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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
    G03848566Courtesy 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
    G03848567Courtesy of HYUNDAI MOTOR CO.
  3. If any section of a wiring harness interferes with the edge of a parts, or a corner, wrap the section of the harness with tape or something similar in order to protect it from damage.
    Fig 3: Wrapping Tape To Wiring Harness
    G03848568Courtesy of HYUNDAI MOTOR CO.
  4. When installing any parts, be careful not to pinch or damage any of the wiring harness.
    Fig 4: Precautions While Installing Any Parts
    G03848569Courtesy of HYUNDAI MOTOR CO.
  5. Never throw relays, sensors or electrical parts, or expose them to strong shock.
    Fig 5: Precautions While Handling Relays, Sensors Or Electrical Parts
    G03848570Courtesy 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 beforehand.
    Fig 6: Precautions For Parts Damaged By Heat
    G03848571Courtesy of HYUNDAI MOTOR CO.
  7. Loose connectors cause problems. Make sure that the connectors are always securely fastened.
    Fig 7: Checking Proper Fastened Connectors
    G03848572Courtesy of HYUNDAI MOTOR CO.
  8. When disconnecting a connector, be sure to grip only the connector, not the wires.
    Fig 8: Precaution While Disconnecting Connectors
    G03848573Courtesy of HYUNDAI MOTOR CO.
  9. Disconnect connector which have catches by pressing in the direction of the arrows shown in the illustration.
    Fig 9: Pressing Catches For Disconnecting Connector
    G03848574Courtesy of HYUNDAI MOTOR CO.
  10. Connect connectors which have catches by inserting the connectors until they make a clicking sound.
    Fig 10: Connecting Connectors Which Have Catches
    G03848575Courtesy 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 contacts the terminal, being careful not to damage the insulation of the wires.
    Fig 11: Checking Continuity Or Voltage Of Connector Terminals
    G03848576Courtesy 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.
    WIRE SIZE SPECIFICATIONS

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