf 11.3-l5.3kilof. If themeasuredalue s withinstalowance,here reno broken iresor s


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ENGINEELECTRIC3. Detach he electricalconnectors or the COIL4. Remove he retainingscrewsand coil from en-gine.5. Installation s the reverseof the removalproce-dure.

1997-00 1.81 and 1994-00 2.4L Engines) See Figure 31

1, Disconnect he negativebattery able.2. Detach he electricalconnector(s) or thecoil(s).3. Remove he spark plug wire(s) o the compan-ion cylinder(s).4 Remove he coil retainingbolts and ift the coilfrom the cylinder head.5. The nstalla tion s the reverseof the removal.3.OL DOHC Engine# See Figure 32

1, Disconnect he negativebattery able.2. Remove he ntakemanifoldplenum upper n-take mamfold) Refer o Section3.3. Tag and remove he sparkplug wires rom theignition coil by gripping he boot and not he cable.4 Detach he electricalconnectors or the coil.5. Remove he retainingscrewsand coil from en-gine.6. Installation s the reverseof the removalproce-dure.

1 lgnltlo c o,,2 sparlt plug case3 Spark plug4 Imltlon fatlure semm 93152g1:Fig. 31 Ignition system component loca,iions-1997-00 1.8L engine shown1999-00 2.4L engine similar

1. Disconnect he negativebatterycable.2. Detach he electricalconnectors or the ransis-tor.3. Remove he retainingscrewsand remove hetransistor rom engine.

Fig. 32 Ignition system componetions-3.01 DOHC engine1. Disconnect he negativebattery ab2. Remove he ntakemanifoldplenumtake manifold).Refer o Section3.3 Detach he electricalconnectors ortor.4. Remove he retainingscrewsand retransistor rom engine.5. Installation s the reverseof the remdure.


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.2-8 ENGINEELECTRICAL

Frontof theVehicle

Fig. 35 1.61(4661) and 2.OL 4663) DDHCenginesFiring order: l-3-4-2Distributorless gnition system

Frontof theVehicle

+

Fig. 36 1997-00 1.6L (4693) and 1999-002.41(4664) Engineswith distributorless g-nitionFiring order: l-3-4-2Distributorless gnition system

Fig. 37 2.4L (4664) engine with dignitionFiring order: l-3-4-2Distributor rotation: Counterclock


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ENGlNEELECTRlTESTINGVoltage Test

able for use by customers.An alternatorbench est is the mostdefinitive way to de-termine he condition of your alternator.REMOVAL&INSTALLATION

1. Make ure heengines OFF, nd urn he 1.51,1.61, 1.6L, 2.OLand2.4L Enginesheadlightsn or 15-20 econdso removenysur-face hargerom hebattery. , See Figures 4, thru 482. Using DVOM et o voltsDC,probe cross 1. Disconnecthenegativeattery able.thebatteryerminals.3. Measurehebatteryoltage. 2. Removehe eftside over anel nderhevehicle.4. Write ownhevoltageeading ndproceedo 3. On urbocharaedalant odels,emovehethenext est. air ntake ose. -No-load Test1. Connect achometero heengine.

4. Removehedrivebelts.5. Removehewater ump ulleys.6. Removehealternatorpper racket/brace.

Ensure hat the transmission s in Park ndthe emergencybrake s set. Blockinga wheelis optional and an addedsafety measure.2. Turnoff all electricaloads radio, lowermo-

tor,wipers, tc.)3. Startheengine nd ncreasengine peedoapproximately500 pm.4. Measurehevoltageeading t hebattery iththeengine olding steady 500 pm.Voltageshould ave aised t east .5volts,butnomore

7. On he1.6L ngineemovehebshieldwashereservoir ndbatteryray.8. On he1.6L ngine,emoveheaboltsat he opof he adiator nd ift upDonotdisconnecthe adiator oses.9. Detachhealternator iring on10. Removehealternator ountinmovehealternator.To nstall:11. Positionhealternatorn he owfixture nd nstall he owermountingoTighten ut ustenougho allow or movalternator.12. On he1.6L ngine,ower he adinstallheupper ttachingolts.

13. On he1.6L ngine,nstallhebashieldwashereservoir ndbatteryray.


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.2-10 ENGINEELECTRICAL 12. Disconnectnd emoveheair nt3. Loosenhe ensionerulley nd ealternatorrivebelt.4. OnCalifornia odels,emoveheconverterssembly.5. Removeheengineoll stoppertassembly.6. On he3.OL DHC ngine, iscoEGRemperatureensor ireand emovpipeassembly.7. On he3.OL OHC ngine,emovplenumtaybracketssembly.8. Detachhealternator iringharntors.Fig, 47 Remove he alternator adjustingbolt

. a a9. Removehealternatorpper nd

mountingolts.10. From eneathhevehicle,emovI^._.To install:11. Positionhealternatorn he owfixture.nstall nd ightenhemountingoto M-18 ft. bs. 20-25Nm).12. Connecthealternator iringharn13. On he3.OL OHC ngine,nstalplenumtaybracketnd ightenhemou13 t. Ibs. 18Nm).14. On he3.OL OHC ngine,nstalpipe nd ightenhe itting onnectionso(60 Nm).15. On he3.OL OHC noine.onne-emperatureensor ire.16. Connectheengineoll stoppert


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ENGINE LECTRICAl.unVeMlil(GSflWtWJ2.Gwwator harness con- connectk,,,3. Engme OS, evel d,pst,&4 Generator

Fig. 51 Alternator mounting 3.51 engine

The tarting ystemncludeshebattery,tartermotor, olenoid,gnition witch, ircuit rotectionandwiring onnectinghecomponents.n nhibitorswitchocatedn hepark/neutralafety witch rTransmissionangeTR) ensors ncludedn hestarting ystemo preventhevehiclerombeing

2. Connectvoltmeteretweenhepositiveer-minal f hebattery nd hestarter +circuit.3. Turnhe gnition ey o heSTART ositionandnotehevoltage n hemeter.4. If voltageeads .5voltsor more,heres highresistancen hestarter ables r hecable round,repair snecessary.f he oltageeadings okpro-teed o henext tep.

3. Removehe esonatoretainingmoveheair ntake ose nd esonatorsrequired.rllse care when removing he air ccover because he air-flow sensor sand s a sensitive component.

4. If equipped ithActive-ECSusp


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.2-12 ENGINEELECTRICAL*This section describes he operatingprinaciples of sendingunits, warning ights andgauges.Sensorswhich provide nformationto the EnafneControlUnit (ECU)or Electronicor Power&in Control Module (FCM/PCM) recovered n Section4 of this manual.

Instrumentanels ontain numberf indicatingdevicesgaugesndwarningights). hese evicesarecomposedf woseparateomponents.nesthesending nit,mountedn heengine r other e-mote art f hevehicle, nd heothers heactualgauge r ight n he nstrumentanel.Severalypes f sending nits xist, owever ostcanbecharacterizedsbeing ither pressureypeor a resistanceype.Pressureype ending nitsconvertiquidpressurentoanelectricalignalwhichis sent o hegauge. esistanceype ending nitsaremost ften sedo measureemperaturendusevariableesistanceo controlhe urrentlow backothe ndicatinqevice. othypes f sendinq nits reconnectednseries ya wimto hebatteryithioughthe gnition witch).Whenhe gnitions urnedON,

currentlows rom hebatteryhroughhe nd icatingdevice ndon o hesending nit.

89572$43Fig. 54 Place he sending unit in water andmeasure he resistance2. Disconnecthesending nitwiringharnessand emovehecoolantemperatureending nit.3. Placehesending nit ip n a panof warm a-ter.Use hermometero measurehewaterempera-tl KP,.4. Measurehe esistancecrosshesending niterminals hile hesending nit s n hewater.5. Note heohm eadingnd ompareo he ol-lowing pecifications:

i, 56, 57, and 561. Disconnecthenegativeattery2. Position suitable rain anundtor.3. Drainheengine oolant evelbcoolantemperatureending nit.4. Disconnecthesending nitwirinthen emovehecoolantemperatureefrom heengine.To install:5. Coathesending nit hreads itthread ealant.6. Installheengine oolantempesending nit nto hebore n heenginto 7-8 ft. Ibs. 10-12Nm).7. Attachheelectrical arnessonnsendina nit.8. fill thecooling ystemo hepro:onnecthenegativeattery able.

l Wateremperaturef 68F 2OC)-2.21-2.69 ilo-ohmsesistancel Wateremperaturef 158F7OCk90.5-117.5 hms esistance

'ESTING


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ENGINE LECTRlC

ing he oil pressuresendingunit

1. Detachheoil pressureauge nitelectricalconnector.2. Use suitableest ioht 12V-3.4W)o aroundtheharnesssideconnecto~ -3. Turn he gnitiono heONposition.4. Checkheconditionf he est ightandgaugeas ollows:a. If all componentsreoperatingroperly,the est ightwill flashor lightsteadily nd heoil pressureauge eedle ill move.

b. If the est ight lashes r lights teadily utthegauge oesnotmove,hegaugemust e e-placed.c. If neitherhe est ightor thegauge per-ate,checkheoil pressureauge ircuit nd e-place,f necessary.

SendingUnit Check1. Removeheelectrical arnessonnectorromthesending nitand emovehesending nit romtheoil filterhead.2. Connectnohmmeteretweenhe erminaland hesending nitbody avity nd heckor con-ductivity.f heres noconductivity,eplacehesend-ingunit.3. Next,nsert very hinwedgehroughheoilhole n heendof hesending nit.Pushhewedgein slightly ndmeasureesistance.here hould e- - -- d . .noconoucovey.4. If heres conductivity,venwhenwedgespushed,eplacehe ending nit.5. If heres noconductivityhen 71psipres-sure s placedhroughheoil hole, hesending nitis operatingroperly.

6. Checko see hat heres noair page hroughhesending nit. f heresleakage,hediaphragms broken nd hunitwill requireeplacement.REMOVAL&INSTALLATIONb See Figures 60 thru 65

1. Disconnecthenegativeattery2. Raise nd upporthevehicle a3. Detachheelectrical arnessonthesending nit, hen emoveheunitterhead.To install:4. Aoolv hinbead f sealanto hportion f heoil pressureending nisealero contactheendof he hreadthesending nit.5. Installhesending nitand ight(12Nm).Donotover-tightenhesendi6. Attachheelectrical arnessonsending nit.7. Carefullyower hevehicle,hennegativeatteryable.


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Troubleshooting Basic Starting System Problems Troubleshooting Basic Charging System ProblemsPmblem

Starter motor rotates engrne slowlycause

* Battery charge low or batterydefecttve

Sobnlon. Charge or replace battery

- Defective crrcurt between batteryand starter motor* Low load current

* Hugh load current

+ Clean and ttghten, or replacecables* Bench-test starter motor Inspectfor wom brushes and weakbrush springs.. Bench-test starter motor Checkengtne for fncbon, drag or coolantrn cylinders. Check nng gear-to-prnton gear clearance.

Starter motor wrll not rotate engrne

Starter motor dnve wrll not engage(solenotd known to be good)

Starter motor dnve wtli notdtsengage

* Battery charge low or battery * Charge or replaoe batterydefecttve* Faulty solenord . Check solenoid ground Reparr orreplace as necessary.* Damaged drive pnron gear or * Replace damaged gear(s)ring gear* Starter motor engagement weak . Bench-test starter motor. Starter motor rotates slowly wtth . Inspect dnve yoke pull-down andhigh load current pornt gap, check for worn endbushtngs. check m-g gear clear-ance. Engine setzed * Repatr engk7e. Defecbve contact pant assembly * Reparr or replace contact porntassembly. Inadequate contact pornt assembly + Repatr connectron at ground screw

ground- Defeckve hold-In co11 * Replace field w~ndrng assembly- Starter motor loose on flywheel . Ttghten mounttng boltshoustng. Worn drive end bustng . Replace bushtrg* Damaged nng gear teeth . Replace ring gear or dnveplate* Drive yoke return spnng broken or . Replace spnngmtsstng

Starter motor dnve d&engagesprematurelyLow load current

* Weak drive assembly thrust spnng * Replace dnve mechamsm* Hold-tn co11 defeckve . Replace field wtndtng assembly *- Worn brushes . Replace brushes* Weak brush springs * Replace spnngs

ProblemNoisy alternator

cause* Loose mounbngs. Loose drive pulley

SoluIion. Ttghten mountrng bolts. Tighten pulley

. Worn beanngs* Brush notse* Internal circuits shorted (Hughpitched whrne)

* Replace alternator. Replace alternator. Replace alternator

Squeal when starting engtne or . Glazed or loose belt * Replace or adfust beltacceleratmgIndicator light rematns on or . Broken belt . Install heftammeter rndrcates drscharge . Broken or dksconnected wares - Repatr or connect Wari

(ejrgrne runmng) * Internal aitemator problems * Replace alternator. Defectrve voltage regulator . Replace vottage regulatoCar Irght bulbs contmually bum out- * Alternator/regulator overchargtng . Replace voltagebatter-v needs water conbnually regulatoriatternatorCar kghts flare on acceleratton . Battery low. Internal alternator/regulator

problems* Charge or replace bat te. Replace alternator/regula

Low voltage output (alternator lghtfltckers conbnually or ammeterneedle wanders)* Loose or worn belt* Dkly or corroded connecttons* Internal alternator/regulator

oroblems

. Replace or adjust beit. Clean o r replace conne* Replace alternator/regula

Ch 2 Engine Electrical

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Transcript of Ch 2 Engine Electrical