1.8 Liter SEPHIA/Spectra Charging System (ENG017)

1.8 LITER SEPHIA/SPECTRA CHARGING SYSTEM

TECHNICAL SERVICE BULLETIN

SUBJECT

1.8 Liter Sephia/Spectra Charging System 

This bulletin provides information on a charging system upgrade for 1998-2001MY Sephia and 2000-2004MY Spectra vehicles equipped with 1.8 liter engines to improve alternator output in high ambient temperatures and severe operating conditions.

Some 1998-2001MY 1.8L Sephia vehicles built between 10/97 - 5/01 and some 2000-2004MY 1.8L Spectra vehicles built between 2/00 - 3/04 may experience battery discharge when operated in high ambient temperatures for extended periods of time at low speeds or at idle with A/C, headlamps and other accessories on. Typically this results in customers reporting an inability to restart the vehicle. To reduce incidence of battery discharge customer complaints, the following new parts are available:

• New higher capacity alternator
• Battery insulator pad (cover)
  Fig 1: Identifying Alternators

  

BATTERY TEST PROCEDURE

Test battery using the Micro 570 tester, refer to TSB, SST 002 for instructions.

ALTERNATOR INSTALLATION PROCEDURE

1. Relieve fuel system pressure by removing the fuel pump relay and running the engine until it stops.
2. Write down the preset radio stations, then disconnect the negative battery cable.
   Fig 2: Removing Fuel Pump Relay

   
   WARNING: Fuel vapors are highly flammable. Death or serious injury could result if they are ignited. Make sure there are no open flames or cigarette smoking in the area of the repair. Adequate ventilation is necessary to prevent a buildup of fumes which could ignite, causing fire or explosion.
3. Remove engine cover, if equipped.
4. Unbolt cruise control assembly from the bulkhead and lay on top of engine.
5. Remove engine ground strap.
6. Remove fuel line using the Quick Connect Fuel Line Tool (refer to TSB Fuel 005 ).
   Fig 3: Removing Fuel Line

   
7. Disconnect alternator electrical connections.
8. Loosen the pivot bolt and belt tensioner bolts. Do not remove.
9. Relieve the tension on the drive belt by rotating the adjustment bolt.
   Fig 4: Identifying Alternator Belt Tension Adjusting Bolt

   
10. Remove the drive belt from the alternator pulley.
11. Remove the belt tensioner hardware.
12. Remove alternator pivot bolt.
13. Remove power steering hose bracket bolt and nut.
    Fig 5: Removing Power Steering Hose Bracket Bolt & Nut

    
14. Move power steering hose to obtain best access for alternator removal.
15. Remove the alternator from the engine compartment.
16. Install new alternator onto the pivot bolt (leave loose).
17. Rotate upper bracket into position on top of alternator.
18. Place belt tensioner hardware on top of alternator.
19. Install tensioner mounting bolt (leave loose).
20. Inspect alternator drive belt and replace, if necessary.
21. Place alternator belt on alternator pulley.
22. Adjust alternator belt by rotating adjustment bolt.
    1. Allowable Belt Deflection:
    2. New Belt: 0.23~0.31 inches (6~8 mm)
    3. Used Belt: 0.28~0.35 inches (7~9 mm)
23. Tighten tensioner bolt to 14~19 ft. lbs. (19~26 Nm)
24. Tighten pivot bolt to 28~38 ft. lbs. (38~51 Nm)
25. Connect electrical connectors to the alternator assembly.
26. Reinstall fuel line, engine ground strap, cruise control assembly, power steering hose brackets, fuel pump relay and engine cover.

BATTERY INSULATOR PAD (COVER) INSTALLATION PROCEDURE

1. Disconnect positive battery terminal from the battery.
2. Install new battery cover over battery in direction shown (cut-out toward bottom front).
   Fig 6: Installing Battery Cover

   
3. Reconnect battery cables, positive cable first.
4. Set clock and pre-set radio stations.
5. Start engine and verify proper operation.

AFFECTED PRODUCTION RANGE

1998-2001MY Sephia vehicles with production from 10/97 - 5/01 and 2000-2004MY Spectra vehicles production from 2/00 - 3/04 that are equipped with 1.8 liter engines only.

PART NUMBER INFORMATION

Description	Previous P/N	New P/N
Alternator	0K2A2 18300	QK2AA 18300
Battery Insulator Pad	N/A	QK2AA 18590

WARRANTY CLAIM INFORMATION

Claim Type	Causal P/N	Qty.	Cond. Code	Cause Code	Repair Description	Labor OP Code	Time	Related Parts	Qty.
W	0K2A2 18300	0	N61	C99	Charging System F/F	37300R00	0.9	QK2AA 18300 QK2AA 18590	1

This repair is to handle customer complaints of a battery discharge condition. Warranty coverage is for the New Vehicle Limited (Basic) Warranty).