Malfunction Of Door Warning Light

Model:          Hyundai Grandeur (XG)
Year model:   2004
Mileage         140142km
Displacement:3500cc
Fuel:            Gasoline
1) Condition:

1. The door ajar warning light fails to operate when the door is opened.
2. Blown fuse once or twice a week.

2) Cause:

1. A short circuit of front right side door.

3) Diagnosis:

1. Check the door connections on the left and the right side – Trouble not found.
2. Check the passenger junction block connector – Abnormal.
3. Check the front right side door warning – A short  circuit between the wire and the Body.

4) Repair Guide:

• Repair front door wiring harness.

more Trouble Shooting

How Does CVVT Works to the Engine?

General Description:
The CVVT( Continuously Variable Valve Timing) System is installed to the chain sprocket of the intake camshaft. This system controls the intake camshaft to provide the optimal valve timing for every driving condition. The ECM controls the oil control valve (OCV), based on the signal output from mass airflow, throttle position and engine coolant temperature. The CVVT controller regulates the intake camshaft angle using oil pressure through the OCV. As Result, the relative position between the camshaft and the crankshaft becomes optimal, and the engine torque improves, fuel economy improves, exhaust emission decrease under driving conditions.
DTC Detecting Condition
Item                 Detecting Condition                               Possible Cause =DTC               = Determines if CAM target is aligned    =loosened CKPS
Strategy          correctly to crank                              = Timing misalignment
=Enable           =No active faults                                                   
Conditions        =Fully warm up at idle                        
= Threshold       =Case 1                                           = 1teeth misalignment at 80 *C(176 *F)
value                                                                      Temperature<90*C(194*F)
= Case 2         = 2 tooth misalignment ot lower than   
                       80*C(176*F) or Higher than 90*C(194*F)
=Diagnosis       = Continuous(within 1 min.)
Time
= Mil On          = 2 driving cycles
Condition
Specification:
Engine oil Temperature:                                                                  Misalignment: 80*C(176*F)<90*C(194*F)                   1 Teeth
Info to Charging System

How to Test the Electronic Voltage Regulator.

This the continuation of Regulated Voltage Test Study 4.
TEST:

1. Turn On the Ignition switch and check to see the voltage indicates the following value.
   
   Voltage: Battery Voltage.
   
   If reads 0V, there is an open circuit in the wire between the alternator “B” terminal and the battery and the battery (-) terminal.
2. Start the engine. keeps all light and accessories off.
3. Run the engine at the speed of about 2,500 rpm and read the voltmeter when the alternator 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 alternator is faulty.
   
   REGULATING VOLTAGE TABLE:
   Voltage regulator ambient                              Regulating Voltage
       temperature *c(*F)                                                         
       -30 (-22)                                                 14.2~ 15.3
        25(77)                                                   14.2 ~ 14.8
        135(275)                                                13.3 ~ 14.8
   
2. Upon completion of the test, reduce the engine speed to idle, and turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Remove the voltmeter and ammeter and the engine tachometer.
5. Connect the alternator output wire to the alternator “B” terminal.
6. Connect the battery ground cable.
   READ MORE PAGE #3

Study 4 of Engine Charging System

= Now we Study the Regulated Voltage test=
= The purpose of this test is to check that the electronic voltage regulator control voltage correctly.
Preparation:

1. Prior to test, check the following items and correct as necessary.
   Check that battery installed on the vehicle is fully charged. The battery checking method is described in the section inspect “Battery”.
   Check the alternator drive belt tension. the belt tension check method is described in the section “Inspect drive belt”
2. Turn ignition switch to off.
3. Disconnect the battery ground cable.
4. Connect the digital voltmeter between the “B” terminal of the alternator and ground. Connect the (+) lead of the voltmeter to the “B” terminal of the alternator. Connect the (-) lead to the good ground or the battery (-) terminal.
5. Disconnect the alternator output wire from the alternator “B” terminal.
6. Connect the DC ammeter (0 to 15A) in series between the “B” terminal and disconnected output wire. Connect the (-) lead wire of the ammeter to the disconnected output wire.
7. Attach the engine tachometer and connect the battery ground cable.

Read more Study 3

Charging Sytem of an Auto bile Study 3

= Output Current Test=
(Click here to Study 2)
* This test determines whether or not the alternator gives an output current that is equivalent to the normal output.
PREPARATION:

1. Prior to the test, check the following items and correct as necessary. Check the battery installed in the vehicle to ensure that is good condition. the battery checking method is described in the section “Battery”. The battery that is used to test the output current should be that has been partially discharged. With a fully charge battery, the test may not be conducted correctly due to an insufficient load. Check the tension of the alternator drive belt”.
2. Turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Disconnect the alternator output wire from the alternator “B” terminal.
5. Connect a DC Ammeter () to 15A) in series between the “B” terminal and disconnected output wire. Be sure to connect the (-) lead wire of the Ammeter to the disconnected output wire.
   
   NOTE:
   = Tightened its connection surely, as a heavy current will flow.
6. Connect a volt meter(0 to 20V) between the “B” terminal and ground. Connect the (+) lead wore to the alternator “B” terminal and (-) lead wire to a good ground.
7. Attach an engine tachometer and connect the battery ground cable.
8. Lead the engine hood cable.

TEST:

1. Check to see that the voltmeter reads as the same value as the battery voltage. If the voltmeter read 0V, and the open circuit in the wire between alternator “B” terminal and battery (-) terminal or poor grounding is suspected.
2. Start the engine and turn on the headlamps.
3. Set the headlamps to high beam and the heater blower 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 start 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 alternator output wire is in good condition, remove the alternator from the vehicle and test it.
   Limit value: 91A min.(130A alternator.
   
   NOTE: 1) The nominal output current value is shown on the nameplate affixed to the alternator body.
   2) The output current value changes with the electrical load and the temperature of the alternator itself.
   Therefore, the nominal output current may not be obtained. if such is the case, keeps the headlamps on the cause discharge of the battery, or use the lights of the another vehicle to increase the electrical load.
   The nominal current may not be obtained if the temperature of the alternator irself or ambient temperature is too high.
   In such a case, reduce the temperature before testing again.
2. Upon completion of the output current test, lower the engine speed to idle and turn off the ignition switch.
3. Disconnect the ground cable.
4. Remove the voltmeter and the ammeter  and tachometer.
5. Connect the alternator output wire to the alternator “B” terminal.
6. Connect the battery ground cable.

 

Charging Sytem of an Auto bile Study 2

Now Study on how to check the battery terminals and fuses.
(Click here to #1)

1. Check the battery terminals are not loosed or corroded.
2. Check the fuses for continuity.

Inspect Drive Belt:
= Visually check the belt for excessive wear, frayed cords ect.
   If any defect has been found replace the drive belt.

Note:
Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, It should be replace.
Visually Check Alternator Wiring and Listen for Abnormal Noise:

1. Check that the wiring is in good condition.
2. Check that there is no Abnormal noise from the alternator while the engine is running.

Check Discharge Warning Light Circuit:

1. Warm up the engine and then turn it off.
2. Turn off all accessories.
3. Turn the ignition switch “ON” check that the discharge warning light is lit.
4. Start the engine. Check that the lights lit. If the light does not go off as specified , troubleshoot the discharge light circuit.

Inspect Charging System
Voltage Drop Test of Alternator Output Wire.
= This test determines whether or not the wiring between the alternator “B” and the battery (+) terminal is good by the voltage drop method.
Preparation:

1. Turn the ignition switch to off.
2. Disconnect the out put wire from the alternator “B” terminal. Connect the (+) lead wire  of ammeter to the “B” terminal of alternator and the (-) lead wire of ammeter to the output wire. Connect the (+) lead wire of voltmeter to the “B” terminal of alternator and the (-) lead wire of voltmeter to the (+) terminal of battery.

Test:

1. Start the engine.
2. Turn on the headlamps and blower motor. and set the engine speed until the ammeter indicates 20A. And then, read the volt meter at this time.

Result:

1. The volt meter may indicates the standard value.(Standard value: 0.2V max)
2. 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 alternator “B” terminal to the battery (+) terminal. Check for loosed connections, color change due to an overheated harness, ect. Correct them before testing again.
3. Upon completion of the test, set the engine speed at idle. Turn off the headlamps, blower motor and the ignition switch.

Charging Sytem of an Auto bile Study 1

Description:
The charging system included a battery , an alternator with a built-in regulator , and the charging indicator light and wire.
The Alternator has built in diodes, rectifying AC current to DC current.
Therefore , DC current appears at alternator ,”B” terminal. In addition , the charging voltage of this alternator is regulated by the battery voltage detection system. The main component of the alternator are the rotor, rectifier, capacitor brushes, bearing and V-ribbed belt pulley. The brush holder contains a built in electronic voltage regulator.
On Vehicle Inspection:
CAUTION:

• Check that the battery cables are connected to the correct terminals.
• Disconnect the battery cables when the battery is given a quick charge.
• Never disconnect the battery while the engine is running.

Check the Battery Voltage

1. If 20 minutes have not passed since the engine was stopped , turn the ignition switch On and turn On the electrical system(head lamp, blower motor, rear defogger ect.) for 60 seconds to removed the surface charge.
2. Turn the ignition switch Off and turn Off the electrical system.
3. Measure the battery voltage between the negative (-) and the positive(+) terminals of the battery.

Standard Voltage: 12.5~ 12.9V at 20 degrees Celsius (68 “F) 
= If the voltage is less than specification, charge the battery.

How to Check a good Ignition Coil

Description:
Ignition timing is controlled by the electronic control ignition timing system.The standard reference ignition timing data for the engine operating conditions are preprogrammed in the memory of the ECM (Engine Control Module).
The engine operating condition, are detected by the various sensor.Based on  this sensor signals and ignition timing data,signal to interrupt the primary current are sent to the ECM. the ignition coil is activated, and timing is controlled.
On Vehicle Inspection = Spark Test

1. Remove the Ignition coil connector.
2. Remove the ignition coil.
3. Using a spark plug socket, remove the spark plug.
4. Install the sparkplug to the ignition coil.
5. Ground the spark plug to the engine.
6. Check is spark occurs while engine is being cracked.
   
   Note:
   Before Cracked the engine it is necessary to remove the fuel pump relay from the fuse box. And the engine will crack within 5-10 seconds only.
7. Inspect the spark plugs.
8. Using the sparkplug socket install the sparkplug.
9. Install the ignition coil.
10. Reconnect the ignition coil connector.
    Spark Test

Spark test
Check the connection of ignition coil connector --–Bad---> Connect securely.
                    
                    OK

Check the ignition -----------------------------------Bad----->Replace the ignition coil.

                    OK

Check the power supply of ignition coil
1) Turn ignition switch on.                  ------------Bad------> Check wiring between ignition switch
                                                                                   and ignition coil
2) Check that there is battery voltage
    at ignition coil positive terminal.

                    OK

Check the camshaft position sensor-------------Bad-------> Replace camshaft position sensor.
                   OK
Check the crankshaft position sensor-----------Bad------> Replace crankshaft position sensor.
                  OK
Check ignition signal from ECM-----------------Bad------> Check wiring between ECM and ignition coil
                                                                             and then try another ECM.
                 OK
Try another ignition coil.

Inspect the Spark plug
1) Remove the ignition coil connector.
2) Remove the ignition coil.
3) Using a spark plug socket, remove the spark plug.
4) Inspect the electrodes and ceramic insulator.

Condition	Dark deposits	White deposits
Description	Fuel mixture too rich -low air intake	-fuel mixture too lean -Advanced ignition timing -Insufficient plug tightening torque

5)Check the electrodes gap.
  
  Standard
Unleaded: 1.0~ 1.1 mm(0.0394~0.0433 in)
Leaded   : 0.8~ 0.9mm(0.0315~0.0354 in)
Inspect the Ignition Coil

1) Measure the primary coil resistance between terminals(+) and (-)
    = Standard value- 0.62 ohms + or – 10%

Egine and Transaxle assembly

Study guide for dis assembling a Hyundai V6 Engine, This may give a little knowledge and disassewmbling Engine and Transaxle.

REMOVAL
Caution

• Use fender covers to avoid damaging painted surfaces.

• To avoid damage, unplug the wiring connectors carefully while holding the connector portion. 

Note

• Mark all wiring and hoses to avoid misconnection.
• Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

1) Disconnect the negative from the battery.
2) Remove the engine cover.
3)Remove the air duct.
4) Remove the intake air hose and air cleaner assembly.

1. Disconnect the Air flow Sensor connector.
2. Disconnect the breather hose (B) from the air cleaner.
3. Disconnect the ECM connector.
4. Remove the intake air hose (C) and air cleaner.

5) Remove the front wheels.
6) Remove under cover.
7) Drain the engine coolant.Remove the radiator cup to speed draining.
8) Remove upper radiator hose and lower radiator hose.
9) Remove trans axle oil cooler hose.
10)Remove fuel hose and PCSV hose.
11)Remove engine wiring.
   1) Disconnect the RH oxygen sensor connector.
   2) Disconnect power steering oil pressure sensor connector.

   3) Disconnect RH injector connector and ignition coil connector.
   4) Disconnect OCV connector and knock sensor connector.
   5) Disconnect LH front oxygen sensor connector.
   6) Disconnect alternator connector.
   7) Disconnect LH ignition coil connector, injector connector condenser connector and ground, and remove    wiring harness protector.
   8) Disconnect LH CMPS and oil pressure switch connector.
   9) Disconnect PCSV connector and MAP sensor connector.
 10) Disconnect RH CMPS and OTS connector.
 11) Disconnect ETC connector and knock sensor connector.
 12) Disconnect water temp. connector.
 13) Disconnect LH  rear oxygen sensor connector and crankshaft position sensor connector.

12) Disconnect the trans axle wire harness connector and remove trans axle control cable.
13) Disconnect EPS connector.
14) Remove heater hose.
15) Remove brake vacuum hose.
16) Remove power steering pump hose.
17) Remove A/C compressor hose.
18) Drain trans axle oil.
19) Remove  lower arm ball joint.
20) Remove tie rod end ball joint
21) Remove stabilizer link.
22) After removing the split pin and nut from steering bar tie rod, disconnect it.
23) Remove the power steering return hose. and drain power steering oil.
24) Remove front roll stopper mounting bolt.
25) Remove rear roll stopper mounting bolt.
26) Remove steering u joint mounting.
27) Remove front exhaust pipe.
28) Supporting the cross member with a jack, remove the stay with the mounting bolt.
29) Remove drive shaft from trans axle.
30) Install jack for supporting the engine and trans axle assembly.
31) Remove the engine mounting bracket.
32) Remove the trans axle bracket.
33) Finally jack up the vehicle.

Engine and Transaxle assembly

Study guide for disassembling a Hyundai V6 Engine, This may give a little knowledge and disassembling Engine and Transaxle.
REMOVAL
Caution

• Use fender covers to avoid damaging painted surfaces.

• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

Note

• Mark all wiring and hoses to avoid misconnection.
• Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

1) Disconnect the negative from the battery.
2) Remove the engine cover.
3)Remove the air duct.
4) Remove the intake air hose and air cleaner assembly.

1. Disconnect the Air flow Sensor connector.
2. Disconnect the breather hose (B) from the air cleaner.
3. Disconnect the ECM connector.
4. Remove the intake air hose (C) and air cleaner.

5) Remove the front wheels.
6) Remove under cover.
7) Drain the engine coolant.Remove the radiator cup to speed draining.
8) Remove upper radiator hose and lower radiator hose.
9) Remove trans axle oil cooler hose.
10)Remove fuel hose and PCSV hose.
11)Remove engine wiring.
   1) Disconnect the RH oxygen sensor connector.
2) Disconnect power steering oil pressure sensor connector.
   3) Disconnect RH injector connector and ignition coil connector.
   4) Disconnect OCV connector and knock sensor connector.
   5) Disconnect LH front oxygen sensor connector.
   6) Disconnect alternator connector.
   7) Disconnect LH ignition coil connector, injector connector condenser connector and ground, and remove    wiring harness protector.
   8) Disconnect LH CMPS and oil pressure switch connector.
   9) Disconnect PCSV connector and MAP sensor connector.
 10) Disconnect RH CMPS and OTS connector.
 11) Disconnect ETC connector and knock sensor connector.
 12) Disconnect water temp. connector.
 13) Disconnect LH  rear oxygen sensor connector and crankshaft position sensor connector.
12) Disconnect the trans axle wire harness connector and remove trans axle control cable.
13) Disconnect EPS connector.
14) Remove heater hose.
15) Remove brake vacuum hose.
16) Remove power steering pump hose.
17) Remove A/C compressor hose.
18) Drain trans axle oil.
19) Remove  lower arm ball joint.
20) Remove tie rod end ball joint
21) Remove stabilizer link.
22) After removing the split pin and nut from steering bar tie rod, disconnect it.
23) Remove the power steering return hose. and drain power steering oil.
24) Remove front roll stopper mounting bolt.
25) Remove rear roll stopper mounting bolt.
26) Remove steering u joint mounting.
27) Remove front exhaust pipe.
28) Supporting the cross member with a jack, remove the stay with the mounting bolt.
29) Remove drive shaft from trans axle.
30) Install jack for supporting the engine and trans axle assembly.
31) Remove the engine mounting bracket.
32) Remove the trans axle bracket.
33) Finally jack up the vehicle.

General information Hyundai Trouble Code

General Description of Hyundai Sonata.

P0221 Electronic Throttle Control.

The Electronic Throttle Control(ETC) system is made of the components throttle body, throttle position sensor (TPS) 1 & 2 and Acceleration Position Sensor (APS) 1&2. TPS 1&2 sharing the same source voltage and ground. The throttle valve opening is control by throttle motor which is controlled by Engine Control Module(PCM). The opposite position indicator shows inverted signal characteristics. TPS 1 output voltage increases smoothly in proportion with the throttle valve opening angle after starting.TPS2 output voltage decreases in inverse proportion with the throttle valve opening angle after starting. TPS provides feedback to the PCM to control the throttle motor in order to control the throttle valve opening angle properly in response to the driving condition.

DTC Checking Condition:

DTC Strategy:

• Plausibility check between TPS1 and TPS2.

Enable Condition:

• No engine stop and engine start.
• No TPS adaptation request.
• No relevant failure.

 Threshold Value:

• An absolute value of TPS1 - TPS2 > 7.6%.              
  
  

Trouble Code:

Sensor and Touble Code

1) P0341 - Camshaft Positon Sensor Circuit Range/Performance.
2)P0343 - Camshaft Position Sensor Circuit High Input.

Description:
Piston position on combustion chamber is the substantial to define the starting of injection timing. All engine pistons are connected to crankshaft by connecting rod. CPS Crankshaft  Position  Sensor senses the information concerning all piston positions and uses this signal to calculate the injection timing and engine speed. Camshaft position sensor (CMPS) Senses the position of camshaft in reference to the upper dead point of compression cylinder and sends this signal, based on w/c the ECM determines the injection sequence of each cylinder and the fuel injection timing

P0016 crankshaft and camshaft correlation.

The cvvt (continuously variable valve timing) system is installed to the chain sprocket of the intake camshaft. This system controls the intake camshaft to provide the optimal valve timing for every driving condition. The ECM controls the oil control valve (OCV), based on the signal output from the mass air flow, throttle position and engine coolant temperature. The CVVT controller regulates the intake camshaft angle using oil pressure through the OCV. As result, the relative position between the camshaft and the crankshaft becomes optimal, and the engine torque improves, fuel economy improves, exhaust emissions decrease under overall driving conditions.

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