SECTION 1E

ENGINE ELECTRICAL
CAUTION:Disconnectthenegativebatterycablebeforeremovingorinstallinganyelectricalunitorwhena
toolorequipmentcouldeasilycomeincontactwithexposedelectricalterminals.Disconnectingthiscable
willhelppreventpersonalinjuryanddamagetothevehicle.TheignitionmustalsobeinLOCKunless
otherwisenoted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-1 Starter Motor (0.8 Kilowatts) . . . . . . . . . . . . . . . 1E-19
Starter Specifications . . . . . . . . . . . . . . . . . . . . . . 1E-1 Starter Motor (1.4 Kilowatts) . . . . . . . . . . . . . . . 1E-28
Generator Specifications . . . . . . . . . . . . . . . . . . . 1E-2 Generator (C5-121D) . . . . . . . . . . . . . . . . . . . . . 1E-40
Battery Specifications . . . . . . . . . . . . . . . . . . . . . . 1E-2 Generator (C5-128D) . . . . . . . . . . . . . . . . . . . . . 1E-47
Fastener Tightening Specifications . . . . . . . . . . . 1E-2 General Description and System
Schematic and Routing Diagrams . . . . . . . . . . . 1E-3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-55
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-3 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-55
Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-4 Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-55
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-5 Reserve Capacity . . . . . . . . . . . . . . . . . . . . . . . . 1E-55
No Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-5 Cold Cranking Amperage . . . . . . . . . . . . . . . . . . 1E-55
Starter Motor Noise . . . . . . . . . . . . . . . . . . . . . . . . 1E-9 Built-In Hydrometer . . . . . . . . . . . . . . . . . . . . . . . 1E-55
Battery Load Test . . . . . . . . . . . . . . . . . . . . . . . . . 1E-9 Charging Procedure . . . . . . . . . . . . . . . . . . . . . . 1E-55
Generator Output Test . . . . . . . . . . . . . . . . . . . . 1E-10 Charging Time Required . . . . . . . . . . . . . . . . . . . 1E-56
Generator System Check . . . . . . . . . . . . . . . . . . 1E-10 Charging a Completely Discharged Battery
(Off the Vehicle) . . . . . . . . . . . . . . . . . . . . . . . . 1E-56
Maintenance and Repair . . . . . . . . . . . . . . . . . . . 1E-11
Jump Starting Procedure . . . . . . . . . . . . . . . . . . 1E-56
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . 1E-11
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-57
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-11
Charging System . . . . . . . . . . . . . . . . . . . . . . . . . 1E-57
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-15
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-57
Battery/Battery Tray . . . . . . . . . . . . . . . . . . . . . . 1E-16
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-57
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-19

SPECIFICATIONS
STARTER SPECIFICATIONS
Application Description
Starter 0.8 Kilowatts
No Load Test @ 10 volts Minimum 60 - Maximum 98 amps
Drive Pinion Speed at: 6,000-12,000 rpm
Solenoid
Hold-in
Hold in Windings @ 10 volts 13 19 amps
13-19
Pull-in Windings @ 10 volts 59-79 amps
Starter 1.4 Kilowatts
No Load Test @ 12.2 volts Minimum 40 - Maximum 90 amps
Drive Pinion Speed at: 3,200-4,800 rpm
Solenoid
Hold-in
Hold in Windings @ 10 volts 13 19 amps
13-19
Pull-in Windings @ 10 volts 59-79 amps

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1E -- 2 ENGINE ELECTRICAL

GENERATOR SPECIFICATIONS
Application Description
Types CS-121D CS-128D

BATTERY SPECIFICATIONS
Application Description
L4 Engine
Cold Cranking Amps 550 amps
RC (Minimum) 90 minutes
Load Test 270 amps
Replacement 85B-60
Minimum Voltage: Estimated Temperature:
9.6 21_C
21 C (70_F)
(70 F)
9.4 20_C
20 C (68_F)
(68 F)
9.1 0_C
0 C (32_F)
(32 F)
8.8 * 10_C (14_F)
( )
8.5 * 18_C (0.4_F)
( )
8.0 Below * 18_C (Below 0_F)

FASTENER TIGHTENING SPECIFICATIONS

Application NSm Lb-Ft Lb-In
Battery Cable Nuts 15 11 -
Battery Carrier Tray Lower Bolts 20 15 -
Battery Carrier Tray Upper Bolts 20 15 -
Battery Retainer Clamp-to-Battery Rod Nuts 5 - 44
Fuel Rail Retaining Bolts 20 15 -
Generator Battery Lead Connector Nut 15 11 -
Generator Drive End Bearing Nut (CS-121D) 81 60 -
Generator Drive End Nut (CS-128D) 100 74 -
Generator Lower Bracket-to-Generator 20 15 -
Generator Shackle Bracket Bolt 20 15 -
Generator Through-Bolts (CS-121D) 10 - 89
Generator Through-Bolts (C5-128D) 25 18 -
Starter End Frame-to-Brush Holder Assembly Bolts
3 - 27
(0.8 Kilowatts)
Starter Field Connector Nut 8 - 71
Starter Mounting Studs 43 32 -
Starter Solenoid Assembly Screws 8 - 71
Starter Solenoid-to-Ignition Terminal Nut 6 - 53
Starter Through-Bolts 6 - 53
Starter Solenoid Terminal-to-Battery Cable Nut 7 - 62

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 ENGINE ELECTRICAL 1E -- 3

SCHEMATIC AND ROUTING DIAGRAMS

STARTING SYSTEM

A202E007

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 1E -- 4 ENGINE ELECTRICAL
CHARGING SYSTEM

A202E008

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 ENGINE ELECTRICAL 1E -- 5

DIAGNOSIS
NO CRANK

Step Action Value(s) Yes No

1. Turn the headlamps ON.
2. Turn the dome lamps ON.
1 -
3. Turn the key to START.
Do the lights dim or go out? Go to Step 2 Go to Step 8
Check the battery state of charge. Go to
2 Is the green eye showing from the built-in - “Charging
hydrometer? Go to Step 3 Procedure”
1. Connect the voltmeter positive lead to the positive
battery terminal.
2. Connect the voltmeter negative lead to the
3 negative battery terminal.
3. Turn the ignition to START. Go to “Charging
Does the voltmeter indicate the value specified? <9.6 v Procedure” Go to Step 4
1. Connect the voltmeter negative lead to the
negative battery terminal.
2. Connect the voltmeter positive lead to the engine
4 block.
3. Place the ignition in the START position.
Does the voltmeter indicate the value specified? >0.5 v Go to Step 5 Go to Step 6
1. Clean and tighten the negative battery cable
connections both at the battery end and at the
5 ground end. - -
2. Replace the cable if needed.
Is the repair complete? System OK
1. Connect the voltmeter positive lead to the starter
“B” terminal.
2. Connect the voltmeter negative lead to the
6 negative battery terminal.
3. Check the cranking voltage.
Does the voltmeter indicate the value specified? <9 v Go to Step 7 Go to Step 13
Clean, tighten, or replace the positive battery cable.
7 - -
Is the repair complete? System OK
Check system fuse EF3 in the engine fuse block.
8 -
Is fuse EF3 blown? Go to Step 9 Go to Step 10
Replace system fuse EF3.
9 - -
Is the repair complete? System OK
Check the connection at the starter “S” terminal.
10 -
Is the connection in good condition? Go to Step 12 Go to Step 11
Repair the starter “S” terminal.
11 - -
Is the repair complete? System OK
1. Connect the voltmeter positive lead to the starter
“S” terminal.
2. Connect the voltmeter negative lead to the
12 negative battery terminal.
3. Place the ignition in the START position.
4. Read the voltage present at the “S” terminal.
Does the voltmeter indicate the specified value? >7 v Go to Step 13 Go to Step 14

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1E -- 6 ENGINE ELECTRICAL

NO CRANK (Cont’d)

Step Action Value(s) Yes No

Repair or replace the starter.
13 - -
Is the repair complete? System OK
Turn on the heater blower.
14 -
Does the blower operate? Go to Step 24 Go to Step 15
1. Disconnect connector C201.
2. Connect the voltmeter positive lead to terminal
1 of connector C201.
15
3. Connect the voltmeter negative terminal to
ground.
Does the voltmeter indicate the specified value? 12 v Go to Step 17 Go to Step 16
Repair the open in the RED/WHT wire from fuse
16 EF3 to Connector C201. - -
Is the repair complete? System OK
Check the contacts of terminal 1 on connector C201.
17 -
Are the contacts OK? Go to Step 19 Go to Step 18
Repair the faulty contact of connector C201.
18 - -
Is the repair complete? System OK
1. Reconnect connector C201.
2. Disconnect the ignition switch connector.
3. Connect the voltmeter positive lead to terminal
19 5 of the ignition switch connector.
4. Connect the voltmeter negative terminal to
ground.
Does the voltmeter indicate the specified value? 11-14 v Go to Step 21 Go to Step 20
Repair the open in the RED/WHT wire from terminal
1 of connector C201 to terminal 5 of the ignition
20 switch connector. - -
Is the repair complete? System OK
Check the contacts of terminal 5 of the ignition
21 switch connector. -
Are the contacts OK? Go to Step 23 Go to Step 22
Repair the faulty contact of the ignition switch
22 connector. - -
Is the repair complete? System OK
Replace the ignition switch.
23 - -
Is the repair complete? System OK
24 Does the vehicle have an automatic transmission? - Go to Step 25 Go to Step 35
1. Disconnect the Park/Neutral switch connector.
2. Connect the voltmeter positive lead to the
Park/Neutral switch connector terminal E,
connected to the RED/BLK wire.
25
3. Connect the voltmeter negative lead to the
negative battery terminal.
4. Place the ignition in the START position.
Does the voltmeter indicate the value specified? <7 v Go to Step 26 Go to Step 31
Check continuity between the Park/Neutral switch
connector terminal G, connected to the RED wire,
26 and the Park/Neutral switch connector terminal E,
connected to the RED/BLK wire.
Does the ohmmeter indicate the specified value? 0W Go to Step 27 Go to Step 30

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 ENGINE ELECTRICAL 1E -- 7

NO CRANK (Cont’d)

Step Action Value(s) Yes No

Check the condition of terminals E and G on both
the Park/Neutral switch connector and on the
27 Park/Neutral switch. -
Are any of these terminals faulty? Go to Step 28 Go to Step 29
Repair the faulty terminal.
28 - -
Is the repair complete? System OK
Repair the open in the RED wire between terminal G
of the Park/Neutral switch connector and the starter
29 “S” terminal. - -
Is the repair complete? System OK
Replace the Park/Neutral switch.
30 - -
Is the repair complete? System OK
1. Reconnect the Park/Neutral switch.
2. Disconnect connector C104.
3. Connect the voltmeter positive lead to terminal
31 10 of connector C104 on the ECM/ABS harness.
4. Connect the voltmeter negative lead to ground.
5. Turn the ignition switch to START.
Does the voltmeter indicate the specified value? 12 v Go to Step 32 Go to Step 39
Check terminal 10 on both sides of connector C104.
32 -
Is one of them faulty? Go to Step 33 Go to Step 34
Repair the faulty terminal.
33 - -
Is the repair complete? System OK
Repair the open in the RED/BLK wire from terminal
10 of connector C104 to terminal E of the
34 Park/Neutral switch. - -
Is the repair complete? System OK
1. Disconnect connector C104.
2. Connect the voltmeter positive lead to terminal
10 of connector C104 on the ECM/ABS harness.
35
3. Connect the voltmeter negative lead to ground.
4. Turn the ignition switch to START.
Does the voltmeter indicate the specified value? 12 v Go to Step 36 Go to Step 39
Check terminal 10 on both sides of connector C104.
36 -
Is one of them faulty? Go to Step 37 Go to Step 38
Repair the faulty terminal.
37 - -
Is the repair complete? System OK
Repair the open in the RED wire from terminal 10 of
38 connector C104 to the starter “S” terminal. - -
Is the repair complete? System OK
1. Disconnect connector C210.
2. Connect the voltmeter positive lead to terminal
14 of connector C210 on the I/P harness.
39
3. Connect the voltmeter negative lead to ground.
4. Turn the ignition switch to START.
Does the voltmeter indicate the specified value? 12 v Go to Step 40 Go to Step 43
Check terminal 14 on both sides of connector C210.
40 -
Is one of them faulty? Go to Step 41 Go to Step 42
Repair the faulty terminal.
41 - -
Is the repair complete? System OK

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1E -- 8 ENGINE ELECTRICAL

NO CRANK (Cont’d)

Step Action Value(s) Yes No

Repair the open in the RED wire from terminal 14 of
42 connector C210 to terminal 10 of connector C104. - -
Is the repair complete? System OK
1. Disconnect the ignition switch connector.
2. Connect the voltmeter positive lead to terminal ST
of the ignition switch.
43
3. Connect the voltmeter negative lead to ground.
4. Turn the ignition switch to START.
Does the voltmeter indicate the specified value? 12 v Go to Step 45 Go to Step 44
Replace the ignition switch.
44 - -
Is the repair complete? System OK
Check terminal ST on the ignition switch and
45 terminal 3 of the ignition switch connector. -
Are the terminals in good condition? Go to Step 46 Go to Step 47
Repair the open in RED wire between terminal 3 of
the ignition switch connector and terminal 14 of
46 connector C210. - -
Is the repair complete? System OK
Repair the faulty terminal.
47 - -
Is the repair complete? System OK

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 ENGINE ELECTRICAL 1E -- 9

STARTER MOTOR NOISE

To correct starter motor noise during starting, use the following procedure:

Checks Action
Check for a high-pitched whine during cranking, before The distance is too great between the starter pinion
the engine fires. The engine cranks and fires properly. and the flywheel. Shimming the starter toward the
flywheel is required.
Check for a high-pitched whine after the engine fires, The distance is too small between the starter pinion
as the key is being released. The engine cranks and and the flywheel. Shimming the starter away from the
fires properly. This intermittent complaint is often flywheel is required.
diagnosed as ‘‘starter hang-in’’ or ‘‘solenoid weak.’’
Check for a loud ‘‘whoop’’ after the engine fires but The most probable cause is a defective clutch. A new
while the starter is still held engaged. The sound is like clutch will often correct this problem.
a siren if the engine is revved while the starter is
engaged.
Check for a ‘‘rumble,’’ a ‘‘growl,’’ or, in severe cases, a The most probable cause is a bent or an unbalanced
‘‘knock’’ as the starter is coasting down to a stop after starter armature. A new armature will often correct this
starting the engine. problem.

If the complaint is noise, correction can be achieved by BATTERY LOAD TEST

proper shimming as follows:
1. Check the battery for obvious damage, such as a
1. Check for a bent or a worn flywheel. cracked or broken case or cover, which could permit
2. Start the engine and carefully touch the outside diam- the loss of electrolyte. If damage is obvious, replace
eter of the rotating flywheel ring gear with chalk or a the battery.
crayon to show the high point of the tooth runout.
Caution: Do not charge the battery if the hydrometer
Turn the engine OFF and rotate the flywheel so that
is clear or light yellow. Instead, replace the battery. If
the marked teeth are in the area of the starter pinion
the battery feels hot or if violent gassing or spewing
gear.
of electrolyte through the vent hole occurs, discontinĆ
3. Disconnect the negative battery cable to prevent the ue charging or reduce the charging rate to avoid injuĆ
cranking of the engine. ry.
4. Check the pinion-to-flywheel clearance by using a
2. Check the hydrometer. If the green dot is visible, go to
wire gauge of 0.5 mm (0.02 inch) minimum thickness
the load test procedure. If the indicator is dark but
or diameter. Center a pinion tooth between two fly-
green is not visible, charge the battery. For charging a
wheel teeth and the gauge. Do not gauge in the cor-
battery removed from the vehicle, refer to “Charging a
ners, where a misleading larger dimension may be
Completely Discharged Battery (Off the Vehicle)” in
observed. If the clearance is under this minimum,
this section.
shimming the starter away from the flywheel is re-
quired. 3. Connect a voltmeter and a battery load tester across
the battery terminals.
5. If the clearance approaches 1.5 mm (0.06 inch) or
more, shimming the starter toward the flywheel is re- 4. Apply a 300-ampere load for 15 seconds to remove
quired. This condition is generally the cause of bro- any surface charge from the battery.
ken flywheel teeth or a broken starter housing. Shim 5. Remove the load.
the starter toward the flywheel by shimming only the 6. Wait 15 seconds to let the battery recover, and apply
outboard starter mounting pad. A shim of 0.40 mm a 270-ampere load.
(0.016 inch) thickness at this location will decrease
the clearance by approximately 0.30 mm Important: The battery temperature must be estimated
(0.012 inch). If normal starter shims are not available, by touch and by the temperature condition the battery
plain washers or other suitable material may be used has been exposed to for the preceding few hours.
as shims. 7. 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.

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1E -- 10 ENGINE ELECTRICAL

GENERATOR OUTPUT TEST

1. Perform the generator system test. Refer to “Gener-
ator System Check” in this section.
2. Replace the generator if it fails that test. Refer to
“Generator” in the On-Vehicle Service section. If it
passes the test, perform the on-vehicle output
check which follows.
Important: Always check the generator for output be-
fore assuming that a grounded “L” terminal circuit has
damaged the regulator.
3. Attach a digital multimeter, an ammeter, and a car-
bon pile load to the vehicle.
Important: Be sure the vehicle battery is fully charged,
and the carbon pile load is turned off.
4. With the ignition switch in the OFF position, check
and record the battery voltage. C102E009

5. Remove the harness connector from the generator.

6. Turn the ignition switch to the RUN position with the GENERATOR SYSTEM CHECK
engine not running. Use a digital multimeter to When operating normally, the generator indicator lamp
check for voltage in the harness connector “L” termi- will come on when the ignition switch is in the RUN posi-
nal. tion and go out when the engine starts. If the lamp oper-
7. The reading should be near the specified battery ates abnormally or if an undercharged or overcharged
voltage of 12 volts. If the voltage is too low, check battery condition occurs, the following procedure may
the indicator “L” terminal circuits for open and be used to diagnose the charging system. Remember
grounded circuits causing voltage loss. Correct any that an undercharged battery is often caused by acces-
open wires, terminal connections, etc., as neces- sories being left on overnight or by a defective switch
sary. Refer to “Charging System” in this section. that allows a lamp, such as a trunk or glove box lamp, to
8. Attach the generator harness connector. stay on.
9. Run the engine at a moderate idle, and measure the Diagnose the generator with the following procedure:
voltage across the battery terminals. The reading 1. Visually check the belt and wiring.
should be above that recorded in Step 14 but less 2. With the ignition switch in the ON position and the en-
than 16 volts. If the reading is over 16 volts or below gine stopped, the charge indicator lamp should be on.
the previous reading, replace the generator. Refer to If not, detach the harness at the generator and
“Generator” in the On-Vehicle Service section. ground the ‘‘L’’ terminal in the harness with a fused,
10. Run the engine at a moderate idle, and measure the 5-ampere jumper lead.
generator amperage output. D If the lamp lights, replace the generator. Refer to
11. Turn on the carbon pile, and adjust it to obtain the “Generator” in the On-Vehicle Service section.
maximum amps while maintaining the battery volt- D If the lamp does not light, locate the open circuit
age above 13 volts. between the ignition switch and the harness con-
12. If the reading is within 15 amps of the generator’s nector. The indicator lamp bulb may be burned out.
rating noted on the generator, the generator is good. 3. With the ignition switch in the ON position and the en-
If not, replace the generator. Refer to “Generator” gine running at moderate speed, the charge indicator
in the On-Vehicle Service section. lamp should be off. If not, detach the wiring harness
13. With the generator operating at the maximum out- at the generator.
put, measure the voltage between the generator D If the lamp goes off, replace the generator. Refer to
housing and the battery negative terminal. The volt- “Generator” in the On-Vehicle Service section.
age drop should be 0.5 volt or less. If the voltage
D If the lamp stays on, check for a short to ground in
drop is more than 0.5 volt, check the ground path
the harness between the connector and the indica-
from the generator housing to the negative battery
tor lamp.
cable.
14. Check, clean, tighten, and recheck all of the ground Important: Always check the generator for output be-
connections. fore assuming that a grounded ‘‘L’’ terminal circuit has
damaged the regulator. Refer to “Generator” in the Unit
Repair section.

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 ENGINE ELECTRICAL 1E -- 11

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE
GENERATOR
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the manifold air temperature (MAT) sen-
sor electrical connector from the air intake tube.

A202E001

3. Remove the breather tube clamp and all other clamps

to remove the air intake tube.

A202E002

4. Remove the battery harness connector nut from the

generator.

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1E -- 12 ENGINE ELECTRICAL
5. Remove the generator shackle bracket bolt and the
washer.
6. Remove the serpentine accessory drive belt. For ve-
hicles equipped with power steering and air condition-
ing, refer to Section 6B, Power Steering Pump for belt
removal.

A202E003

7. Remove the bolt and the retaining clamp of the har-

ness.

A202E004

8. For vehicles with the SOHC engine, remove the nuts

and the washers which hold the generator lower
bracket-to-generator bolts.

A102E234

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 ENGINE ELECTRICAL 1E -- 13
9. For vehicles with the DOHC engine, remove the
throttle body. Refer to Section 1F, Engine Controls.
10. Remove the fuel rail mounting bolts.
Notice: Take extreme care not to damage the fuel injec-
tor O-rings to prevent fuel leaks when the fuel rail is re-
seated.
11. Unseat the fuel rails from the cylinder head, and
slightly push the fuel rail assembly clear of the cylin-
der head in the direction of the master cylinder.
12. Remove the nut and the washers which hold the
generator lower bracket-to-generator bolt.
13. Carefully remove the generator.

A102E254

Installation Procedure
1. Install the generator at the generator lower bracket
and insert the generator bolts.
2. Install the nuts and the washers on the generator low-
er bracket-to-generator bolts (SOHC engine is
shown).
Tighten
Tighten the generator lower bracket-to-generator
nuts to 20 NSm (15 lb-ft).

A102E234

3. Install the serpentine accessory drive belt on vehicles

not equipped with power steering and air condition-
ing.
4. Secure the generator to the shackle bracket with the
bolt (SOHC engine is shown). For vehicles equipped
with power steering and air conditioning, refer to SecĆ
tion 6B, Power Steering Pump.
Tighten
Tighten the generator shackle bracket bolt to 20 NSm
(15 lb-ft).

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1E -- 14 ENGINE ELECTRICAL
5. Connect the harness connector to the back of the
generator.
6. Install the generator lead to the battery and fasten
the lead with the nut.
Tighten
Tighten the generator battery lead connector nut to
15 NSm (11 lb-ft).
7. Lubricate the injector O-rings on the DOHC engine
with engine oil.
8. Install the fuel rail assembly.
Tighten
Tighten the fuel rail retaining bolts to 20 NSm (15 lb-
ft).
9. Install the throttle body. Refer to Section 1F, Engine
Controls.
A102E232

10. Install the harness retaining clamp bolt.

A202E004

11. Install the air intake tube and the connector.

A202E002

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 ENGINE ELECTRICAL 1E -- 15
12. Install the MAT electrical connector to the air intake
tube.
13. Connect the negative battery cable.

A202E001

STARTER
Removal Procedure
1. Remove the nut that secures the starter ground wire
to the mounting stud.
2. Remove the ground wire.
3. Remove the lower and then the upper starter stud/
weld nut assemblies. (The lower stud/weld nut as-
sembly is shown.)

B202E005

4. Remove the starter solenoid nuts to disconnect the

electrical cables.
5. Remove the starter assembly.

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1E -- 16 ENGINE ELECTRICAL

Installation Procedure
1. Place the starter assembly in position using an assis-
tant to prop up the starter to aid in fastening the upper
mounting stud with the weld nut.
2. Install the upper and the lower starter mounting studs
with the weld nuts.
Tighten
Tighten the starter mounting studs to 43 NSm (32 lb-
ft).

B202E005

3. Position the starter electrical wires on the solenoid

terminals.
4. Position the ground wire on the lower stud.
5. Install the starter solenoid nuts.
Tighten
Tighten the starter solenoid terminal-to-battery cable
terminal nut to 7 NSm (62 lb-in).
Tighten the starter solenoid terminal-to-ignition termi-
nal nut to 6 NSm (53 lb-in).
6. Install the ground wire nut.
Tighten
Tighten the ground wire terminal to the point at which
it meets the nut. Then tighten the ground wire termi-
nal an additional quarter turn.

A102E236

BATTERY/BATTERY TRAY
Removal Procedure
1. Disconnect the negative battery cable and then dis-
connect the positive battery cable.
2. Remove the nuts from the battery rods that fasten the
battery hold-down bar clamp.

A102E241

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 ENGINE ELECTRICAL 1E -- 17
3. Check the battery carrier tray for obvious cracks or
damage. Detach the carrier tray if necessary by re-
moving the upper and the lower bolts.

A202E005

Installation Procedure
1. Install the battery carrier by fastening the carrier tray
upper and lower bolts.
Tighten
Tighten the battery carrier tray upper and lower bolts
to 20 NSm (15 lb-ft).

A202E005

2. Install the battery into the tray.

3. Fasten the bar clamp to the battery by loosely attach-
ing 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 5 NSm (44 lb-in).

A102E241

DAEWOO T-100 BL3

1E -- 18 ENGINE ELECTRICAL
4. Connect the negative and the positive battery cables.
Tighten
Tighten the battery cable nuts to 15 NSm (11 lb-ft).

A102E240

DAEWOO T-100 BL3

 ENGINE ELECTRICAL 1E -- 19

UNIT REPAIR
STARTER MOTOR (0.8 KILOWATTS)
Disassembly Procedure
1. Remove the starter. Refer to “Starter” in this section.
2. Remove the starter through-bolts.

A302E002

3. Remove the field connector nut. Disconnect the field

connector.

A302E003

4. Pry off the commutator end frame/brush/brush holder

assembly from the field frame.
5. Remove the bolts that secure the end frame to the
brush/brush holder assembly.
6. Inspect the brushes, the pop-out springs, and the
plastic spring retainers for wear and damage. Re-
place the parts, if necessary.

A302E004

DAEWOO T-100 BL3

1E -- 20 ENGINE ELECTRICAL
7. Check the armature to see if it turns freely. If the ar-
mature does not turn freely, break down the assembly
beginning with Step 9. Otherwise, give the armature a
no-load test.

A302E005

Important: If the specified current draw does not in-

clude the solenoid, deduct from the armature reading
the specified current draw of the solenoid hold-in wind-
ing.
Notice: Complete the testing in a minimum amount of
time to prevent overheating and damaging the solenoid.
8. To begin the no-load test, close the switch and
compare the rpm, the current, and the voltage read-
ings with the specifications. Refer to “Starter Specifi-
cations” in this section. Make disconnections only
with the switch open. Use the test results as follows:
8.1. Rated current draw and no-load speed indi-
cate a normal condition for the starter motor.
8.2. Low free speed and high current draw indicate
too much friction (tight, dirty, or worn bear-
ings, or a bent armature shaft), a shorted ar-
A102E219
mature, or a shorted armature and fields.

8.3. Failure to operate with high current draw indi-

cates a direct ground in the terminal or fields,
or “frozen” bearings.
8.4. Failure to operate with no current draw indi-
cates an open field circuit, open armature
coils, broken brush springs, worn brushes,
high insulation between the commutator bars,
or other causes which will prevent good con-
tact between the brushes and the commuta-
tor.
8.5. Low no-load speed and low current indicate
high internal resistance and high current
draw, which usually means shorted fields.

A102E219

DAEWOO T-100 BL3

 ENGINE ELECTRICAL 1E -- 21
9. Separate the field frame from the armature assem-
bly.

A302E006

10. Remove the solenoid assembly screws.

A102E226

11. Rotate the solenoid and remove it along with the

plunger return spring.

A102E247

DAEWOO T-100 BL3

1E -- 22 ENGINE ELECTRICAL
Important: If the solenoid is not removed from the start-
ing motor, the connector strap terminals must be re-
moved from the terminal on the solenoid before making
these tests.
12. Test the solenoid windings by checking the current
draw.
12.1. Check the hold-in windings by connecting
an ammeter in series with a 12-volt battery,
the switch terminal, and to ground.
12.2. Connect the carbon pile across the battery.
12.3. Adjust the voltage to 10 volts. The ammeter
reading should be 13 to 19 amperes.

A102E221

Important: Current will decrease as the windings heat

up. Current draw readings that are over specifications
indicate shorted turns or a ground in the windings of the
solenoid Both conditions require replacement of the so-
lenoid. Current draw readings that are under specifica-
tions indicate excessive resistance. No reading
indicates an open circuit.
13. Check both windings, connecting them as in the pre-
ceding test.
13.1. Ground the solenoid motor terminal.
13.2. Adjust the voltage to 10 volts. The ammeter
reading should be 59 to 79 amperes.
13.3. Check the connections and replace the so-
lenoid, if needed.

A102E221

14. Remove the plunger with the boot and the shift lever
assembly.

A302E007

DAEWOO T-100 BL3

 ENGINE ELECTRICAL 1E -- 23
15. Remove the armature assembly from the starter
housing.

A302E008

16. Disassemble the shaft assembly by separating the

bushing from the shaft.
17. Remove the collar and the locking ring from the
groove on the shaft.

A102E220

18. Remove the pinion stop and the drive from the shaft.

A102E248

DAEWOO T-100 BL3

1E -- 24 ENGINE ELECTRICAL
19. Inspect the armature shaft, the collar, and the pinion
for discoloration, damage, or wear. Replace the
parts, as needed.
20. Inspect the armature commutator. If the commuta-
tor is rough, it should be turned down. The outside
diameter of the commutator must measure at least
41.91 mm (1.650 inches) after it is undercut or
turned. Do not turn out-of-round commutators.
21. Inspect the points where the armature conductors
join the commutator bars. Make sure the armature
conductors and the commutator bars have a good
connection. A burned commutator bar is usually evi-
dence of a poor connection.
22. If test equipment is available, check the armature for
short circuits by placing it on a growler and holding a
saw blade over the armature core while the arma-
ture is rotated. If the saw blade vibrates, replace the
A302E008 armature.
23. Recheck the armature after cleaning between the
commutator bars. If the saw blade vibrates, replace
the armature.

Assembly Procedure
1. Clean all of the starter motor parts, but do not use
grease-dissolving solvents for cleaning the armature
and the field coils.
2. Lubricate the drive and the bushings.
3. If proceeding with just the reassembly of the solenoid,
perform Steps 4 and 5.
4. If the starter and the solenoid were fully disas-
sembled, begin reassembly by installing the shift le-
ver assembly with the plunger and the boot.

A302E007

DAEWOO T-100 BL3

 ENGINE ELECTRICAL 1E -- 25
5. Position the solenoid assembly and the return spring
against the plunger, applying the sealer to the sole-
noid flange.

A102E247

6. Fasten the solenoid assembly with the screws.

Tighten
Tighten the starter solenoid assembly screws to
8 NSm (71 lb-in).

A102E226

7. Install the drive and the pinion stop on the armature

shaft.

A102E248

DAEWOO T-100 BL3

1E -- 26 ENGINE ELECTRICAL
8. Install the lock ring into the groove on the armature
shaft.
9. Insert the collar.

A102E220

10. Install the field frame.

A302E006

11. With new brushes positioned in the brush holder as-

sembly, measure the inside diameter of the brush
holder assembly.
12. Insert the brush holder assembly on a plastic, steel,
or wooden dowel about the same diameter as the in-
side diameter of the brush holder assembly.

A302E009

DAEWOO T-100 BL3

 ENGINE ELECTRICAL 1E -- 27
13. Position the end of the dowel with the armature
commutator end. Slide the brush holder assembly
onto the armature.
14. Install the end frame on the brush holder assembly
with the bolts.
Tighten
Tighten the starter end frame-to-brush holder assem-
bly bolts to 3 NSm (27 lb-in).

A302E010

15. Install the starter through-bolts.

Tighten
Tighten the starter through-bolts to 6 NSm (53 lb-in).

A302E002

16. Install the starter field coil connection to the starter

terminal and fasten it with the nut.
Tighten
Tighten the starter field connector nut to 8 NSm (71 lb-
in).

A302E011

DAEWOO T-100 BL3

1E -- 28 ENGINE ELECTRICAL
Important: The pinion clearance must be correct to pre-
vent the buttons on the shift lever yoke from rubbing on
the clutch collar during cranking.
17. When the solenoid is replaced, it is necessary to
check the pinion clearance.

A302E001

18. Disconnect the motor field coil connector from the

solenoid motor terminal and carefully insulate the
connector.
19. Connect one 12-volt battery lead to the solenoid
switch terminal and the other to the starter frame.
20. Flash a jumper lead momentarily from the solenoid
motor terminal to the starter frame, allowing the pin-
ion to shift in the cranking position, where it will re-
main until the battery is disconnected.
Important: A means for adjusting the pinion clearance
is not provided on the starter motor. If the clearance
does not fall within the limits, check for improper installa-
tion and replace all worn parts.
21. Push the pinion back as far as possible to take up
any movement, and check the clearance with a feel-
er gauge. The clearance should be 0.25 to 3.56 mm
A102E227
(0.01 to 0.14 inch).

STARTER MOTOR (1.4 KILOWATTS)

Disassembly Procedure
1. Remove the starter. Refer to “Starter,” in this section.
2. Remove the starter through-bolts.

A102E239

DAEWOO T-100 BL3

 ENGINE ELECTRICAL 1E -- 29
3. Remove the commutator end frame/brush holder as-
sembly.
4. Inspect the brushes, the pop-out springs, and the
brush holders for wear and damage. Replace the as-
sembly, if necessary.

A102E215

Important: This test should be made for each ground or

insulated brush to ensure continuity through both
brushes and leads. If the lamp fails to light, the field coil
is open and will require replacement.
5. For only those starters having a shunt coil connec-
tion, use a test lamp, placing one lead on the shunt
coil terminal while connecting the other lead to a
ground brush or an insulated brush.

A102E216

6. When testing a series coil for ground, separate the

series and the shunt coil strap terminals during the
test.
6.1 With the strap terminals not touching the case
or the other ground, using a test lamp, placing
one lead on the grounded brush holder and
the other lead on either insulated brush.
6.2 If the lamp is lit, a grounded series coil is indi-
cated and must be repaired or replaced.
6.3 Test for an open circuit on each insulated
brush by placing one lead on the series coil
terminal and the other lead on the insulated
brush.
6.4 If the test lamp is not lit, the series coil is open
and will require repair or replacement.

A102E217

DAEWOO T-100 BL3

1E -- 30 ENGINE ELECTRICAL
7. Check the armature to see if it turns freely. If the ar-
mature does not turn freely, break down the assembly
immediately, starting with Step 14. Otherwise, give
the armature a no-load test.

A102E218

Notice: Complete the testing in a minimum amount of

time to prevent overheating and damaging the solenoid.
Important: If the specified current draw does not in-
clude the solenoid, deduct from the armature reading
the specified current draw of the solenoid hold-in wind-
ing.
8. To begin the no-load test, close the switch and
compare the rpm, the current, and the voltage read-
ings with the specifications. Refer to “Starter Specifi-
cations” in this section. Make disconnections only
with the switch open. Use the test results as follows:
8.1 Rated current draw and no-load speed indi-
cate a normal condition for the starter motor.
8.2 Low free speed and high current draw indicate
too much friction from tight, dirty, or worn
bearings, or a bent armature shaft, a shorted
A102E219
armature, or a shorted armature or fields.

8.3 Failure to operate with high current draw indi-

cates a direct ground in the terminal or fields,
or “frozen” bearings.
8.4 Failure to operate with no current draw indi-
cates an open field circuit, open armature
coils, broken brush springs, worn brushes,
high insulation between the commutator bars,
or other causes which would prevent good
contact between the brushes and the commu-
tator.
8.5 Low no-load speed and low current indicate
high internal resistance and high current
draw, which usually mean shorted fields.

A102E219

DAEWOO T-100 BL3

 ENGINE ELECTRICAL 1E -- 31
9. Remove the solenoid assembly screws.

A102E226

10. Remove the field connector nut. Disconnect the field

connector.

A102E243

11. Rotate the solenoid 90 degrees and remove it along

with the plunger return spring.

A102E247

DAEWOO T-100 BL3

1E -- 32 ENGINE ELECTRICAL
Important: If the solenoid is not removed from the start-
ing motor, the connector strap terminals must be re-
moved from the terminal on the solenoid before making
these tests.
12. Test the solenoid windings by checking the current
draw.
12.1 Check the hold-in windings by connecting
an ammeter in series with a 12-volt battery,
the switch terminal, and to ground.
12.2 Connect the carbon pile across the battery.
12.3 Adjust the voltage to 12.2 volts. The am-
meter reading should be 12 to 21 amperes.

A102E221

Important: Current will decrease as the windings heat

up. Current draw readings that are over specifications
indicate shorted turns or a ground in the windings of the
solenoid. Both conditions require replacement of the so-
lenoid. Current draw readings that are under specifica-
tions indicate excessive resistance. No reading
indicates an open circuit.
13. Check both windings, connecting them according to
the preceding test.
13.1 Ground the solenoid motor terminal.
13.2 Adjust the voltage to 12.2 volts. The am-
meter reading should be 60 to 90 amperes.
13.3 Check the connections and replace the so-
lenoid, if necessary.

A102E221

14. Slide the field frame with the enclosed armature as-
sembly away from the starter assembly.
15. Remove the shield.

A102E222

DAEWOO T-100 BL3

 ENGINE ELECTRICAL 1E -- 33
16. Separate the field frame from the armature.

A102E242

17. Inspect the shaft, the bearing, and the pinion for dis-
coloration, damage, or wear. Replace, if necessary.
18. Inspect the armature commutator. If the commuta-
tor is rough, it should be turned down. The outside
diameter of the commutator must measure at least
41.91 mm (1.650 inches) after it is undercut or
turned. Do not turn out-of-round commutators.
19. Inspect the points where the armature conductors
join the commutator bars. Make sure they have a
good connection. A burned commutator bar is usu-
ally evidence of a poor connection.
20. If test equipment is available, check the armature for
short circuits by placing it on a growler, and holding
back a saw blade over the armature core while the
armature is rotated. If the saw blade vibrates, re-
place the armature.
21. Recheck the armature after cleaning between the
commutator bars. If the saw blade vibrates, replace
A102E223 the armature.

22. Remove the gears, the bushings, and the washer.

23. Remove the cushion and the driveshaft assembly
from the starter housing.

A202E006

DAEWOO T-100 BL3

1E -- 34 ENGINE ELECTRICAL
24. Disassemble the driveshaft assembly by first sepa-
rating the needle bearing from the driveshaft.
25. Remove the collar and the locking ring from the
groove in the driveshaft.

A102E220

26. Remove the pinion stop and the drive from the drive-
shaft.

A102E248

27. Remove the gear support and the collar from the dri-
veshaft.

C302E016

DAEWOO T-100 BL3

 ENGINE ELECTRICAL 1E -- 35
28. If not done in the previous steps, remove the screws
that hold the solenoid assembly into the housing,
and remove the nut from the field coil connector.

A102E226

29. Rotate the solenoid 90 degrees and remove it along

with the return spring.

A102E247

30. Remove the plunger with the boot and the shift lever
assembly. Test the solenoid windings, if not done in
Step 12.

A302E007

DAEWOO T-100 BL3

1E -- 36 ENGINE ELECTRICAL
Important: The pinion clearance must be correct to pre-
vent the buttons on the shift lever yoke from rubbing on
the clutch collar during the cranking.
31. When the starter motor is disassembled and the so-
lenoid is replaced, it is necessary to check the pinion
clearance when the starter is reassembled.

A102E237

32. Disconnect the motor field coil connector from the

solenoid motor terminal and carefully insulate the
connector.
33. Connect one 12-volt battery lead to the solenoid
switch terminal and the other to the starter frame.
34. Flash a jumper lead momentarily from the solenoid
motor terminal to the starter frame, allowing shifting
of the pinion in the cranking position, where it will re-
main until the battery is disconnected.
Important: A means for adjusting the pinion clearance
is not provided on the starter motor. If the clearance
does not fall within the limits, check for improper installa-
tion and replace all worn parts.
35. Push the pinion back as far as possible to take up
any movement, and check the clearance with a feel-
er gauge. The clearance should be 0.25 to 3.56 mm
A102E227
(0.01 to 0.14 inch).

Assembly Procedure
1. Clean all of the starter motor parts, but do not use
grease-dissolving solvents for cleaning the armature
and the field coils.
2. Lubricate the gears with lubricant. (Begin at Step 7 if
proceeding with just the reassembly of the solenoid.)
3. If full disassembly of the starter and the solenoid was
performed, begin reassembly by placing the gear
support and the collar on the driveshaft assembly.

C302E016

DAEWOO T-100 BL3

 ENGINE ELECTRICAL 1E -- 37
4. Install the drive and the pinion stop on the driveshaft.

A102E248

5. Install the lock ring into the groove on the driveshaft

and insert the collar.
6. Install the needle bearing.

A102E220

7. Install the shift lever assembly with the plunger and

the boot.

A302E007

DAEWOO T-100 BL3

1E -- 38 ENGINE ELECTRICAL
8. Lubricate the gears with lubricant and install the dri-
veshaft assembly with the bushing and the washer
on the gear end.
9. Install the cushion and the gears.

A102E224

10. Lubricate the drive end of the armature shaft with lu-
bricant and install the new gear and the bearing, if
necessary.

A102E223

11. Position the solenoid assembly and the return spring

against the plunger, applying sealer to the solenoid
flange.

A102E247

DAEWOO T-100 BL3

 ENGINE ELECTRICAL 1E -- 39
12. Fasten the solenoid assembly with the screws.
Tighten
Tighten the starter solenoid assembly screws to
8 NSm (71 lb-in).
13. Install the field coil connection to the starter termi-
nal. Install the nut.
Tighten
Tighten the starter field connector nut to 8 NSm
(71 lb-in).

A102E226

14. Position the armature assembly into the field frame.

15. Place the shield on the armature and the field frame
assembly.
16. Install the armature and the field frame assembly
with the shield into the starter housing.

A102E222

17. Position the commutator end frame/brush holder as-

sembly, lining up the end frame holes with the
through-bolt holes in the housing.

A102E215

DAEWOO T-100 BL3

1E -- 40 ENGINE ELECTRICAL
18. Install the starter through-bolts.
19. Install the starter. Refer to “Starter” in this section.
Tighten
Tighten the starter through-bolts to 6 NSm (53 lb-in).
20. Refer to “Starter” in this section.

A102E239

GENERATOR (C5-121D)
Disassembly Procedure
1. Remove the generator. Refer to “Generator” in the
On-Vehicle Service section.
2. Mark a match line that cannot easily be removed on
the end frame to make assembly easier.
3. Pry off the plastic cover to expose the stator connec-
tions.

A102E201

Notice: If the stator connections are not welded, melt

the lead. Avoid excessive heating, as it can damage the
diodes in the rectifier bridge.
4. Remove the stator connections from the rectifier
bridge terminals by unsoldering or cutting the wires.

A102E258

DAEWOO T-100 BL3

 ENGINE ELECTRICAL 1E -- 41
5. Remove the generator through-bolts.

A102E203

Important: The fastening torque of this nut is 81 NSm

(60 lb-ft) and may not normally be unfastened using
hand strength.
6. Move to the drive end of the generator and remove
the drive end bearing nut.

A102E251

7. Remove the pulley and the collars.

A102E259

DAEWOO T-100 BL3

1E -- 42 ENGINE ELECTRICAL
8. Test the rotor for an open circuit by using the ohm-
meter with the drive end frame assembled. The
reading should be sufficiently high, or the rotor must
be replaced.

A102E252

9. Test the rotor for open and short circuits. The read-
ing should be 1.7 to 2.3 ohms, or the rotor should be
replaced.

A102E205

10. Remove the drive end frame from the shaft.

11. For vehicles with an internal generator fan, remove
the drive end frame and the fan.

A102E206

DAEWOO T-100 BL3

 ENGINE ELECTRICAL 1E -- 43
12. Remove the rotor assembly.

A102E207

13. Remove the stator.

14. Test the stator for an open circuit using the ohmme-
ter.

A102E208

15. Pry off the baffle.

16. Remove the rectifier/regulator/brush holder assem-
bly screws.
17. Remove the brush holder assembly and the regula-
tor, cutting the terminal between the regulator and
the rectifier bridge.
Important: If the brush can be reused, reassemble the
brush to the holder with the retaining pin, after cleaning
the brush with a soft, clean cloth.

A102E256

DAEWOO T-100 BL3

1E -- 44 ENGINE ELECTRICAL
18. Test the rectifier bridge by connecting the ohmmeter
terminals to the bridge and the heat sink.

A102E211

19. Retest by connecting the ohmmeter terminals in re-

verse.

A102E204

20. Replace the rectifier bridge, if each reading is the

same.
21. Test the remaining two diodes after the above pro-
cedure.
Notice: Some kinds of digital ohmmeters are not suited
for the test of the bridge diode. In this case, consult the
manufacturer regarding the test capacity.
22. Test the diodes by connecting the ohmmeter termi-
nals to the bridge terminal and the base plate. If the
reading is the same, the rectifier bridge should be
replaced.

A102E211

DAEWOO T-100 BL3

 ENGINE ELECTRICAL 1E -- 45
23. Remove the ring in the slip ring end frame.

A102E212

Assembly Procedure
1. Install the new ring in the slip ring end frame.
2. Push the new bearing outer lace into the bottom of
the end frame casting.

A102E257

3. Solder the brush holder terminal to the regulator ter-

minal, if removed.
4. Fix the brush holder with the retainer pin, and solder
the regulator/brush holder assembled terminal to the
rectifier terminal.
5. Apply silicone grease between the bridge and the end
frame for radiation purposes.
6. Fasten the screws holding the rectifier regulator/
brush holder assembly to the end frame.
7. Punch the new baffle with the pin into the brush.

A102E256

DAEWOO T-100 BL3

1E -- 46 ENGINE ELECTRICAL
8. Install the stator.

A102E213

Notice: Take care to prevent damage to the vehicle by

protecting the diode in the rectifier bridge from exces-
sive heat while soldering or welding.
9. Solder or weld the connectors of the rectifier bridge.

A102E202

10. Install the outside cover.

A102E201

DAEWOO T-100 BL3

 ENGINE ELECTRICAL 1E -- 47
11. Position the rotor assembly shaft with the drive end
frame in the slip ring end assembly until the gap be-
tween the outer lace and the end frame casting is
1.9 mm (0.075 inch).
12. Install the generator through-bolts.
Tighten
Tighten the generator through-bolts to 10 NSm (89 lb-
in).

A102E203

13. Position the fan, the collars, and the pulley on the
rotor shaft and secure with the nut.
Tighten
Tighten the generator drive end bearing nut to 81 NSm
(60 lb-ft).
14. Install the generator. Refer to “Generator” in the On-
Vehicle Service section.

A102E251

GENERATOR (CS-128D)
Disassembly Procedure
1. Remove the generator. Refer to “Generator” in this
section.
2. Remove the driveshaft nut.

A102E251

DAEWOO T-100 BL3

1E -- 48 ENGINE ELECTRICAL
3. Remove the pulley and the collar from the driveshaft.

C302E002

4. Pry off the plastic cover that encloses the rectifier and
the regulator/brush holder assemblies.
5. Inspect the cover for damage.

C302E014

6. Remove the generator through-bolts.

C302E003

DAEWOO T-100 BL3

 ENGINE ELECTRICAL 1E -- 49
7. Remove the bolts that fasten the rectifier assembly
and the regulator assembly to the slip ring end frame.

C302E004

8. To remove the regulator/brush holder and the rectifier

assemblies, first melt the solder of the lead that con-
nects the regulator/brush holder assembly to the rec-
tifier assembly. Then melt the lead to the stator,
followed by the other rectifier assembly leads to the
stator (as shown).

C302E005

9. Test each of the three diodes of the rectifier assembly

for continuity. Connect the ohmmeter probes on each
side of the diode. Retest by connecting the ohmmeter
probes in reverse. If the readings are the same, re-
place the rectifier.

C302E006

DAEWOO T-100 BL3

1E -- 50 ENGINE ELECTRICAL
10. Mark a line perpendicular to the crack between the
case of the drive end frame and that of the slip ring
end frame.
11. Pry open the drive end frame from the slip ring end
frame.
12. Remove the collar.

C302E007

13. Remove the fan.

C302E008

14. Separate the rotor from the slip ring end frame.

C302E009

DAEWOO T-100 BL3

 ENGINE ELECTRICAL 1E -- 51
15. Using an ohmmeter, test the stator for ground. If the
reading is low, replace the stator.
16. Check the stator for an open circuit by placing the
probes on two terminals. If the reading is high (infi-
nite), replace the stator.

C302E010

17. Using an ohmmeter, test the rotor for an open cir-

cuit. Check for continuity between the slip rings.
Standard resistance (cold) is 2.8 to 3.0 ohms. If
there is no continuity, replace the rotor.

C302E011

18. Using an ohmmeter, inspect the rotor for ground.

Check for continuity between the rotor and the slip
ring. If there is no continuity between the rotor and
the slip ring, replace the rotor.

C302E012

DAEWOO T-100 BL3

1E -- 52 ENGINE ELECTRICAL

Assembly Procedure
1. Check the bearing on the fan side of the rotor assem-
bly. Replace the bearing if it is rough or worn, espe-
cially if the generator is diagnosed as having a noisy
bearing with the vehicle running.
2. If required, install a new bearing and insert the bear-
ing retainer on the rotor assembly shaft.

C302E013

3. Press the rotor assembly onto the end frame.

4. Install the fan on the rotor shaft.

C302E008

5. Install the collar.

C302E007

DAEWOO T-100 BL3

 ENGINE ELECTRICAL 1E -- 53
6. Install the slip ring end frame assembly by lining up
the terminal ends of the stator with the end frame
cover holes, and then lining up the marks that were
made on the drive end frame case and the slip ring
end frame case before the two cases were sepa-
rated.
7. Install the generator through-bolts.
Tighten
Tighten the generator through-bolts to 25 NSm (18 lb-
ft).

C302E003

8. Install the rectifier assembly by first soldering its ter-

minals to the stator terminal ends.
9. If the brushes are worn, solder the terminal of the
new brush holder assembly to the regulator assem-
bly.

C302E015

10. Solder the terminal of the regulator/brush holder as-

sembly to the rectifier assembly.
11. Fasten the rectifier and the regulator/brush holder
assemblies to the slip ring end frame with the bolts.
Tighten
Tighten the rectifier and the regulator/brush holder
assembly bolts to the point at which they are touching
their respective mounting plates. Then tighten the
bolts with an additional quarter turn.

C302E004

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1E -- 54 ENGINE ELECTRICAL
12. Snap in the cover.
13. Install the collar and the pulley on the drive end
shaft.

C302E002

14. Install the drive end nut.

Tighten
Tighten the generator drive end nut to 100 NSm
(74 lb-ft).
15. Install the generator in the vehicle. Refer to “Gener-
ator” in this section.

A102E251

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 ENGINE ELECTRICAL 1E -- 55

GENERAL DESCRIPTION The battery is not designed to last indefinitely. However,

with proper care, the battery will provide many years of
AND SYSTEM OPERATION service.
If the battery tests well, but fails to perform satisfactorily
BATTERY in service for no apparent reason, the following factors
may point to the cause of the trouble:
The battery has three major functions in the electrical
system. First, the battery provides a source of energy D Vehicle accessories left on overnight.
for cranking the engine. Second, the battery acts as a D Slow average driving speeds used for short periods.
voltage stabilizer for the electrical system. Finally, the D The vehicle’s electrical load is more than the genera-
battery can, for a limited time, provide energy when the tor output, particularly with the addition of aftermarket
electrical demand exceeds the output of the generator. equipment.
The sealed battery is standard on all cars. There are no D Defects in the charging system, such as electrical
vent plugs in the cover. The battery is completely shorts, a slipping generator belt, a faulty generator, or
sealed, except for two small vent holes in the sides. a faulty voltage regulator.
These vent holes allow the small amount of gas pro-
D Battery abuse, including failure to keep the battery
duced in the battery to escape.
cable terminals clean and tight, or a loose battery
The sealed battery has the following advantages over hold-down.
conventional batteries:
D Mechanical problems such as shorted or pinched
D No water need be added for the life of the battery. wires in the electrical system.
D It is protected against overcharge. If too much volt-
age is applied to the battery, it will not accept as much BUILT-IN HYDROMETER
current as a conventional battery. In a conventional
The sealed battery has a built-in, temperature-compen-
battery, the excess voltage will still try to charge the sated hydrometer in the top of the battery. This hydrom-
battery, leading to gassing, which causes liquid loss. eter is to be used with the following diagnostic
D It is not as liable to self-discharge as a conventional procedure:
battery. This is particularly important when a battery 1. When observing the hydrometer, make sure that the
is left standing for long periods of time. battery has a clean top.
D It has more power available in a lighter and a smaller 2. Under normal operation, two indications can be ob-
case. served:
D GREEN DOT VISIBLE - Any green appearance is
RATINGS interpreted as a “green dot,” meaning the battery is
A battery has two ratings: (1) A reserve capacity rating ready for testing.
designated at 27_C (81_F), which is the time a fully D DARK GREEN DOT IS NOT VISIBLE - If there is
charged battery will provide 25 amperes current flow at a cranking complaint, the battery should be tested.
or above 10.5 volts; (2) A cold cranking amp rating de- The charging and electrical systems should also
termined under testing at -18_C (0_F), which indicates be checked at this time.
the cranking load capacity.
3. Occasionally, a third condition may appear:
D CLEAR OR BRIGHT YELLOW - This means the
RESERVE CAPACITY fluid level is below the bottom of the hydrometer.
The reserve capacity is the maximum length of time it is This may have been caused by excessive or pro-
possible to travel at night with the minimum electrical longed charging, a broken case, excessive tipping,
load and no generator output. Expressed in minutes, re- or normal battery wear. Finding a battery in this
serve capacity (or RC rating) is the time required for a condition may indicate high charging by a faulty
fully charged battery, at a temperature of 27_C (81_F) charging system. Therefore, the charging and the
and being discharged at a current of 25 amperes, to electrical systems may need to be checked if a
reach a terminal voltage of 10.5 volts. cranking complaint exists. If the cranking com-
plaint is caused by the battery, replace the battery.
COLD CRANKING AMPERAGE
The cold cranking amperage test is expressed at a bat- CHARGING PROCEDURE
tery temperature of -18_C (0_F). The current rating is 1. Batteries with the green dot showing do not require
the minimum amperage, which must be maintained by charging unless they have just been discharged, such
the battery for 30 seconds at the specified temperature, as in cranking a vehicle.
while meeting a minimum voltage requirement of 2. When charging sealed-terminal batteries out of the
7.2 volts. This rating is a measure of cold cranking ca- vehicle, install the adapter kit. Make sure all the char-
pacity.

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1E -- 56 ENGINE ELECTRICAL
ger connections are clean and tight. For best results, Important: Some chargers feature polarity protection
batteries should be charged while the electrolyte and circuitry, which prevents charging unless the charger
the plates are at room temperature. A battery that is leads are correctly connected to the battery terminals. A
extremely cold may not accept current for several completely discharged battery may not have enough
hours after starting the charger. voltage to activate this circuitry, even though the leads
3. Charge the battery until the green dot appears. The are connected properly, making it appear that the bat-
battery should be checked every half-hour while tery will not accept charging current. Therefore, follow
charging. Tipping or shaking the battery may be nec- the specific charger manufacturer’s instruction for by-
essary to make the green dot appear. passing or overriding the circuitry so that the charger will
turn on and charge a low-voltage battery.
4. After charging, the battery should be load tested. Re-
fer to “Starter Motor” in this section. 3. Battery chargers vary in the amount of voltage and
current provided. The time required for the battery to
CHARGING TIME REQUIRED accept a measurable charge current at various volt-
ages may be as follows:
The time required to charge a battery will vary depend-
ing upon the following factors:
Voltage Hours
D Size of Battery - A completely discharged large
heavy-duty battery requires more than twice the re- 16.0 or more Up to 4 hours
charging as a completely discharged small passenger 14.0-15.9 Up to 8 hours
car battery. 13.9 or less Up to 16 hours
D Temperature - A longer time will be needed to
charge any battery at -18_C (0_F) than at 27_C D If the charge current is not measurable at the end
(81_F). When a fast charger is connected to a cold of the above charging times, the battery should be
battery, the current accepted by the battery will be replaced.
very low at first. The battery will accept a higher cur- D If the charge current is measurable during the
rent rate as the battery warms. charging time, the battery is good, and charging
D Charger Capacity - A charger which can supply only should be completed in the normal manner.
5 amperes will require a much longer charging period
Important: It is important to remember that a complete-
than a charger that can supply 30 amperes or more.
ly discharged battery must be recharged for a sufficient
D State-of-Charge - A completely discharged battery number of ampere hours (AH) to restore the battery to a
requires more than twice as much charge as a one- usable state. As a general rule, using the reserve capac-
half charged battery. Because the electrolyte is nearly ity rating (RC) as the number of ampere hours of charge
pure water and a poor conductor in a completely dis- usually brings the green dot into view.
charged battery, the current accepted by the battery
is very low at first. Later, as the charging current D If the charge current is still not measurable after
causes the electrolyte acid content to increase, the using the charging time calculated by the above
charging current will likewise increase. method, the battery should be replaced.
D If the charge current is measurable during the
CHARGING A COMPLETELY charging time, the battery is good, and charging
should be completed in the normal manner.
DISCHARGED BATTERY
(OFF THE VEHICLE) JUMP STARTING PROCEDURE
Unless this procedure is properly followed, a perfectly 1. Position the vehicle with the good (charged) battery
good battery may be needlessly replaced. so that the jumper cables will reach from one battery
The following procedure should be used to recharge a to the other.
completely discharged battery: 2. Turn off the ignition, all the lights, and all the electrical
1. Measure the voltage at the battery terminals with an loads in both vehicles. Leave the hazard flasher on if
accurate voltmeter. If the reading is below 10 volts, there may be other traffic and any other lights needed
the charge current will be very low, and it could take for the work area.
some time before the battery accepts the current in 3. In both vehicles, apply the parking brake firmly.
excess of a few milliamperes. Refer to “Charging
Time Required” in this section, which focuses on the Notice: Make sure the cables are not on or near pulleys,
factors affecting both the charging time required and fans, or other parts that will move when the engine
the rough estimates in the table below. Such low cur- starts, damaging the parts.
rent may not be detectable on ammeters available in 4. Shift an automatic transaxle to Park (P), or a manual
the field. transaxle to Neutral (N).
2. Set the battery charger on the high setting.

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 ENGINE ELECTRICAL 1E -- 57
C a u t i o n : D o n o t u s e c a b l e s t h a t h a v e l o o s e o r m i s s Ć field current. The regulator switches rotor field current
i n g i n s u l a t i o n , o r i n j u r y c o u l d r e s u l t . on and off at a fixed frequency of about 400 hertz. By
varying the on-/off-time time, correct average field cur-
5. Clamp one end of the first jumper cable to the positive
rent for proper system voltage control is obtained. At
terminal on the battery. Make sure it does not touch
high speeds, the on-time may be 10 percent and the off-
any other metal parts. Clamp the other end of the
time 90 percent. At low speeds, with high electrical
same cable to the positive terminal on the other bat-
loads, the on-time may be 90 percent and the off-time
tery. Never connect the other end to the negative ter-
10 percent.
minal of the discharged battery.
Caution: Do not attach the cable directly to the negĆ CHARGING SYSTEM
ative terminal of the discharged battery. Doing so
The Delco-Remy CS charging system has several mod-
could cause sparks and a possible battery exploĆ
sion, possibly resulting in personal injury. els available, including the CS-121D and the CS-128D.
The number denotes the outer diameter in millimeters of
6. Clamp one end of the second cable to the negative the stator laminations.
terminal of the booster battery. Make the final con- CS generators use a new type of regulator that incorpo-
nection to a solid engine ground, such as the engine rates a diode trio. A Delta stator, a rectifier bridge, and a
lift bracket, at least 450 millimeters (18 inches) from rotor with slip rings and brushes are electrically similar to
the discharged battery. earlier generators. A conventional pulley and a fan are
7. Start the engine of the vehicle with the good battery. used. There is no test hole.
Run the engine at a moderate speed for several min-
utes. Then start the engine of the vehicle which has STARTER
the discharged battery.
Wound field starter motors have pole pieces, arranged
8. Remove the jumper cables by reversing the above around the armature, which are energized by wound
sequence exactly. Remove the negative cable from field coils.
the vehicle with the discharged battery first. While re-
moving each clamp, take care that it does not touch Enclosed shift lever cranking motors have the shift lever
any other metal while the other end remains at- mechanism and the solenoid plunger enclosed in the
drive housing, protecting them from exposure to dirt, icy
tached.
conditions, and splashes.
In the basic circuit, solenoid windings are energized
GENERATOR when the switch is closed. The resulting plunger and
The Delco-Remy CS charging system has several mod- shift lever movement causes the pinion to engage the
els available, including the CS-121D and the CS-128D. engine flywheel ring gear. The solenoid main contacts
The number denotes the outer diameter in millimeters of close. Cranking then takes place.
the stator lamination.
When the engine starts, pinion overrun protects the ar-
CS generators are equipped with internal regulators. A mature from excessive speed until the switch is opened,
Delta stator, a rectifier bridge, and a rotor with slip rings at which time the return spring causes the pinion to dis-
and brushes are electrically similar to earlier generators. engage. To prevent excessive overrun, the switch
A conventional pulley and a fan are used. There is no should be released immediately after the engine starts.
test hole.
Unlike three-wire generators, the CS-121D and the STARTING SYSTEM
CS-128D may be used with only two connections: bat-
The engine electrical system includes the battery, the
tery positive and an ‘‘L’’ terminal to the charge indicator
ignition, the starter, the generator, and all the related wir-
lamp.
ing. Diagnostic tables will aid in troubleshooting system
As with other charging systems, the charge indicator faults. When a fault is traced to a particular component,
lamp lights when the ignition switch is turned to ON, and refer to that component section of the service manual.
goes out when the engine is running. If the charge indi-
The starting system circuit consists of the battery, the
cator is on with the engine running, a charging system
starter motor, the ignition switch, and all the related elec-
defect is indicated. This indicator light will glow at full
trical wiring. All of these components are connected
brilliance for several kinds of defects, as well as when
the system voltage is too high or too low. electrically.
The regulator voltage setting varies with the tempera-
ture and limits the system voltage by controlling the rotor

DAEWOO T-100 BL3