2002 > G 2.

0 DOHC > Engine Electrical System > Ignition System > General Information

GENERAL DESCRIPTION
In a conventional vehicle, the ignition coil produces a high voltage current which the distributor sends
current, at the required time, to each spark plug.
The Sportage however uses a totally new ignition system. In this system two sensors (the camshaft
position sensor and the crankshaft position sensor) tell the Engine Control Module (ECM) which cylinder is
ready to fire. The ECM then sends an ignition signal to an electronic ignition coil. This ignition coil then
produces and sends a high voltage current to the proper spark plug.
Ignition coils

Camshaft position (CMP) sensor

Crankshaft position (CKP) sensor

High tension leads

Spark plugs

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2002 > G 2.0 DOHC > Engine Electrical System > Ignition System > Ignition Coil > Repair procedures

CHASSIS ACCELERATION SENSOR

Inspection
1. With the component connector still connected, connect a voltmeter between terminal 3 (BLU/GRN) and
ground.
2. Turn the ignition switch ON.
3. Tap the chassis acceleration sensor bracket with a wrench.
4. Verify that a voltage spike (less than 1V) is output from the chassis acceleration sensor.
5. If no voltage spike is observed, replace the chassis acceleration sensor.
REMOVAL
1. Disconnect the battery cable.
2. Disconnect the high tension leads.
3. Disconnect the ignition coil connectors.
4. Remove the four ignition coil mounting bolts.
5. Remove the ignition coils.

INSTALLATION
1. Position the ignition coils :
Locate the two coils above the #2 and #4 spark plugs, and firmly push down to connect.
2. Insert and tighten the four ignition coil mounting bolts.

Tighten bolts to 14 -19 lb-ft (19 - 25 N·m)

3. Reconnect the ignition coil connectors.

4. Reattach the high tension leads. Be certain to make connections correctly; leads are marked.
5. Reconnect battery cable.

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2002 > G 2.0 DOHC > Engine Electrical System > Ignition System > Ignition Coil > Repair procedures

CHASSIS ACCELERATION SENSOR

Inspection
1. With the component connector still connected, connect a voltmeter between terminal 3 (BLU/GRN) and
ground.
2. Turn the ignition switch ON.
3. Tap the chassis acceleration sensor bracket with a wrench.
4. Verify that a voltage spike (less than 1V) is output from the chassis acceleration sensor.
5. If no voltage spike is observed, replace the chassis acceleration sensor.

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2002 > G 2.0 DOHC > Engine Electrical System > Ignition System > Spark Plug > Repair procedures

REMOVAL

Do not attempt any maintenance on spark plugs if engine is hot.

1. Disconnect the negative battery terminal.

2. Carefully remove the high-tension leads.
3. Use compressed air to blow away any dirt or debris from around the spark plug hole.
4. Check that spark plug socket fits squarely on the spark plug and then remove the spark plug.

INSTALLATION
1. Install the spark plug into the cylinder head

Tighten spark plug to 18-22 Ib-ft (25-30 N·m).

2. Reconnect the high-tension lead.

3. Reconnect the negative battery cable.

INSPECTION
1. Reconnect the negative battery cable.
2. Connect the spark plug to the high-tension lead.
3. Hold the spark plug with insulated pliers 0.2 to 0.39 inch (5-10 mm) from a ground.

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2002 > G 2.0 DOHC > Engine Electrical System > Ignition System > Spark Plug > Repair procedures

DO NOT TOUCH THE VEHICLE BODY DURING NEXT INSTRUCTION.

4. While holding the spark plug, have a second person crank the engine. Verify that a strong blue spark
jumps from the spark plug to the ground. Replace the spark plug if there is no arc.
5. Check for, and implement correction.
A. Carbon deposits. Clean out or replace plug.
B. Oil fouling. Correct oil problem, replace plug.
C. Worn or burnt electrode. If present, replace plug.
D. Broken or burnt ceramic insulator. If present replace plug.
E. Damaged spark plug ring. If so, replace ring.
F. Improper spark plug gap. Regap if possible, otherwise replace.

Gap: 0.039 - 0.043 in (1.0 -1.1 mm)

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2002 > G 2.0 DOHC > Engine Electrical System > Ignition System > Spark Plug Cable > Repair procedures

INSPECTION
High-tension leads
1. Remove high-tension leads from the coils and the spark plugs.
2. Check for breaks in insulation.
3. Check inside high-tension lead connectors for corrosion or carbon deposits.
4. Connect high-tension leads to an ohmmeter and check resistance.

Resistance : 16kΩ per 3.28ft (1m)

5. Replace if defective.

INSTALLATION
1. Install high-tension lead to the coils and speak plugs.
2. Be certain to make connections correctly leads are marked.

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2002 > G 2.0 DOHC > Engine Electrical System > Ignition System > Troubleshooting

DIAGNOSIS
Problem Possible Cause Action
Engine control module detects fault Interrogate engine control module.
Engine light is "NO"
in system Repair as required
Engine runs rough Spark plug failure Check, clean or replace plugs
High-Tension lead arcing to the Replace High-tension leads
ground Check/Replace ignition coil(s)
Ignition coil(s) faulty Check/Replace sensor
CMP sensor faulty Check/Replace sensor
CKP sensor faulty
Engine fails to start, starter Fuse failure Check/Replace IGN fuse
turning Low battery current Check charging system
Ignition coil(s) failure Check/Replace coil(s)
CMP sensor failure Check/Replace sensor
CKP sensor failure Check/Replace sensor

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2002 > G 2.0 DOHC > Engine Electrical System > Ignition System > Repair procedures

INSPECTION
Ignition timing can only become off for the following reasons. A problem with a sensor, which will be
detected by the ECM or a misalignment of the camshaft to the crankshaft. This last problem indicates a
problem with the timing belt, maintenance on which is covered in Group 10, Engine. There is no need to
adjust engine timing after replacement of a coil.
Ignition Timing Check Procedure
1. Warm up the engine and let idle.
2. Turn all other electrical systems OFF.
3. Ground the test connector to the vehicle with a jumper wire.
4. Connect the timing light to high-tension lead number one.
5. Check that the ignition timing mark on the crankshaft pulley aligns with the timing mark on the engine
block.

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 2002 > G 2.0 DOHC > Engine Electrical System > Ignition System > Specifications

SPECIFICATIONS
Fastener tightening
Ignition Coil Bolt 14-22 lb-ft (19-30 N·m)
Spark Plugs 11-17 lb-ft (15-23 N·m)

General specification
Engine Idle Speed 800±50 rpm
Ignition Coil Type Dual Coil
Primary Coil Resistance 0.45-0.55kΩ ＠ 68℉ (20℃)
Secondary Coil
13-15kΩ ＠ 68℉ (20℃)
Resistance
High-Tension Lead 16kΩ per 3.28 feet (1m)
Spark Plug Gap 0.039-0.043 (1.0-1.1)
Spark Plug Type NGK BKR6E - 11

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 2002 > G 2.0 DOHC > Engine Electrical System > Charging System > Schematic Diagrams

CIRCUIT DIAGRAM

The gerenator has a self-diagnostic function to warm of no voltage output in the charging system. If a
problem arises, the generator warming lamp light up.

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2002 > G 2.0 DOHC > Engine Electrical System > Charging System > Alternator > Components and Components Location

COMPONENTS

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2002 > G 2.0 DOHC > Engine Electrical System > Charging System > Alternator > Repair procedures

REMOVAL
1. Remove negative battery cable.
2. Remove front bolts from air cleaner inlet pipe.
3. Loosen end clamp on inlet.
4. Remove top hose from resonance chamber and remove air cleaner inlet pipe.
5. Open B-terminal cover cap.
6. Remove B-terminal nut.
7. Remove B-terminal lead.

8. Disconnect the generator's L- and S-terminal connectors.

9. Loosen pivot bolt and tensioner mounting bolt. Do not remove.

10. Relieve tension on drive belt by rotating adjustment bolt.

11. Remove drive belt from generator pulley.
12. Remove tensioner mounting bolt and belt tensioner.
13. Remove generator pivot bolt.
14. Loosen bolt at base of adjusting bracket and rotate the bracket up.
15. Lift generator from engine compartment.
INSTALLATION
1. Position generator on engine.
2. Install, but leave loose, pivot bolt.
3. Rotate bracket down into position on top of generator.

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2002 > G 2.0 DOHC > Engine Electrical System > Charging System > Alternator > Repair procedures

4. Place belt tensioner into position on adjustment bracket.

5. Install tensioner mounting bolt, leave loose.
6. Place drive belt on generator pulley.
7. Adjust belt tension by rotating adjustment bolt.

Allow deflectiom :
New belt : 0.23-0.31in (6-8mm)
Old belt : 0.28-0.35in (7-9mm)

8. Tighten tensioner bolt.

Tighten tensioner bolt to 14-19lb·ft (19-26N·m).

9. Tighten pivot bolt and bracket bolt.

Tighten pivolt bolt to 28-38lb·ft (38-51N·m).

10. Connect generator L- and S-terminal connectors.

11. Connect B-terminal lead.
12. Install and tighten B-terminal nut.
13. Close B-terminal nut cover.
14. Install air intake inlet pipe and tighten end clamp.
15. Connect top hose to resonance chamber.
16. Install front air intake inlet pipe bolts.
17. Connect negative battery cable.

● Be sure the battery connections are not reversed. This will damage the rectifier.
● Do not use high voltage testers, such as a megger. They will damage the rectifier.
● Remember that battery voltage is always applied to the alternator B-terminal.
● Do not ground the L-terminal while the engine is running.
● Do not start the engine while the coupler is disconnected from the L- and S-terminals.

DISASSEMBLY

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2002 > G 2.0 DOHC > Engine Electrical System > Charging System > Alternator > Repair procedures

Insert protective material in the jaws of a vise.

1. Place the generator in the vise.

2. Remove the cap screws from front housing.

3. Use a 200-watt soldering iron to heat the rear of the bearing box to allow the bearing to be removed from
the rear housing.

If the bearing box is not heated, the bearing cannot be pulled out because the rear bearing and
rear housing fit together very tightly.

4. Use a flat-blade screw driver to separate the front housing from the stator.

Be careful not to lose the stopper spring that fits around the rear bearing.

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2002 > G 2.0 DOHC > Engine Electrical System > Charging System > Alternator > Repair procedures

5. Place the rotor in a vise and loosen the lock nut, then disassemble the pulley, rotor, and front housing.

Insert protective material in the jaws of the vise.

Before putting the generator in it.

6. Replace the front bearing. Using a socket which exactly fits the outer race of the bearing, carefully push
in the front bearing. Use a hand press or a vise.

7. Replace the rear bearing. Remove rear bearing with a bearing puller. When installing, make sure the
groove on the bearing rim is on the slip ring side.

8. Remove the B-terminal nut and the insulating bushing.

9. Remove the screws holding the rectifier and the brush holder.
10. Separate the rear bracket and stator.

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2002 > G 2.0 DOHC > Engine Electrical System > Charging System > Alternator > Repair procedures

11. Use a soldering iron to remove the solder from the rectifier and the stator leads, and then remove the
IC regulator.

Disconnect quickly. If the soldering iron is used for more than five seconds, the rectifier may be
damaged by the heat.

12. Replace the brushes. Remove the solder from the pigtail, and then remove the brush.

13. When connecting the brush, solder the pigtail so that the wear limit line of the brush projects 0.079-
0.118 in (2-3 mm) out of the brush holder.

INSPECTION
1. Rotor
(1) Measure the resistance between the slip rings with an ohmmeter. If it is not within standard
resistance, replace the rotor.

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2002 > G 2.0 DOHC > Engine Electrical System > Charging System > Alternator > Repair procedures

Standard resistance : 3.5-4.5Ω

(2) Check for continuity between the slip ring and the core with a circuit tester. Replace the rotor if there
is continuity.

(3) If the slip ring surface is rough, smooth with a lathe or fine sandpaper.
2. Stator
(1) Check for continuity between the stator coil leads with a circuit tester.

(2) Replace the stator if there is no continuity

(3) Check for continuity between the stator coil leads and the core with a circuit tester.
(4) Replace the stator if there is continuity.

3. Rectifier
(1) Check for continuity between each diode with an ohmmeter.
Negative

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2002 > G 2.0 DOHC > Engine Electrical System > Charging System > Alternator > Repair procedures

(Black) Posive (Red) Continuity

E Pn, P₁ , P₂ , P₃ ○
B Pn, P₁ , P₂ , P₃ ×
T Pn, P₁ , P₂ , P₃ ×
Pn, P₁ , P₂ , P₃ E ×
B ○
Pn, P₂ , P₃ T ○
Pn T ×

(2) Replace if necessary.

4. Brush
If the brushes are worn to or beyond the limit, replace them with new ones.

Standard: 0.85 in (21.5 mm)

Minimum: 0.32 in (8.0 mm)

5. Brush Spring

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 2002 > G 2.0 DOHC > Engine Electrical System > Charging System > Alternator > Repair procedures

(1) Measure the force of the brush spring with a spring pressure gauge.
(2) Replace the spring if necessary.

Standard force: 0.71-0.96 Ib-ft (3.1-4.1 Nm)

Minimum: 0.36-0.52 Ib-ft (1.60-2.4 Nm)

(3) Read the spring pressure with the brush tip projecting 0.08 in (2 mm).

6. Bearing
(1) Check for abnormal noise, looseness, insufficient lubrication, etc.
(2) Replace the bearing(s) if there is any abnormality.

ASSEMBLY

Be sure to remove wire after assembly is completed.

Assemble in the reverse order of disassembly, referring to the following points.

1. Before assembly, use a finger to hold the brushes in the brush holder. Pass a wire 0.08 in, 1.6-2.0 in (2
mm, 40-50 mm) through the hole shown in the figure.

2. Secure the brushes in position.

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2002 > G 2.0 DOHC > Engine Electrical System > Charging System > Battery > General Information

BATTERY

● HYDROGEN GAS IS PRODUCED DURING NORMAL BATTERY OPERATION. THIS GAS CAN
EXPLODED IF FLAMES, SPARKS, OR LIGHTED TOBACCO ARE BROUHT NEAR THE
BATTERY. WHEN CHARGING OR USING A BATTERY IN AN ENCLOSED SPACE, ALWAYS
PROVIDE VENTILATION AND SHIELD YOUR FACE AND EYES.
● KEEP BATTERIES OUT OF REACH OF CHILDREN. BATTERIES CONTAIN SULFURIC ACID.
AVOID CONTACT WITH SKIN OR EYES.
ALSO, SHIELD YOUR EYES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST
POSSIBLE SPLASHING OF THE ACID SOLITION. IN CASEOF ACID CONTACT WITH SKIN,
EYE, OR CLOTHING, FLUSH IMMEDIATCAL ATTENTION. IF ACID IS SWALLOWED, CALL A
PHYSIAN IMMEDIATELY.

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2002 > G 2.0 DOHC > Engine Electrical System > Charging System > Battery > Troubleshooting

Battery discharge test

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 2002 > G 2.0 DOHC > Engine Electrical System > Charging System > Battery > Repair procedures

INSPECTION
Terminal and cable
1. Check the tightness of the terminals to ensure good electrical connections. Clean the terminals and
coat them with grease after tightening.
2. Inspect for corroded or frayed battery cables.
3. Check the rubber protector on the positive terminal for proper coverage.

Electrolyte level
1. Check whether or not the electrolyte level lies between the UPPER LEVEL and the LOWER LEVEL
lines.
2. If low, add distilled water until the UPPER LEVEL line is reached. Do not overfill.
3. Charge battery before checking specific gravity.

Specific gravity
1. Measure the specific gravity of each cell with a hydrometer.
2. If the specific gravity reading is below standard, recharge the battery.

Standard gravity: 1.280 at 77°F (25°C)

3. If the hydrometer readings for the highest and lowest cells vary 0.05 or more, replace battery.

Quick charging

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2002 > G 2.0 DOHC > Engine Electrical System > Charging System > Battery > Repair procedures

● BEFORE PERFORMING MAINTENANCE OR RECHARGING THE BATTERY, TURN OFF ALL

ACCESSORIES AND STOP THE ENGINE.
● THE NEGATIVE CABLE MUST BE REMOVED FIRST AND INSTALLED LAST.
● SET THE BATTERY IN WATER WHEN QUICK CHARGING TO PREVENT OVERHEATING
THE BATTERY.

1. Remove the battery from the vehicle and remove the vent caps to perform a quick charge.

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 2002 > G 2.0 DOHC > Engine Electrical System > Charging System > Description and Operation

GENERAL DESCRITION
Battery assembly

READ THE BATTERY LABEL FOR SAFETY INFORMATION BEFORE WORKING ON THE
BATTERY.

Generator
The generator consists of a voltage regulator, a stator, a rectifier and a rotor. The generator is a serviceable
item, but there is no maintenance schedule.

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2002 > G 2.0 DOHC > Engine Electrical System > Charging System > Troubleshooting

DIAGNOSIS
Problem Possible Cause Action
No power from Loose or corroded cables Check battery cables
battery Lost ground wire Check groun wire
Discharged battery Check batter
Check generator
Generator light is Generator voltage out of specification Check drive belt and pulley
"ON" Check wire harness
Check generator

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 2002 > G 2.0 DOHC > Engine Electrical System > Charging System > Specifications

SPECIFICATIONS
Fastener Tightening Specifications
Bearing Housing Screws 14-48 lb-in (2.0-5.4 N·m)
Cover Bolts 18-48 lb-in (2.0-5.4 N·m)
Pivot Bolt 28-38 lb-ft (38-51 N·m)
Pulley Lock Nut 44-72 lb-ft (59-98 N·m)
Rectifier Screws 18-48 lb-in (2.0-5.4 N·m)
Tensioner Mounting Bolt 14-19 lb-ft (19-26 N·m)

General Specification
Battrery Voltage(V) 12V, nagataive ground
Type and capacity (5
60AH
hour refe)
Generator Type AC
Output(V-A) 12-70
Regulator type (V) Transistorzid (Built-in IC regulator)
Drive Belt Tension New 0.24-0.32in (6-8mm)/22lb (98N)
Used 0.28-0.35in (7-9mm)/22lb (98N)

SPECIFICATIONS
Fastener Tightening Specifications
Bearing Housing Screws 14-48 lb-in (2.0-5.4 N·m)
Cover Bolts 18-48 lb-in (2.0-5.4 N·m)
Pivot Bolt 28-38 lb-ft (38-51 N·m)
Pulley Lock Nut 44-72 lb-ft (59-98 N·m)
Rectifier Screws 18-48 lb-in (2.0-5.4 N·m)
Tensioner Mounting Bolt 14-19 lb-ft (19-26 N·m)

General Specification
Battrery Voltage(V) 12V, nagataive ground
Type and capacity (5
60AH
hour refe)
Generator Type AC

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2002 > G 2.0 DOHC > Engine Electrical System > Charging System > Specifications

Output(V-A) 12-70
Rehgulator Type(V) Transistorzid (Built-in IC regulator)
Drive Belt Tension New 0.24-0.32in (6-8mm)/22lb (98N)
Used 0.28-0.35in (7-9mm)/22lb (98N)

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2002 > G 2.0 DOHC > Engine Electrical System > Starting System > Schematic Diagrams

CIRCUIT DIAGRAM

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 2002 > G 2.0 DOHC > Engine Electrical System > Starting System > Starter > Description and Operation

GENERAL DESCRIPTION
The DOHC engine with an automatic transmission uses a gear reduction starter. Other
engine/transmission combinations useconventional starters. Both starter assemblies consist of a motor, a
solenoid, a drive pinion and a housing.
When the ignition key is in the START position the solenoid is energized and it extends the drive pinion,
engaging the flywheel. The solenoid also closes an electrical contact, supplying battery current to the
starter motor. This currentspins the motor, the drive pinion and the flywheel.
Clutch pedal position (CPP) switch (Manual Transmission Vehicles)
The clutch pedal position switch is a safety switch which closes the circuit between the starter and the
ignition switch when the clutch pedal is depressed.

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2002 > G 2.0 DOHC > Engine Electrical System > Starting System > Starter > Components and Components Location

COMPONENTS

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2002 > G 2.0 DOHC > Engine Electrical System > Starting System > Starter > Repair procedures

REMOVAL
1. Disconnect negative battery cable.
2. Remove the upper two bolts from the intake manifold bracket.
3. Raise vehicle and support.
4. Remove the two bolts on the clutch release cylinder and push aside (M/T).

5. Remove the lower two intake manifold bracket bolts.

6. Remove intake manifold bracket.
7. Remove the two upper starter bolts.

8. Remove the lower starter bolt.

9. Pull the starter from the clutch (M/T) / torque converter (A/T) housing and prop in place.
10. Lower the vehicle.
11. From above, disconnect the S-terminal connector.
12. Remove nut and lock washer on B-terminal.
13. Disconnect B-terminal.

14. Raise and support vehicle.

15. Push transmission wire harness aside.
16. Remove starter.
INSTALLATION
1. Place starter in engine well.
2. Lower vehicle.
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2002 > G 2.0 DOHC > Engine Electrical System > Starting System > Starter > Repair procedures

3. Connect B-terminal wire.

4. Install washer and nut on B-terminal and tighten.
5. Connect S-terminal.
6. Lower intake manifold bracket into position and insert the two upper bolts.

7. Raise and support vehicle.

8. Place starter in position.
9. Insert the two upper starter bolts.
10. Insert lower starter bolt.

The starter may require adjustment after installation. If required, rotate the starter slightly to
provide proper clearance.

11. Tighten the three starter bolts.

Tighten the bolts to 27-40 Ib-ft (37-54 N·m).

12. Insert lower bracket bolts and tighten.

Tighten the bolts to 27-40 Ib-ft (37-54 N·m)

13. Position clutch release cylinder and install bolts (M/T).

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2002 > G 2.0 DOHC > Engine Electrical System > Starting System > Starter > Repair procedures

Tighten the bolts to 27-40 Ib-ft (37-54 N·m)

14. Lower vehicle.

15. Tighten the two upper intake manifold bolts.

Tighten the bolts to 27-40 Ib-ft (37-54 N·m)

DISASSEMBLY
1. Remove the nut from the solenoid M-terminal.
2. Remove the field wire from the solenoid M-terminal.
If pinion depth shims are found between the solenoid and the drive end housing, remove them and set
aside.

3. Remove the solenoid screws and the magnetic switch.

4. Remove the solenoid plunger spring.

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2002 > G 2.0 DOHC > Engine Electrical System > Starting System > Starter > Repair procedures

5. Disengage the plunger from the lever and remove the plunger.

6. Remove the bolts from the rear cover. Separate the motor assembly from the drive end housing. Also
separate the motor assembly from the planetary gear set, if present.

7. Remove the lever from the drive pinion.

8. Use a deep well socket, or similar tool, to drive the stopper from the snap ring.

9. Remove the snap ring from its groove in the pinion shaft.
10. Remove the stopper and drive pinion from the pinion shaft.
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2002 > G 2.0 DOHC > Engine Electrical System > Starting System > Starter > Repair procedures

11. Remove the two brush plate screws and the rear cover.

12. Remove the armature from the field coil housing.

13. Remove the armature washers from the end of the armature.
INSPECTION
1. Solenoid
(1) Continuity (S-terminal and M-terminal)
Check for continuity between S- and M-terminals with ohmmeter. Replace the solenoid if there is no
continuity.

(2) Continuity (S-terminal and Body)

Check for continuity between the S-terminal and the body with ohmmeter. Replace the solenoid if
there is no continuity.

(3) Grounding
Check continuity between M- and B-terminals with an ohmmeter. Replace the solenoid if there is
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2002 > G 2.0 DOHC > Engine Electrical System > Starting System > Starter > Repair procedures

continuity.
2. Brush and brush holder
(1) Insulation
Check continuity between each insulated brush and the plate with ohmmeter. Replace the brush
holder if there is continuity.

(2) Measure the force of the brush spring with a commercially available spring balance.

Brush spring force: 2.0 lb (8.8 N)

(3) Replace the spring if necessary.

3. Brush
If a brush is worn to, or beyond, the wear limit, replace all the brushes.
Type FE Engine
Standard 0.67 in (17 mm)
Wear Limit 0.45 in (11.5mm)

4. Field coil
(1) Check for continuity between the M-terminal wire and the brushes with an ohmmeter. Replace the
yoke assembly if there is no continuity.

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2002 > G 2.0 DOHC > Engine Electrical System > Starting System > Starter > Repair procedures

(2) Check continuity between the M-terminal wire and yoke with an ohmmeter. Replace the yoke
assembly if there is continuity.
(3) Check if the field coil is loose. Replace the yoke assembly if necessary.

5. Armature
(1) Check continuity between the commutator and the core with an ohmmeter. Replace the armature if
there is continuity.

(2) Check continuity between the commutator and the shaft with an ohmmeter. Replace the armature if
there is continuity.

(3) Place the armature on V-blocks, and measure the runout with a dial indicator.
If the runout is not within specification, repair it with a lathe or replace the armature.

Runout: 0.002 in (0.05 mm)

Maximum: 0.016 in (0.4 mm)

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2002 > G 2.0 DOHC > Engine Electrical System > Starting System > Starter > Repair procedures

(4) Replace the armature if the outer diameter of the commutator is at, or less than, the grind limit.
(5) If the commutator surface is dirty, wipe it with a cloth; if it is rough, repair it with a lathe or fine
sandpaper.
Engine FE Engine
Grind Limit 1.22 in (31 mm)

(6) Segment groove depth

If the depth of the mold between segments is at, or less than, the minimum, replace the armature.

Depth: 0.02-0.03 in (0.5-0.8 mm)

Minimum: 0.008 in (0.2 mm)

ADJUSTMENT
Pinion gap
1. Disconnect the wiring from M-terminal.
2. Apply battery power to the S-terminal and ground the starter motor body. The pinion will eject outward
and then stop.
3. Measure the clearance (pinion gap) between the pinion and the stopper.

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2002 > G 2.0 DOHC > Engine Electrical System > Starting System > Starter > Repair procedures

Be careful not to let electricity flow continuously for more than 10 seconds.

Pinion gap : 0.020-0.079 in (0.5-2.0 mm)

4. If the pinion gap is not within the specified range, make the adjustment by increasing or decreasing the
number of washers used between the solenoid and the drive housing. The gap will become smaller if the
number of washers is increased.

Do not use more washers than plates.

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2002 > G 2.0 DOHC > Engine Electrical System > Starting System > Troubleshooting

DIAGNOSIS
Problem Possible Cause Action
Starter fails to crank No current from battery Check charging system
engine Break in wire harness Check wire harness
TR or CPP switch not engaged Check TR or CPP switch
Break in ignition key circuit Check ignition switch
Internal failure Replace solenoid or starter
Starter spins/no Drive pinion not extending Replace starter assembly
engine crank. Flywheel damage See Group Engine
Starter cranks Battery current is low Check charging system
slowly. Loose cable or corroded terminal Check wire harness connections
Generator light is Battery voltage out of Specification. Check charging system
ON during cranking.

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 2002 > G 2.0 DOHC > Engine Electrical System > Starting System > Specifications

SPECIFICATIONS
Faster tightening
Starter Motor Bolts 27-40 lb-ft (37-54 N·m)
B-Terminal Nut 12-17 lb-ft (16-23 N·m)
Intake Manifold Bracket Bolts 27-40 lb-ft (37-54 N·m)

General
Type Direct (DOHC with A/T-Gear Reduction)
Output 12 hp (0.9 kw) (DOHC with A/T-16 hp (1.2 kw)
Standard 0.67 in (17 mm)
Brush Length
Wear Limit 0.45 in (11.5 mm)
Spring Force 2.0 lb (8.8 N)
Standard 0.002 in (0.05 mm)
Armature Runout
Limit 0.016 in (0.4 mm)

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2002 > G 2.0 DOHC > Engine Electrical System > Troubleshooting > P0300

Diagnostic Trouble Codes Diagnosis Charts

Diagnostic trouble code No.
Random misfire detected
P0300
Diagnostic trouble code No.
Cylinder 1 misfire detected
P0301
Diagnostic trouble code No.
Cylinder 2 misfire detected
P0302
Diagnostic trouble code No.
Cylinder 3 misfire detected
P0303
Diagnostic trouble code No.
Cylinder 4 misfire detected
P0304
[Related items] ● Vacuum leak in air intake system
● CKPS circuit malfunction
● Ignition circuit malfunction
● Faulty ignition coil or plug wire
● Spark plug malfunction
● Low compression due to blown head gasket, leaking valve or piston
ring
● Low/high fuel pressure due to faulty pressure regulator, restricted fuel
lines, plugged fuel filter or faulty fuel pump
● Fuel injector circuit malfunction
● Faulty fuel injector

If any injectors, HO2S, ECTS, and MAFS codes are present, do all
repairs associated with those codes before proceeding this
troubleshooting guide.

Step Inspection Action

Connect SCAN TOOL to data link Do all repairs associated with those
connector or OBD-II check connector. Yes
1 codes before proceeding this procedure.
Turn ignition to ON and monitor DTCs.
Are any other codes set? No Go to step 2.
Check for any split, disconnected or
Yes Go to step 3.
perforated vacuum hoses. Also, check
2
PCV valve for proper operation.
No Replace faulty vacuum hoses or PCV.
Are vacuum hoses and PCV okay?
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2002 > G 2.0 DOHC > Engine Electrical System > Troubleshooting > P0300

Turn ignition to OFF and disconnect Yes Go to step 4.

ignition coil connector.
Turn ignition to ON and measure voltage
of ignition coil power circuit between Open circuit or short circuit to chassis
3
ignition coil harness connector and ground between ignition coil harness
No
chassis ground. connector and main relay.
· Specification : approximately B+ Repair as necessary.
Is battery voltage within specifications?
Turn ignition to OFF and check ignition
coils and plug wires for cracks or carbon
Yes Go to step 5.
tracing. Check rsistance orf primary coils
(0.45~0.55Ω at 20℃) and secondary coils
4
(13~15 KΩ at 20℃).
Check for resistance of plug wires (16KΩ
No Repair or replace as necessary.
per 1m).
Are ignition coils and plug wires OK?
Disconnect CKP connector and measure
resistance between CKP terminal 2 and
terminal 3 (800~900Ω at 20℃)
Remove CKPS and calculate air gap Yes Go to step 6.
between sensor and flywheel/torque
converter (0.95~1.7 mm [0.037~0.067 in])
{measure distance from hosing to teeth
5
on flywheel/torque converter
(measurement "A") and from mounting
surface on sensor to sensor tip
(measurement "B") subtract "B" from "A" No Repair as necessary.
= air gap}
Are air gap and resistance
measurements within specifications?
Thoroughly check for loose, bent or
corroded terminals between CKPS and Yes Go to step 7.
ECM.
Measure resistance of CKPS ground
6 circuit between CKPS harness connector Open circuit between CKPS harness
and chassis ground. No connector and chassis ground.
· Specification : below 1Ω Repair as necessary.
Does resistance indicate continuity
circuit?

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2002 > G 2.0 DOHC > Engine Electrical System > Troubleshooting > P0300

Release fuel pressure and attach fuel

pressure gauge to service port on fuel
rail. Yes Go to step 8.
Start an engine and warm up to operating
7 temperature. Check for fuel pressure at
idle.
· Fuel pressure at idle : 40~43 psi No Check fuel delivery system.
(276~296 kPa, 2.87~3.02kg/cm²)
Is fuel pressure within specification?
Remove spark plugs and check gap
(1.0~1.1 mm [0.039~0.043 in]) and plug Yes Go to step 9.
8 condition.
Are spark plugs gapped properly and in No Repair as necessary.
good condition?
Perform compression test [approximately Yes Go to step 10.
(193 psi, 1360 kPa, 13.6kg/cm²) at 300
9 rpm (no more than 10% between highest Perform leak down test to determine
and lowest cylinder)]. No source of low compression and repair as
Is compression OK? necessary.

Return vehicle to original condition. Clear all diagnostic trouble codes. Verify by driving vehicle
10
with SCAN TOOL connected and monitor for pending codes.

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2002 > G 2.0 DOHC > Engine Electrical System > Troubleshooting > P0560

Diagnostic Trouble Code Diagnosis Charts

Diagnostic trouble code No.
Battery backup line malfunction
P0560
[Relatd items] ● Open or short between ECM and battery
● ECM internal faulty

Step Inspection Action

Thoroughly check for poor connection,
Turn ignition to OFF and disconnect misplaced, corroded terminals at ECM
Yes
ECM connector. connector.
Measure voltage of backup circuit Repair as necessary.
1
between battery and chassis ground. Open circuit or short circuit to chassis
· Specification : approximately B+ ground between ECM harness connector
Is voltage within specification? No
and battery.
Repair as necessary.
● Temporarily install a known good ECM and check for proper operation. If problem is
corrected replace ECM.
2
● Return vehicle to original condition. Clear all diagnostic trouble codes. Verify by driving
vehicle with SCAN TOOL connected and monitor for pending codes.

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