SERVICE MANUAL
  Applies to: Hyundai Coupe/Tiburon 1998-2001
GROUP
Engine Electrical System Charging System
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INSPECTION
VOLTAGE DROP TEST OF GENERATOR OUTPUT WIRE

This test determines whether or not the wiring between the generator "B" terminal and the battery (+) terminal good by the voltage drop method.

PREPARATION
  1. Turn the ignition switch to "OFF."

    NOTE
    To find abnormal conditions of the connection, actions should not be taken on the two terminals and each connections during the test.
  1. Connect a digital voltmeter between the generator "B" terminal. and battery (+) terminal. Connect the (+) lead wire of the voltmeter to the "B" terminal and the (-) lead wire to the battery (+) terminal.

CONDITIONS FOR THE TEST
  1. Start the engine.

  1. Turn on the headlamps, blower motor and so on. And then, read the voltmeter under this condition.

RESULT
  1. It is okay if the voltmeter indicates the standard value.

    Standard value: 0.2V max.

  1. If the value of the voltmeter is higher than expected (above 0.2V max.), poor wiring is suspected. In this case check the wiring from the generator "B" terminal to the fusible link to the battery (+) terminal. Check for loose connections, color change due to an overheated harness, etc. Correct them before testing again.

  1. Upon completion of the test, set the engine speed at idle. Turn off the head lamps, blower motor and the ignition switch.

OUTPUT CURRENT TEST

This test judges whether or not the generator gives an output current that is equivalent to the nominal output.

PREPARATION
  1. Prior to the test, check the following items and correct as necessary.

    1. Check the battery installed in the vehicle to ensure that it is in good condition. The battery checking method is de scribed in "BATTERY".
      IMPORTANT
      The battery that is used to test the output current should be one that has been partially discharged. With a fully charged battery, the test may not be conducted correctly due to an insufficient load.
    1. Check the tension of the generator drive belt. The belt tension check method is described in the section "COOLING".
  1. Turn off the ignition switch.

  1. Disconnect the battery ground cable.

  1. Disconnect the generator output wire from the generator "B" terminal.

  1. Connect a DC ammeter (0 to 100A) in series between the "B" terminal and the disconnected output wire. Be sure to connect the (-) lead wire of the ammeter to the disconnected output wire.

    NOTE
    Tighten each connection securely, as a heavy current will flow. Do not rely on clips.
  1. Connect a voltmeter (0 to 20V) between the "B" terminal and ground. Connect the (+) lead wire to the generator "B" terminal and (-) lead wire to a good ground.

  1. Attach an engine tachometer and connect the battery ground cable.

  1. Leave the engine hood open.

TEST
  1. Check to see that the voltmeter reads the same value as the battery voltage. If the voltmeter reads 0V, and open circuit in the wire between the generator "B" terminal and battery (-) terminal, a blown fusible link or poor grounding is suspected.

  1. Start the engine and turn on the headlights.

  1. Set the headlights to high beam and the heater blower switch to HIGH, quickly increase the engine speed to 2,500 rpm and read the maximum output current value indicated by the ammeter.

    NOTE
    After the engine starts up, the charging current quickly drops. Therefore, the above operation must be done quickly to read the maximum current value correctly.
RESULT
  1. The ammeter reading must be higher than the limit value. If it is lower but the generator output wire is in good condition, remove the generator from the vehicle and test it.

    Limit value: 63A min 90A generator

    NOTE
    • The nominal output current value is shown on the nameplate affixed to the generator body.
    • The output current value changes with the electrical load and the temperature of the generator itself. Therefore, the nominal output current many not be obtained. If such is the case, keep the headlights on the cause discharge of the battery, or use the lights of another vehicle to increase the electrical load. The nominal output current may not be obtained if the temperature of the generator itself or ambient temperature is too high. In such a case, reduce the temperature before testing again.
  1. Upon completion of the output current test, lower the engine speed to idle and turn off the ignition switch.

  1. Disconnect the battery ground cable.

  1. Remove the ammeter and voltmeter and the engine tachometer.

  1. Connect the generator output wire to the generator "B" terminal.

  1. Connect the battery ground cable.

REGULATED VOLTAGE TEST

The purpose of this test is to check that the electronic voltage regulator controls voltage correctly.

PREPARATION
  1. Prior to the test, check the following items and correct if necessary.

    1. Check that the battery installed on the vehicle is fully charged. For battery checking method, see "BATTERY."
    1. Check the generator drive belt tension. For belt tension check, see section, "COOLING."
  1. Turn ignition switch to "OFF."

  1. Disconnect the battery ground cable.

  1. Connect a digital voltmeter between the "S(L)" terminal of the generator and ground. Connect the (+) lead of the voltmeter to the "S(L)" terminal of the generator. Connect the (-) lead to good ground or the battery (-) terminal.

  1. Disconnect the generator output wire from the generator "B" terminal.

  1. Connect a DC ammeter (0 to 100A) in series between the "B" terminal and the disconnected output wire. Connect the (-) lead wire of the ammeter to the disconnected output wire.

  1. Attach the engine tachometer and connect the battery ground cable.

TEST
  1. 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 generator "S(L)" terminal and the battery and the battery (+), or the fusible link is blown.

  1. Start the engine. Keep all lights and accessories off.

  1. Run the engine at a speed of about 2,500 rpm and read the voltmeter when the generator output current drops to 10A or less.

Result
  1. If the voltmeter reading agrees with the value listed in the Regulating Voltage Table below, the voltage regulator is functioning correctly. If the reading is other than the standard value, the voltage regulator or the generator is faulty.

Regulating Voltage Table
Voltage regulator ambient temperature C(F)
Regulating voltage V
-20 (-4)
14.2-15.4
20 (68)
13.9-14.9
60 (140)
13.4-14.6
80 (176)
13.1-14.5
  1. Upon completion of the test, reduce the engine speed to idle, and turn off the ignition switch.

  1. Disconnect the battery ground cable.

  1. Remove the voltmeter and ammeter and the engine tachometer.

  1. Connect the generator output wire to the generator "B" terminal.

  1. Connect the battery ground cable.