Kia Carnival Diesel

Engine Electrical System

General Information
Model : Carnival / Sedona

2000 > 2.9L Diesel >
SPECIFICATIONS
Battery and alternator
Engine/Transaxle J3 TCI Diesel

Item M/T A/T
Battery Voltage 12V-negative
Type PT80-33FL MF
Capacity (20 hour rate) 80AH
Alternator Type AC
Output 12V-110A
Regulator type Transistorized (Bulit-in IC regulator)
Regulator voltage 14.1~14.7V
Starter motor
Engine/Transaxle J3 TCI Diesel

Item M/T A/T
Starter motor Type Pre-engaged drive
Output(V-KW) 12-2.2
Battery and alternator
Engine/Transaxle KV6 Gasoline

Item M/T A/T
Battery Voltage 12V-negative
Type PT80-33FL
Capacity (20 hour rate) 80AH
Alternator Type AC
Output 12V-110A
Regulator type Transistorized (Bulit-in IC regulator)
Regulator voltage 14.1~14.7V

Charging System - Alternator

2000 > 2.9L Diesel >
CIRCUIT DIAGRAM
2000 > 2.9L Diesel >
DIAGNOSTIC GUIDE
No. Items
1 Being not charged
2 Engine starts-alternator warning
3 Discharging of battery
Symptom troubleshooting
1 Being not charged

Step Inspection Action
1 Check the battery voltage. Yes Go to next step.
Standard : about 12.4V No Check the battery.
2 Start engine and check if alternator warning Yes Go to step 4.
lamp goes out No Go to next step.
3 Check if voltage at alternator terminals are
correct.
Check wire harness between battery and
Yes
terminal "B".
Check wiring harness.

No
Replace alternator.
4 1. Connect an ammeter ((150A Max :

KV6), (100A Max : J3)) between
terminal "B" and harness. Yes Charging system normal.
2. Start engine.
3. Check if engine is 2500~3000rpm.
4. Check if ampere of load (turn more one
of many electrical system on) high than No Go to next step.
ampere of unload (Turns blower, head
lamp, rear defroster, etc,off).
5 Yes Replace alternator.
Check if drive belt tension is OK
No Check drive belt tension.
1 Discharging of battery
1 Measure open circuit voltage of battery with a Yes Go to next step.
Quick charge for 2 hour and recheck
digital voltmeter capable of reading 0.01V. No voltage if the voltage is below 12.4V,
replace battery.
2 Apply load test to the battery by using a
battery load tester
Yes Go to next step.
Quick charge record battery voltage at the end

of 15 seconds : is the voltage more than
specification?
No Replace battery.
3 Measure open circuit voltage of battery. Yes Battery is OK.

Standard : above 12.4V No Charge battery.
2000 > 2.9L Diesel >
REMOVAL
1. Disconnect negative battery cable.
2. Lower an auto tensioner with spanner and then remove drive belt.
3. Remove "B" terminal lead and then disconnect alternator "L" and "S" terminal connector.
4. Remove alternator.
5. Install in reverse order of removal.
Tightening torque : 33.2lb-ft (45.1N·m, 4.6kg-m)


Charging System - Battery

2000 > 2.9L Diesel >
INSPECTION
1. Electrolyte level
(1) Check whether or not the electrolyte level lines between "UPPER LEVEL" line and "LOWER LEVEL"
line.
(2) If low add distilled water to "UPPER LEVEL" line.
Do not overfill.
2. Specific gravity of electrolyte of electrolyte

Measure specific gravity with a hydrometer.
Specific gravity : 1.27~1.29 (at 77°F (25°C))
3. Terminal and cable

(1) Check that battery terminal connections are tight to ensure good electrical connections.
(2) Check for corroded or frayed battery cables.
(3) Check rubber protector on positive terminal for proper coverage.
(4) Clean terminals, if necessary and lightly coat them with grease.
Drive belt
Check drive belt and pulley for wear, cracks and praying. Replace if necessary.

Starting System

2000 > 2.9L Diesel >
SYMPTOM GUIDE
No. Items
1 Will not crank-starter motor dose not operate
2 Will not crank-starter motor spins
3 Cranks slowly
4 Generator warning light illuminates with engine running
5 Discharged battery
Syptom troubleshooting
1 Will not crank-starter motor dose not operate

1 Check if engine cranks with fully charged Yes Check charging system.
battery. No Go to next step.
2 Check if battery voltage is supplied at B
terminal
Yes Go to next step
No Check wiring harness.
3 Check if battery voltage is supplied at S

terminal with clutch pedal depressed (M/T), Yes Replace starter unit
car in PARK (A/T) and ignition switch in
START position.
• Check transaxle range switch (A/T)

(Refer to section Auto transaxle)
No
• Check ignition switch
• Check wiring harness
2 Will not crank-starter motor spins

Step Inspection n
1 Check if drive pinion is pulled out while Remove starter and check flywheel ring
Yes
cranking gear teeth and starter drive pinion teeth.
(Click heard when pulled out) Check solenoid.
No
Repair or replace as necessary.
3 Cranks slowly
1 Check charging system. (Refer to section
Check if engine cranks normally when fully Yes
charging system)
charged
No Go to next step.
2 Yes Repair or replace connection.
Check starter cable connection for
looseness and corrosion. Check for seized motor armature. Repair
No
or replace as necessary.
4 Alternator warning lamp illuminates with engine running

1 Check wiring harness between Alternator L
Check for correct battery voltage at idle. Yes
terminal and generator warning lamp.
Specification : 14.1~14.7V
No Check charging system.
5 Discharged battery
1 Turn ignition switch ON and check dark
Check charging system. Yes current as shown.
(Refer to section Charging system) Dark current : Below 20mA
No Repair or replace parts as necessary.

Starting System - Starter

2000 > 2.9L Diesel >
STRUCTURAL VIEW
Component
2000 > 2.9L Diesel >
INSPECTION
Pull in voltage
1. Inspect the battery voltage.
Voltage : above 12.4V
2. After starting the engine, check if the starter rotates smoothly.

3. If the starter dose not rotate, check the "S" terminal voltage during cranking engine.
Voltage : above 8V
A. Above 8V : Inspection the starter.

B. Below 8V : inspection wiring (main fuse, ignition switc and transaxle range switch (A/T))
Solenoid
1. Pull-in coil
• Remove the battery negative cable.

• Remove the "M" terminal starting motor
(1) Do the continuity test between "S" and "M" terminal.

(2) If it is open, replace the solenoid.
2. Hold-in coil
(1) Do the continuity test between "S" and solenoid body.
(2) If it is opened, replace the solenoid.
INSPECTION
Pull in voltage
1. Inspect the battery voltage.
Voltage : above 12.4V
2. After starting the engine, check if the starter rotates smoothly.

3. If the starter dose not rotate, check the "S" terminal voltage during cranking engine.
Voltage : above 8V
A. Above 8V : Inspection the starter.

B. Below 8V : inspection wiring (main fuse, ignition switc and transaxle range switch (A/T))
Solenoid
1. Pull-in coil
• Remove the battery negative cable.

• Remove the "M" terminal starting motor
(1) Do the continuity test between "S" and "M" terminal.

(2) If it is open, replace the solenoid.
2. Hold-in coil
(1) Do the continuity test between "S" and solenoid body.
(2) If it is opened, replace the solenoid.

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Engine Electrical System

Engine Electrical System

Model : Carnival / Sedona

Engine/Transaxle J3 TCI Diesel

Engine/Transaxle J3 TCI Diesel

Battery and alternator

Engine/Transaxle KV6 Gasoline

Engine Electrical System

Model : Carnival / Sedona

1 Being not charged

Check wiring harness.

4 1. Connect an ammeter ((150A Max :

Yes Go to next step.

Quick charge record battery voltage at the end

3 Measure open circuit voltage of battery. Yes Battery is OK.

5. Install in reverse order of removal.

Tightening torque : 33.2lb-ft (45.1N·m, 4.6kg-m)

Engine Electrical System

Model : Carnival / Sedona

2. Specific gravity of electrolyte of electrolyte

Specific gravity : 1.27~1.29 (at 77°F (25°C))

3. Terminal and cable

Engine Electrical System

Model : Carnival / Sedona

1 Will not crank-starter motor dose not operate

No Check wiring harness.

3 Check if battery voltage is supplied at S

• Check transaxle range switch (A/T)

2 Will not crank-starter motor spins

4 Alternator warning lamp illuminates with engine running

Engine Electrical System

Model : Carnival / Sedona

Voltage : above 12.4V

2. After starting the engine, check if the starter rotates smoothly.

A. Above 8V : Inspection the starter.

• Remove the battery negative cable.

(1) Do the continuity test between "S" and "M" terminal.

Voltage : above 12.4V

2. After starting the engine, check if the starter rotates smoothly.

A. Above 8V : Inspection the starter.

• Remove the battery negative cable.

(1) Do the continuity test between "S" and "M" terminal.

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