Import Tech Tips

ACURA 1990-1993 Legend 2.7L; 3.0L
1990-1993 Legends may experience a condition of low battery charge due to a misaligned glove box light switch. The switch may fail to turn off the glove box light when the door is closed, causing a continuous drain on the battery. The strain of constantly recharging a low battery may also cause the alternator to fail prematurely. Acura's solution to the problem is an extension cap, which fits over the switch plunger and insures that the light will be switched off when the door is closed. The Acura part number is 34245-SPO-A03

ACURA 1986-1989 Legend 2.7L; 3.0L
1986-1889 Acura Legends with the 2.5L and 2.7L engine may experience a low state of battery charge and a high rate of alternator replacement. This occurs most often in vehicles driven on short trips or in slow-moving traffic. Heavy use of electrical accessories (lights, wipers, A/C, heater, rear window defroster, stereos, etc.) contributes further to this condition. The problem is that at low engine speeds, the alternator turns too slowly to generate enough current to meet the demand on the electrical system. In most cases, the battery is able to supply the difference, but in doing so, its state of charge is lowered. If the vehicle is never driven at highway speeds, the battery will gradually be drained until it is unable to start the car. If the vehicle does get driven at highways speeds, the alternator will turn fast enough to generate its full rated output, and will power all of the accessories as well as recharge the battery. However alternators are not designed to work at full output for any length of time. If the accessory demand remains heavy, and if the state of battery charge is low, the alternator may be required to maintain full output continuously. The heat and stress of continuous operation at maximum output dramatically shortens the service life of an alternator and inevitably leads to premature failure. To prevent this problem, Acura offers a kit (Acura part number 06310-PL2-004) consisting of a smaller diameter alternator pulley and a shorted drive belt. Installation of the kit increases alternator speed over the entire range of engine speeds. This improves alternator output at idle, allowing it to better keep up with demand and spend less time at its maximum

ACURA 1986-1989 Integras 1.6L
1986-1989 Integras may experience a no-start or low battery condition due to the following:

• Short trip driving with the rear window defogger switched on
• High under hood temperature

The heavy load imposed on the electrical system by the rear window defogger may prevent the alternator from maintaining a full charge on the battery. It has also been found that the high temperatures in the engine compartment reduce the battery's capacity and shorten its life. To eliminate the problem, Acura has developed a kit that contains a defogger switch designed to shut the system off after 25 minutes and a heat shield to protect the battery from engine heat.

• Use kit number 063770SD2-A011 for 1986-1987 Integras.
• Use kit number 06377-SD2-A11 for 1998-1999 Integras.

ACURA 1988-1989 Integra 1.6L; 1994-1998 Integra 1.8L; 1997 CL 2.2L
Beginning with the 1988 model years, certain Acura Integras and CLs were equipped with an Electronic Load Detention (ELD) module which was designed to improve fuel economy by almost shutting off the alternator during light throttle and idle. If the module fails, the ECM loses a sensor and that vehicle may experience stalling, rough idle, or low / no alternator output. Fault code 20 will be set.

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HONDA 1986-1989 Many
1986- 1989 Hondas may experience a no-start or low battery condition due to the following:

The heavy load imposed on the electrical system by the rear window defogger may prevent the alternator from maintaining a full charge on the battery. It has also been found that the high temperature in the engine compartment reduce the battery's capacity and shorten its life. To eliminate these problems, Honda has designed defogger switch that shuts the system off after 25 minutes (part number 35500-SE0-A11) and a heat shield that protects the battery from engine heat (part number 063770SE3-A00).

HONDA 1990-1997 Accord 2.2L; 1998 Accord 2.3L; 1992-1993 Civic & CRX 1.5L; 1992-1998 Civic 1.6L
Beginning with the 1990 model year, certain Hondas were equipped with an Electronic Load Detention (ELD) module which was designed to improve fuel economy by almost shutting off the alternator during light throttle and idle. If the module fails, the ECM loses a sensor and the vehicle may experience stalling, rough idle, or low / no alternator output. Fault code 20 will be set.

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HYUNDAI 1992-1993 Sonata 2.0L; 2.4L; 3.0L
1992-1993 Sonatas may develop a low battery charge condition that may lead to a no-start situation. If a thorough check of the starting and charging systems finds no other problems, check the cooling fan circuits. There is an in-line diode in the wiring harness behind the battery that corrodes and becomes conductive, allowing the cooling fans to run even with the key out of the engine. The Hyundai part number for the replacement diode is 91798-33000.

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ISUZU 1986-1995 Amigo, P'up, Rodeo, Trooper 2.3L; 2.6L
Many 1986-1995 Isuzu trucks with the 2.3L and 2.6L engine develop a low battery charge condition caused by weak alternator output. The problem is not necessarily a bad alternator; it is often been found to be the result of damage to the alternator wiring harness. The harness passes through a metal retainer near the back of the alternator, and over time, the retainer can chafe through the harness, grounding it out. Before replacing the alternator, inspect the harness and repair or replace it if required. Also check all connectors and cables for signs of corrosion. High-resistance connections can easily prevent the alternator from maintaining a full charge in the battery.

ISUZU 1992-1998 Trooper 3.2L, 3.5L
When replacing the starter on 1992-1998 Troopers with the 3.2L and 3.5L engine it is advisable to make sure that the charging system is working within specifications. Know problems with the alternator wiring harness can result in reduced output that may leave the battery in a low state of charge. The alternator wiring harness is prone to chafing and shorting near the back of the alternator, where it passes through a retainer and corroded connector terminals in the harness may prevent the alternator from delivering full output to the battery. The OEM starter used in these Troopers is particularly sensitive to heat damage caused by low voltage operation; many OEM Isuzu cores show evidence of burned brushes and melted commutators. The ST-319 has been re-engineered to better withstand the heat of low voltage operation; however the best insurance against premature failure is to make certain that the electrical system provides it with full starting current.

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MAZDA 1988-1992 626 2.2L
1988-1992 Mazda 626s with the 2.2L engine may experience a hard-start / no-start condition during very cold weather. The condition usually occurs after the vehicle has been driven for a short while and then stopped for 30 to 40 minutes. It may then be difficult to restart. Mazda has determined that the problem is caused by frost forming on the #1 and #2 main relay contacts. Although the relay warms up while driving, moisture inside the relay freezes on the contacts once the car is stopped and begins to cool down. Mazda has designed a newer moisture resistant relay (part number B630-18-811), which is a direct plug-in replacement for the original. Installation of this relay will solve the problem.

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NISSAN 1991 Pathfinder, Pickup 2.4L; 3.0L
1991 Nissan trucks may develop a hard-start / no-start / low battery condition resulting from no output by the alternator. Before replacing the alternator, check the yellow wire at diode connector %(E of the alternator warning light circuit. Many trucks were assembled with a wire tie around the yellow wire at this connector. The tie should have been attached to the connector instead. Over time, vibration may cause the tie to damage the wire, resulting in zero output from the alternator at speeds below 3500 RPM. To correct this problem, repair any damage to the wire or connector and secure the connector properly.

NISSAN 1985-1994 Maxima 3.0L
1985-1994 Maximas have experienced a variety of electrical problems. When investigating a problem with the charging system, be aware of the following

Some Maximas may develop a constant electrical draw that drains the battery overnight. This may be accompanied by the appearance of Fault code DTC13, which indicates a problem with the cylinder head temperature sensor. The problem has actually been found to be with the sensor wiring harness, which chafes and shorts out, causing the A/C cooling fans to run continuously. Repairing or replacing any damaged wiring and rerouting the harness further away from the temperature sensor will cure the problem.

1985-1994 Maximas may experience a low state of battery charge and a high rate of alternator failure. This occurs most often in vehicles driven on short trips or in slow-moving traffic. Heavy use of the electrical accessories (lights, wipers, A/C, heater fan, rear window defroster, stereos, etc.) contributes further to this condition.

The problem is that at low engine speeds, the alternator turns too slowly to generate enough current to meet the demand on the electrical system. In most cases, the battery is able to supply the difference, but in doing so, its state of charge is lowered.

If the vehicle is rarely driven at highway speeds, the battery will gradually be drained until it is unable to start the car.

If the vehicle does get driven at highway speeds, the alternator will turn fast enough to generate its full rated output, and will power all the accessories as well as recharge the battery. However, alternators are not designed to work at full output for any length of time. If the accessory demand remains heavy, and if the state of battery charge is low, the alternator may be required to maintain full output continuously. The heat and stress of such operation dramatically shortens the service life of an alternator and often causes visible damage. It is common to see Maxima alternators whose diodes have literally popped open from the strain of continuous full-output operation.

To relieve this problem, Nissan recommends installation of a smaller alternator pulley (69mm diameter) along with a shorter drive belt (part number 11720-16E02). Both are available through Nissan dealers. Use of the smaller pulley makes the alternator turn faster for a given engine speed, improving its output at idle, and allowing it to be more effective at meeting electrical demand at low driving speeds. This, in turn means that less need to work at maximum output once the car reaches highway speed.

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