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Servicing The Electrical System

  1. Prior to servicing the electrical system, be sure to turn off the ignition switch and disconnect the battery ground cable.
    NOTE: In the course of MFI or ELC system diagnosis, when the battery cable is removed, any diagnostic trouble code retained by the computer will be cleared. Therefore, if necessary, read the diagnostic before removing the battery cable.
    Fig 1: Disconnecting Battery Ground Cable
    G03842236Courtesy of HYUNDAI MOTOR CO.
  2. Attach the wiring harnesses with clamps so that there is no slack. However, for any harness which passes the engine or other vibrating parts of the vehicle, allow some slack within a range that does not allow the engine vibrations to cause the harness to come into contact with any of the surrounding parts and then secure the harness by using a clamp.
    Fig 2: Attaching Wiring Harnesses With Clamps
    G03842237Courtesy of HYUNDAI MOTOR CO.
  3. If any section of a wiring harness interferes with the edge of a part, or a corner, wrap the section of the harness with tape or something similar in order to protect if from damage.
    Fig 3: Wrapping Section Of Harness With Tape
    G03842238Courtesy of HYUNDAI MOTOR CO.
  4. When installing any parts, be careful not to pinch or damage any of the wiring harness.
    Fig 4: Precaution For Not To Pinch Or Damage Any Of Wiring Harness
    G03842239Courtesy of HYUNDAI MOTOR CO.
  5. Never throw relays, sensors or electrical parts, or expose them to strong shock.
    Fig 5: Precaution For Sensors Or Electrical Parts
    G03842240Courtesy of HYUNDAI MOTOR CO.
  6. The electronic parts used in the computer, relays, etc. are readily damaged by heat. If there is a need for service operations that may cause the temperature to exceed 80°C (176°F), remove the electronic parts before hand.
    Fig 6: Removing Electronic Parts Before Hand
    G03842241Courtesy of HYUNDAI MOTOR CO.
  7. Loose connectors cause problems. Make sure that the connectors are always securely fastened.
    Fig 7: Fastening Connectors
    G03842242Courtesy of HYUNDAI MOTOR CO.
  8. When disconnecting a connector, be sure to grip only the connector, not the wires.
    Fig 8: Precaution For Gripping Wires
    G03842243Courtesy of HYUNDAI MOTOR CO.
  9. Disconnect connector which have catches by pressing in the direction of the arrows shown in the illustration.
    Fig 9: Disconnecting Connector
    G03842244Courtesy of HYUNDAI MOTOR CO.
  10. Connect connectors which have catches by inserting the connectors until they make a clicking sound.
    Fig 10: Connecting Connectors
    G03842245Courtesy of HYUNDAI MOTOR CO.
  11. When using a circuit tester to check continuity or voltage on connector terminals, insert the test probe into the harness side. If the connector is a sealed connector, insert the test probe through the hole in the rubber cap until it contacts the terminal, being careful not to damage the insulation of the wires.
    Fig 11: Checking Continuity Or Voltage
    G03842246Courtesy of HYUNDAI MOTOR CO.
  12. To avoid overloading the wiring, take the electrical current load of the optional equipment into consideration, and determine the appropriate wire size.
DETERMINING WIRE SIZE

Nominal size SAE gauge No. Permissible current
In engine compartment Other areas
0.3 mm2 AWG 22 - 5A
0.5 mm2 AWG 20 7A 13A
0.85 mm2 AWG 18 9A 17A
1.25 mm2 AWG 16 12A 22A
2.0 mm2 AWG 14 16A 30A
3.0 mm2 AWG 12 21A 40A
5.0 mm2 AWG 10 31A 54A
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