STARTING & CHARGING SYSTEM

K ELECTRICAL

STARTING & CHARGING SYSTEM

SECTION SC B

E
CONTENTS
APPLICATION NOTICE .............................................. 3 DARK CURRENT INSPECTION ......................... 24 F
How to Check Vehicle Type ..................................... 3 OPERATION PROCEDURE OF CURRENT
PRECAUTIONS .......................................................... 4 MEASUREMENT PROBE FOR CONSULT-II ..... 25
Precautions for Supplemental Restraint System Trouble Diagnoses (HR Engine Models) ................ 26 G
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN- DIAGNOSIS PROCEDURE ................................ 26
SIONER” .................................................................. 4 PRE-DIAGNOSIS INSPECTION ......................... 26
PREPARATION ........................................................... 5 DIAGNOSIS CHART BY SYMPTOM .................. 26
H
Special Service Tools ............................................... 5 INSPECTION FLOW BY CHARGE WARNING
BATTERY .................................................................... 6 LAMP ................................................................... 26
How to Handle Battery ............................................. 6 CHARGE WARNING LAMP LINE INSPECTION... 27
METHODS OF PREVENTING OVER-DIS- VOLTAGE DETECTION LINE AND CHARGE I
CHARGE ............................................................... 6 WARNING LAMP INSPECTION ......................... 28
CHECKING ELECTROLYTE LEVEL .................... 6 INSPECTION OF INSUFFICIENT ALTERNA-
SPECIFIC GRAVITY CHECK ............................... 7 TOR POWER GENERATION .............................. 29 J
Battery Test and Charging Chart .............................. 8 INSPECTION OF EXCESSIVE ALTERNATOR
CHART I ................................................................ 8 POWER GENERATION ...................................... 30
CHART II ............................................................... 9 DARK CURRENT INSPECTION ......................... 31
SC
A: SLOW CHARGE ............................................. 10 OPERATION PROCEDURE OF CURRENT
B: STANDARD CHARGE .................................... 12 MEASUREMENT PROBE FOR CONSULT-II ..... 32
C: QUICK CHARGE ............................................ 13 Trouble Diagnoses (K9K Engine Models) .............. 33
Removal and Installation ........................................ 15 DIAGNOSIS PROCEDURE ................................ 33 L
CHARGING SYSTEM ............................................... 16 PRE-DIAGNOSIS INSPECTION ......................... 33
System Description (CR Engine Models) ............... 16 DIAGNOSIS CHART BY SYMPTOM .................. 33
System Description (HR Engine Models) ............... 16 INSPECTION FLOW BY CHARGE WARNING M
System Description (K9K Engine Models) ............. 16 LAMP ................................................................... 33
Wiring Diagram — CHARGE — /CR Engine Models... 17 CHARGE WARNING LAMP LINE INSPECTION... 34
Wiring Diagram — CHARGE — /HR Engine Models... 18 VOLTAGE DETECTION LINE AND CHARGE
Wiring Diagram — CHARGE — /K9K Engine Mod- WARNING LAMP INSPECTION ......................... 35
els ........................................................................... 19 INSPECTION OF INSUFFICIENT ALTERNA-
Trouble Diagnoses (CR Engine Models) ................ 21 TOR POWER GENERATION .............................. 37
DIAGNOSIS PROCEDURE ................................ 21 INSPECTION OF EXCESSIVE ALTERNATOR
PRE-DIAGNOSIS INSPECTION ......................... 21 POWER GENERATION ...................................... 37
DIAGNOSIS CHART BY SYMPTOM .................. 21 DARK CURRENT INSPECTION ......................... 38
INSPECTION FLOW BY CHARGE WARNING OPERATION PROCEDURE OF CURRENT
LAMP .................................................................. 21 MEASUREMENT PROBE FOR CONSULT-II ..... 39
CHARGE WARNING LAMP LINE INSPECTION... 22 Removal and Installation (CR Engine Models) ....... 40
INSPECTION OF INSUFFICIENT ALTERNA- REMOVAL ........................................................... 40
TOR POWER GENERATION .............................. 23 INSTALLATION ................................................... 41
INSPECTION OF EXCESSIVE ALTERNATOR Removal and Installation (HR Engine Models) ....... 41
POWER GENERATION ...................................... 24 REMOVAL ........................................................... 41

SC-1
 INSTALLATION .................................................... 42 REMOVAL ............................................................52
Removal and Installation (K9K Engine Models) ..... 43 INSTALLATION ....................................................52
REMOVAL ........................................................... 43 Removal and Installation (HR Engine Models) .......52
INSTALLATION .................................................... 43 REMOVAL ............................................................52
Disassembly ........................................................... 43 INSTALLATION ....................................................53
REAR COVER ..................................................... 43 Removal and Installation (K9K Engine Models) ......53
REAR BEARING ................................................. 44 REMOVAL ............................................................53
Inspection ............................................................... 44 INSTALLATION ....................................................53
ROTOR CHECK .................................................. 44 Disassembly and Assembly ....................................53
BRUSH CHECK .................................................. 44 Inspection ................................................................56
STATOR CHECK ................................................. 44 MAGNETIC SWITCH CHECK .............................56
Assembly ................................................................ 45 PINION/CLUTCH CHECK ...................................56
RING FITTING IN REAR BEARING .................... 45 BRUSH CHECK ...................................................56
REAR COVER INSTALLATION ........................... 45 YOKE CHECK .....................................................58
STARTING SYSTEM ................................................. 46 ARMATURE CHECK ...........................................58
System Description ................................................. 46 Assembly ................................................................59
M/T MODELS ...................................................... 46 PINION PROTRUSION LENGTH ADJUST-
A/T MODELS ....................................................... 46 MENT ...................................................................59
Wiring Diagram — START — /CR and HR Engine SERVICE DATA AND SPECIFICATIONS (SDS) ......61
Models .................................................................... 47 Battery .....................................................................61
Wiring Diagram — START — /K9K Engine Models... 49 Starter .....................................................................61
Trouble Diagnoses .................................................. 51 Alternator ................................................................61
Removal and Installation (CR Engine Models) ....... 52

SC-2
 APPLICATION NOTICE

APPLICATION NOTICE PFP:00000

A
How to Check Vehicle Type EKS00Q77

Confirm K9K engine type with Model written on identification plate (refer to GI-44, "IDENTIFICATION INFOR-
MATION" ), then refer to service information in SC section. B
Vehicle type Engine type
xTKxxxxK12Vxx Euro3 48kW
xTKxxxxK12Yxx Euro3 60kW
C

xTKxxxxK12Txx Euro4 50kW

xTKxxxxK12Uxx Euro4 63kW D

SC

SC-3
 PRECAUTIONS

PRECAUTIONS PFP:00011

Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER” EKS007Z9

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
● Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

SC-4
 PREPARATION

PREPARATION PFP:00002
A
Special Service Tools EKS007ZY

Tool number
Description
Tool name B

EG1187 1900 C
Current measurement probe for System diagnose and inspection
CONSULT-II
D
MKIA0065E

SC

SC-5
 BATTERY

BATTERY PFP:00011

How to Handle Battery EKS007ZB

CAUTION:
● If it becomes necessary to start the engine with a booster battery and jumper cables, use a 12-volt
booster battery.
● After connecting battery cables, ensure that they are tightly clamped to battery terminals for good
contact.
● Never add distilled water through the hole used to check specific gravity.
METHODS OF PREVENTING OVER-DISCHARGE
The following precautions must be taken to prevent over-discharging a battery.
● The battery surface (particularly its top) should always be kept
clean and dry.
● The terminal connections should be clean and tight.
● At every routine maintenance, check the electrolyte level.
This also applies to batteries designated as “low maintenance”
and “maintenance-free”.

MEL040F

● When the vehicle is not going to be used over a long period of

time, disconnect the negative battery terminal. (If the vehicle has
an extended storage switch, turn it off.)

MEL041F

● Check the charge condition of the battery.

Periodically check the specific gravity of the electrolyte. Keep a
close check on charge condition to prevent over-discharge.

MEL042F

CHECKING ELECTROLYTE LEVEL

WARNING:
Do not allow battery fluid to come in contact with skin, eyes, fabrics, or painted surfaces. After touch-
ing a battery, do not touch or rub your eyes until you have thoroughly washed your hands. If acid con-
tacts eyes, skin or clothing, immediately flush with water for 15 minutes and seek medical attention.

SC-6
 BATTERY

● Remove the cell plug using a suitable tool.

● Add distilled water up to the MAX level. A

MEL043F

D
Sulphation
A battery will be completely discharged if it is left unattended
for a long time and the specific gravity will become less than
1.100. This may result in sulphation on the cell plates. E
To determine if a battery has been “sulphated”, note its voltage
and current when charging it. As shown in the figure, less cur-
rent and higher voltage are observed in the initial stage of F
charging sulphated batteries.
A sulphated battery may sometimes be brought back into ser-
vice by means of a long, slow charge, 12 hours or more, fol-
lowed by a battery capacity test. G

SEL709E

SPECIFIC GRAVITY CHECK H

1. Read hydrometer and thermometer indications at eye level.
2. Convert into specific gravity at 20°C (68°F).
Example: I
● When electrolyte temperature is 35°C (95°F) and specific gravity
of electrolyte is 1.230, converted specific gravity at 20°C (68°F)
is 1.240. J
● When electrolyte temperature is 0°C (32°F) and specific gravity
of electrolyte is 1.210, converted specific gravity at 20°C (68°F)
is 1.196. SC
MEL042FA

SEL007Z

SC-7
 BATTERY

Battery Test and Charging Chart EKS007ZC

CHART I

SEL754W

*1. SC-7, "SPECIFIC GRAVITY *2. SC-9, "CHART II" *3. SC-10, "A: SLOW CHARGE"
CHECK"
*4. SC-12, "B: STANDARD CHARGE" *5. SC-13, "C: QUICK CHARGE"

SC-8
 BATTERY

CHART II
A

SEL755W
I
*. SC-8, "CHART I"

● Check battery type and determine the specified current using the following table. J
Fig. 1 Discharging Current (Load Tester)
Type Current (A)
SC
28B19R(L) 90
34B19R(L) 99
46B24R(L) 135 L
55B24R(L) 135
50D23R(L) 150
55D23R(L) 180 M
65D26R(L) 195
80D26R(L) 195
75D31R(L) 210
063 [YUASA type code] 210
95D31R(L) 240
115D31R(L) 240
025 [YUASA type code] 240
065 [YUASA type code] 255
027 [YUASA type code] 285
075 [YUASA type code] 300
110D26R(L) 300
95E41R(L) 300
067 [YUASA type code] 325

SC-9
 BATTERY

Type Current (A)

130E41R(L) 330
096 [YUASA type code] 375
096 [YUASA type code] 375
010S [YUASA type code] 360
LB1 FCM 047 620 [FULMAN type code] 420
LB2 FCM 055 622 [FULMAN type code] 510
LB2 FCM 050 622 [FULMAN type code] 600

A: SLOW CHARGE

SEL756W

*1. SC-7, "SPECIFIC GRAVITY *2. SC-9, "CHART II"

CHECK"

SC-10
 BATTERY

Fig. 2 Initial Charging Current Setting (Slow Charge)

A
CON-VERTED SPECIFIC GRAVITY

BATTERY TYPE B

010S [YUASA type code]

096L [YUASA type code]
025 [YUASA type code]

027 [YUASA type code]

063 [YUASA type code]

067 [YUASA type code]

096 [YUASA type code]

065 [YUASA type code]

075 [YUASA type code]

[FULMEN type code]

[FULMEN type code]

[FULMEN type code]

BL1 FCM 047 620

LB2 FCM 050 622

LB2 FCM 055 622

115D31R(L)

110D26R(L)

130E41R(L)
50D23R(L)

55D23R(L)

65D26R(L)

80D26R(L)

75D31R(L)

95D31R(L)
28B19R(L)

34B19R(L)

46B24R(L)

55B24R(L)

95E41R(L)
D

E
Below 1.100

14.0 (A)
8.5 (A)

9.0 (A)
2.55 2.75 3.0 11.0
4.0 (A) 5.0 (A) 7.0 (A) 8.0 (A) 10.0 (A)
(A) (A) (A) (A)
F

● Check battery type and determine the specified current using the table shown above.
● After starting charging, adjustment of charging current is not necessary. G
Fig. 3 Additional Charge (Slow Charge)
H

SEL757W
SC
*. SC-9, "CHART II"

CAUTION:
● Set charging current to value specified in Fig. 2. If charger is not capable of producing specified L
current value, set its charging current as close to that value as possible.
● Keep battery away from open flame while it is being charged.
● When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, M
as this may cause a spark.
● If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its
temperature is below 60°C (140°F).

SC-11
 1.190 - 1.220 1.160 - 1.190 1.130 - 1.160 1.100 - 1.130 CON-VERTED SPECIFIC GRAVITY

28B19R(L)

34B19R(L)

2.0 (A)
2.0 (A)
3.0 (A)
4.0 (A)
CHECK"
2.1(A) 2.8(A) 3.4(A) 4.1(A) LB1 FCM 047 620 [FULMEN type code]

2.3(A) 3.3(A) 4.0(A) 4.8(A) LB2 FCM 050 622 [FULMEN type code]

46B24R(L)

55B24R(L)

4.0 (A)
5.0 (A)

2.0 (A)
3.0 (A)
B: STANDARD CHARGE

*1. SC-7, "SPECIFIC GRAVITY

2.4(A) 3.3(A) 4.2(A) 2.0(A) LB2 FCM 055 622 [FULMEN type code]

50D23R(L)

55D23R(L)

025 [YUASA type code]

3.0 (A)
4.0 (A)
5.0 (A)
6.0 (A)
027 [YUASA type code]

65D26R(L)
80D26R(L)

*2. SC-9, "CHART II"

SC-12
063 [YUASA type code]
BATTERY

4.0 (A)
5.0 (A)
6.0 (A)
7.0 (A)
067 [YUASA type code]

BATTERY TYPE
Fig. 4 Initial Charging Current Setting (Standard Charge)
096 [YUASA type code]

5.0 (A) 6.0 (A) 7.0 (A) 8.0 (A) 75D31R(L)

95D31R(L)

115D31R(L)

110D26R(L)

95E41R(L)

5.0 (A)
7.0 (A)
8.0 (A)
9.0 (A)
065 [YUASA type code]

075 [YUASA type code]

096L [YUASA type code]

010S [YUASA type code]

6.0 (A)
8.0 (A)
9.0 (A)
SEL758W

10.0 (A)
7.0 (A) 9.0 (A) 11.0 (A) 13.0 (A) 130E41R(L)
 BATTERY

● Check battery type and determine the specified current using the table shown above.
● After starting charging, adjustment of charging current is not necessary. A

Fig. 5 Additional Charge (Standard Charge)

B

SEL759W
E
*. SC-9, "CHART II"

CAUTION:
● Do not use standard charge method on a battery whose specific gravity is less than 1.100. F
● Set charging current to value specified in Fig. 4. If charger is not capable of producing specified
current value, set its charging current as close to that value as possible.
● Keep battery away from open flame while it is being charged. G
● When connecting charger, connect leads first, then turn on charger. Do not turn on charger first,
as this may cause a spark.
● If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its H
temperature is below 60°C (140°F).
C: QUICK CHARGE
I

SC

L
SEL760W

*. SC-9, "CHART II"

SC-13
 BATTERY

Fig. 6 Initial Charging Current Setting and Charging Time (Quick Charge)

LB1 FCM 047 620 [FULMEN type code]

BL2 FCM 050 622 [FULMEN type code]

LB2 FCM 055 622 [FULMEN type code]

010S [YUASA type code]

096L [YUASA type code]
025 [YUASA type code]

027 [YUASA type code]

063 [YUASA type code]

067 [YUASA type code]

096 [YUASA type code]

065 [YUASA type code]

075 [YUASA type code]

BATTERY TYPE

115D31R(L)

110D26R(L)

130E41R(L)
50D23R(L)

55D23R(L)

65D26R(L)

80D26R(L)

75D31R(L)

95D31R(L)
28B19R(L)

34B19R(L)

46B24R(L)

55B24R(L)

95E41R(L)
CURRENT [A]

40 (A)
21(A)

23(A)

24(A)
10 (A) 15 (A) 20 (A) 25 (A) 30 (A)
1.100 - 1.130

2.5 hours
1.130 - 1.160

2.0 hours
1.160 - 1.190

1.5 hours
CONVERTED SPECIFIC GRAVITY
1.190 - 1.220

1.0 hours
Above 1.220

0.75 hours (45 min.)

● Check battery type and determine the specified current using the table shown above.
● After starting charging, adjustment of charging current is not necessary.
CAUTION:
● Do not use quick charge method on a battery whose specific gravity is less than 1.100.
● Set initial charging current to value specified in Fig. 6. If charger is not capable of producing spec-
ified current value, set its charging current as close to that value as possible.
● Keep battery away from open flame while it is being charged.
● When connecting charger, connect leads first, then turn on charger. Do not turn on charger first,
as this may cause a spark.
● Be careful of a rise in battery temperature because a large current flow is required during quick-
charge operation.
If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its
temperature is below 60°C (140°F).

SC-14
 BATTERY

● Do not exceed the charging time specified in Fig. 6, because charging battery over the charging
time can cause deterioration of the battery. A
Removal and Installation EKS007ZD

Observe the following to ensure proper servicing. B

CAUTION:
● When removing, remove negative terminal first. But for
installation, install positive terminal first.
C
● Tighten parts to the specified torque shown below.
Battery bracket mounting bolt:
D
: 12.7 - 15.7 N·m (1.3 - 1.6 kg-m, 10 - 11 ft-lb)
Battery cable tightening nut:
: 3.0 - 5.0 N·m (0.31 - 0.51 kg-m, 27 - 44 in-lb)
MKIA0066E E

SC

SC-15
 CHARGING SYSTEM

CHARGING SYSTEM PFP:00011

System Description (CR Engine Models) EKS007ZE

The alternator provides DC voltage to operate the vehicle's electrical system and to keep the battery charged.
The voltage output is controlled by the IC regulator.
Terminal B supplies power to charge the battery and operate the vehicle's electrical system. The charging cir-
cuit is protected by the 100A link.
The alternator is grounded to the body.
With the ignition switch in the ON or START position, power is supplied
● 10A fuse [No. 2, located in the fuse block (J/B)]
● to combination meter terminal 28 for the charge warning lamp.
Ground is supplied
● to terminal 38 of the combination meter
● through terminal 4 (L) of the alternator.
The charge warning lamp will illuminate. When the alternator is providing sufficient voltage with the engine
running, the ground is opened and the charge warning lamp will go off.
If the charge warning lamp illuminates with the engine running, a fault is indicated.
System Description (HR Engine Models) EKS00P17

The alternator provides DC voltage to operate the vehicle's electrical system and to keep the battery charged.
The voltage output is controlled by the IC regulator.
Power is supplied at all times to alternator terminal 3 through:
● 10A fuse [No. 26, located in the fuse block (J/B)].
Terminal B supplies power to charge the battery and operate the vehicle's electrical system. Output voltage is
controlled by the IC regulator at terminal 4 detecting the input voltage. The charging circuit is protected by the
100A link.
The alternator is grounded to the body.
With the ignition switch in the ON or START position, power is supplied
● 10A fuse [No. 2, located in the fuse block (J/B)]
● to combination meter terminal 28 for the charge warning lamp.
Ground is supplied
● to terminal 38 of the combination meter
● through terminal 2 (L) of the alternator.
The charge warning lamp will illuminate. When the alternator is providing sufficient voltage with the engine
running, the ground is opened and the charge warning lamp will go off.
If the charge warning lamp illuminates with the engine running, a fault is indicated.
System Description (K9K Engine Models) EKS00K2U

The alternator provides DC voltage to operate the vehicle's electrical system and to keep the battery charged.
The voltage output is controlled by the IC regulator.
With the ignition switch in the ON or START position, power is supplied to alternator terminal 4 (S) through:
● IPDM E/R (Intelligent Power Distribution Module Engine Room)
Terminal B supplies power to charge the battery and operate the vehicle's electrical system. Output voltage is
controlled by the IC regulator at terminal 4 (S) detecting the input voltage. The charging circuit is protected by
the 100A link.
The alternator is grounded to the body.
With the ignition switch in the ON or START position, power is supplied
● 10A fuse [No. 2, located in the fuse block (J/B)]
● to combination meter terminal 28 for the charge warning lamp.
Ground is supplied
● to terminal 38 of the combination meter
● through terminal 3 (L) of the alternator.
The charge warning lamp will illuminate. When the alternator is providing sufficient voltage with the engine
running, the ground is opened and the charge warning lamp will go off.
If the charge warning lamp illuminates with the engine running, a fault is indicated.
SC-16
 CHARGING SYSTEM

Wiring Diagram — CHARGE — /CR Engine Models EKS007ZF

SC

MKWA4064E

SC-17
 CHARGING SYSTEM

Wiring Diagram — CHARGE — /HR Engine Models EKS00P18

MKWA4065E

SC-18
 CHARGING SYSTEM

Wiring Diagram — CHARGE — /K9K Engine Models EKS00K2V

SC

MKWA4230E

SC-19
CHARGING SYSTEM

MKWA3474E

SC-20
 CHARGING SYSTEM

Trouble Diagnoses (CR Engine Models) EKS007ZG

DIAGNOSIS PROCEDURE A
1. Check malfunction symptoms or customer's remarks.
2. Perform pre-diagnosis inspection. Refer to SC-21, "PRE-DIAGNOSIS INSPECTION" .
3. Perform trouble diagnosis for each trouble symptom. Refer to SC-21, "DIAGNOSIS CHART BY SYMP- B
TOM"
4. Repair or replace parts indicated inspection flow based on the charge warning lamp. Refer to SC-21,
"INSPECTION FLOW BY CHARGE WARNING LAMP" . C
5. End
PRE-DIAGNOSIS INSPECTION D
1. Perform alternator belt inspection. Refer to EM-14, "DRIVE BELTS" .
2. Inspect battery.
3. Check alternator terminal B for loose or improper connection. E
4. Check alternator connector and terminals for loose connection, disconnection and bend.
5. Check connecting condition of harness for charging system harness (fusible link terminal and battery ter-
minal). F
6. After performing 1 to 5 above, go to trouble diagnosis for symptoms. Refer to SC-21, "DIAGNOSIS
CHART BY SYMPTOM" .
DIAGNOSIS CHART BY SYMPTOM G
Symptom Reference page
Battery discharge Refer to SC-21, "INSPECTION FLOW BY CHARGE WARN- H
Charge warning lamp illuminates. ING LAMP" .

Other than the above symptoms (splashing out of battery fluid, Refer to SC-24, "INSPECTION OF EXCESSIVE ALTERNA-
nasty smell and others) TOR POWER GENERATION" . I
INSPECTION FLOW BY CHARGE WARNING LAMP
1. CHARGE WARNING LAMP INSPECTION J
1. Turn ignition switch ON.
2. Check if charge warning lamp illuminates.
SC
Does charge warning lamp illuminate?
YES >> GO TO 2.
NO >> Go to SC-22, "CHARGE WARNING LAMP LINE
L
INSPECTION" .

M
MKIB0555E

2. CHARGE WARNING LAMP INSPECTION

1. Set engine speed at 2,500 rpm.
2. Check if charge warning lamp illuminates.
Does charge warning lamp illuminate?
YES >> Go to SC-24, "INSPECTION OF EXCESSIVE ALTER-
NATOR POWER GENERATION" .
NO >> Go to SC-23, "INSPECTION OF INSUFFICIENT
ALTERNATOR POWER GENERATION" .

MKIB0555E

SC-21
 CHARGING SYSTEM

CHARGE WARNING LAMP LINE INSPECTION

CAUTION:
If open circuit is detected in L terminal, alternator cannot start generating.
INSPECTION PROCEDURE
1. CHARGE WARNING LAMP INSPECTION
1. Turn ignition switch OFF.
2. Disconnect alternator connector
3. Connect alternator connector terminal 4 to ground.

MKIB1916E

4. Turn ignition switch ON.

Does charge warning lamp illuminate?
YES >> GO TO 4.
NO >> GO TO 2.

MKIB0555E

2. CONNECTOR INSPECTION
1. Turn ignition switch OFF.
2. Check meter and terminals (meter side, and harness side) for damage, deformation or improper connec-
tion.
OK or NG
OK >> GO TO 3.
NG >> Repair terminals and connectors.

3. CONTINUITY INSPECTION
1. Disconnect combination meter connector.
2. Check continuity between combination meter connector terminal 38 and ground, and combination meter
connector terminal 38 and alternator connector terminal 4.
38 - Ground : Continuity should not exist.
38 - 4 : Continuity should exist.
OK or NG
OK >> Replace combination meter. (Do not replace alternator, since it is normal.)
NG >> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.)

SC-22
 CHARGING SYSTEM

4. CHARGE WARNING LAMP INSPECTION A

1. Turn ignition switch OFF.
2. Connect alternator connector.
3. Turn ignition switch ON. B
Does charge warning lamp illuminate?
YES >> Repair alternator connector. (Poor connection and inter-
mittent problem) (Do not replace alternator, since it is C
normal.)
NO >> Replace alternator. (circuit malfunction in alternator)
D
MKIB0555E

INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION

E
CAUTION:
Check them using charged battery performed battery inspection.
1. VOLTAGE INSPECTION F
1. Increase engine speed to 2,500 rpm.
2. Turn electrical load to ON. (Headlamp LO turns on, blower fan
motor maximum airflow amount) G
3. Check battery voltage.
Is the inspection result 12.8V to 15.1V?
H
YES >> GO TO 2.
NO >> Replace alternator. (Alternator power generation error.)
I
MKIA0067E

2. CURRENT INSPECTION J

1. Turn the ignition switch OFF.

2. Disconnect the battery ground cable. SC
3. Attach current measurement probe for CONSULT-II to the harness for alternator terminal B.
(If the probe can not be attached properly, then connect the sub-
harness between alternator terminal B and the vehicle side har- L
ness as shown in figure, and attach the probe to sub-harness.)
4. Connect battery ground cable.
5. Increase engine speed to 2,500 rpm. M
6. Turn electrical load to ON. (Headlamp LO turns on, blower fan
motor maximum airflow amount, rear window defogger)
7. Check alternator terminal B current.
CAUTION:
Be careful of rotating parts because the engine is running. MKIA0068E

Is the inspection result 30A or more?

YES >> GO TO dark current inspection. Refer to SC-24, "DARK CURRENT INSPECTION" . (Alternator is
normal. Do not replace.)
NO >> Replace alternator. (Alternator power generation error.)

SC-23
 CHARGING SYSTEM

INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION

1. ALTERNATOR VOLTAGE INSPECTION
1. Increase engine speed to 2,500 rpm.
2. Check battery voltage.
Is the inspection result 16V or less?
YES >> Replace alternator. (Alternator power generation error.)
NO >> Replace alternator. (Excessive alternator power genera-
tion.)

MKIA0067E

DARK CURRENT INSPECTION

Dark Current: Small current while ignition switch is “OFF”.
NOTE:
● If battery ground cable is disconnected from battery terminal, a large dark current may not be reproduced.
When battery discharge occurs, never disconnect battery terminal while using ammeter.
● Do not connect CONSULT-II CONVERTER to data link connector when measuring dark current. CON-
SULT-II power should be supplied using AC adapter or internal battery.
1. Attach current measurement probe for CONSULT-II to battery
ground cable. Refer to SC-25, "OPERATION PROCEDURE OF
CURRENT MEASUREMENT PROBE FOR CONSULT-II" .
2. Check that all electrical equipment is turned OFF.
3. Remove key. Close and lock doors. Check that room lamp turns
off.
4. Measure dark current. Is it 50mA or less? Refer to SC-25,
"OPERATION PROCEDURE OF CURRENT MEASUREMENT
PROBE FOR CONSULT-II" .
NOTE: MKIA0070E
Dark current stable time is different due to equipment and use of
the vehicle. If it is not 50mA or less after leaving for 1 minute, measure dark current again after leaving for
30 minutes or more.
If YES, GO TO 7. If NO, GO TO 5.
5. Remove and install fuses one by one. Search for the fuse that greatly changes dark current.
NOTE:
If dark current is greatly reduced when removing the fuse, and even if dark current is not greatly increased
when installing it again, the fuse circuit may be the cause.
6. Check that dark current changes when moving the suspect circuit harness. If dark current changes, check
harness for short. If dark current does not change, electronic unit in the circuit may not be entering the
energy-saving mode when it turns OFF. If it does not enter the energy-saving mode, replace electronic
unit.
7. No malfunction for alternator and electrical equipment. Electric load may be larger than alternator generat-
ing ability. Check the customer's usage.

SC-24
 CHARGING SYSTEM

OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II

For details, refer to the supplied “CONSULT-II Current Probe Operation Manual”. A
1. Turn current probe power supply OFF and connect to CONSULT-II. (Red: CH1, Black: Ground)
2. Touch “SUB MODE”.
B
3. Touch “Extending Measurement Mode” on “SUB MODE” screen.
4. CAUTION is displayed, touch “OK”.
C

E
MKIA0071E

5. Set current probe range switch at the range to measure, turn

current probe power supply ON. When measuring dark current, F
set 4A range. (Check that POWER indicator turns on. Refer to
CONSULT-II Current Probe Operation Manual.)
6. Touch the same measuring range at CONSULT-II. G
NOTE:
If current probe measuring range is different from CONSULT-II
measuring range, incorrect value is displayed. H

MKIA0072E
I
7. Adjust 0 point of current probe or CONSULT-II. (Do not clamp
anything to probe.)
NOTE: J
If 0 point is dislocated greatly, adjust at current probe side gen-
erally.
SC

L
MKIA0073E

8. Align current direction mark, clamp harness, and measure cur- M

rent. If current direction is incorrect, it is displayed negative
value.
NOTE:
● When current is measured, close probe joint securely.

● If multiple harnesses are clamped, measurement cannot be

performed. Always clamp only one.

MKIA0074E

SC-25
 CHARGING SYSTEM

Trouble Diagnoses (HR Engine Models) EKS00P19

DIAGNOSIS PROCEDURE
1. Check malfunction symptoms or customer's remarks.
2. Perform pre-diagnosis inspection. Refer to SC-26, "PRE-DIAGNOSIS INSPECTION" .
3. Perform trouble diagnosis for each trouble symptom. Refer to SC-26, "DIAGNOSIS CHART BY SYMP-
TOM" .
4. Repair or replace parts indicated inspection flow based on the charge warning lamp. Refer to SC-26,
"INSPECTION FLOW BY CHARGE WARNING LAMP" .
5. End
PRE-DIAGNOSIS INSPECTION
1. Perform alternator belt inspection. Refer to EM-115, "DRIVE BELTS" .
2. Inspect battery.
3. Check alternator terminal B for loose or improper connection.
4. Check alternator connector and terminals for loose connection, disconnection and bend.
5. Check connecting condition of harness for charging system harness (fusible link terminal and battery ter-
minal).
6. After performing 1 to 5 above, go to trouble diagnosis for symptoms. Refer to SC-26, "DIAGNOSIS
CHART BY SYMPTOM" .
DIAGNOSIS CHART BY SYMPTOM
Symptom Reference page
Battery discharge Refer to SC-26, "INSPECTION FLOW BY CHARGE WARN-
Charge warning lamp illuminates. ING LAMP" .

Other than the above symptoms (splashing out of battery fluid, Refer to SC-30, "INSPECTION OF EXCESSIVE ALTERNA-
nasty smell and others) TOR POWER GENERATION" .

INSPECTION FLOW BY CHARGE WARNING LAMP

1. CHARGE WARNING LAMP INSPECTION
1. Turn ignition switch ON.
2. Check if charge warning lamp illuminates.
Does charge warning lamp illuminate?
YES >> GO TO 2.
NO >> Go to SC-27, "CHARGE WARNING LAMP LINE
INSPECTION" .

MKIB0555E

2. CHARGE WARNING LAMP INSPECTION

1. Start engine.
2. Check if charge warning lamp goes off.
Does charge warning lamp goes off?
YES >> GO TO 3.
NO >> Go to SC-28, "VOLTAGE DETECTION LINE AND
CHARGE WARNING LAMP INSPECTION" .

MKIB0556E

SC-26
 CHARGING SYSTEM

3. CHARGE WARNING LAMP INSPECTION A

1. Set engine speed at 2,500 rpm.
2. Check if charge warning lamp illuminates.
Does charge warning lamp illuminate? B
YES >> Go to SC-30, "INSPECTION OF EXCESSIVE ALTER-
NATOR POWER GENERATION" .
NO >> Go to SC-29, "INSPECTION OF INSUFFICIENT C
ALTERNATOR POWER GENERATION" .

D
MKIB0555E

CHARGE WARNING LAMP LINE INSPECTION

E
CAUTION:
If open circuit is detected in L terminal, alternator cannot start generating.
INSPECTION PROCEDURE F
1. CHARGE WARNING LAMP INSPECTION
1. Turn ignition switch OFF. G
2. Disconnect alternator connector
3. Connect alternator connector terminal 2 to ground.
H

MKIB1917E J

4. Turn ignition switch ON.

Does charge warning lamp illuminate? SC
YES >> GO TO 4.
NO >> GO TO 2.
L

MKIB0555E

2. CONNECTOR INSPECTION
1. Turn ignition switch OFF.
2. Check meter and terminals (meter side, and harness side) for damage, deformation or improper connec-
tion.
OK or NG
OK >> GO TO 3.
NG >> Repair terminals and connectors.

SC-27
 CHARGING SYSTEM

3. CONTINUITY INSPECTION
1. Disconnect combination meter connector.
2. Check continuity between combination meter connector terminal 38 and alternator connector terminal 2.
38 - 2 : Continuity should exist.
OK or NG
OK >> Replace combination meter. (Do not replace alternator, since it is normal.)
NG >> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.)

4. CHARGE WARNING LAMP INSPECTION

1. Turn ignition switch OFF.
2. Connect alternator connector.
3. Turn ignition switch ON.
Does charge warning lamp illuminate?
YES >> Repair alternator connector. (Poor connection and inter-
mittent problem) (Do not replace alternator, since it is
normal.)
NO >> Replace alternator. (circuit malfunction in alternator)

MKIB0555E

VOLTAGE DETECTION LINE AND CHARGE WARNING LAMP INSPECTION

INSPECTION PROCEDURE
1. CHARGE WARNING LAMP INSPECTION
1. Turn ignition switch OFF.
2. Disconnect alternator connector.
3. Turn ignition switch ON.
Does charge warning lamp stay ON?
YES >> GO TO 5.
NO >> GO TO 2.

MKIB0555E

2. VOLTAGE INSPECTION
Check voltage between alternator connector terminal 3 and ground.
3 - Ground : 12V or more
Is the inspection result 12V or more?
YES >> Replace alternator.
NO >> GO TO 3.

MKIB1918E

SC-28
 CHARGING SYSTEM

3. CONNECTOR INSPECTION A
1. Turn ignition switch OFF.
2. Check alternator connector and terminal 3 (alternator side, and harness side) for damage, deformation or
improper connection. B
OK or NG
OK >> GO TO 4.
NG >> Repair terminals and connectors. C

4. CHECK FUSE
D
Check if alternator S terminal fuse #26 (10A) is blown.
OK or NG
OK >> Repair harness between fuse #26 (10A) and alternator connector terminal 4. (Do not replace E
alternator, since it is normal.)
NG >> Replace fuse. (Do not replace alternator, since it is normal.)

5. CONTINUITY INSPECTION F

1. Turn ignition switch OFF.

2. Disconnect combination meter connector. G
3. Check continuity between combination meter connector terminal 38 and ground, and combination meter
connector terminal 38 and alternator connector terminal 2.
38 - Ground : Continuity should not exist. H
38 - 2 : Continuity should exist.
OK or NG I
OK >> Replace combination meter. (Do not replace alternator, since it is normal.)
NG >> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.)
INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION J
CAUTION:
Check them using charged battery performed battery inspection.
1. VOLTAGE INSPECTION SC

1. Increase engine speed to 2,500 rpm.

2. Turn electrical load to ON. (Headlamp LO turns on, blower fan L
motor maximum airflow amount)
3. Check battery voltage.
Is the inspection result 12.8V to 15.1V? M
YES >> GO TO 2.
NO >> Replace alternator. (Alternator power generation error.)

MKIA0067E

SC-29
 CHARGING SYSTEM

2. CURRENT INSPECTION
1. Turn the ignition switch OFF.
2. Disconnect the battery ground cable.
3. Attach current measurement probe for CONSULT-II to the harness for alternator terminal B.
(If the probe can not be attached properly, then connect the sub-
harness between alternator terminal B and the vehicle side har-
ness as shown in figure, and attach the probe to sub-harness.)
4. Connect battery ground cable.
5. Increase engine speed to 2,500 rpm.
6. Turn electrical load to ON. (Headlamp LO turns on, blower fan
motor maximum airflow amount, rear window defogger)
7. Check alternator terminal B current.
CAUTION:
Be careful of rotating parts because the engine is running. MKIA0068E

Is the inspection result 30A or more?

YES >> GO TO dark current inspection. Refer to SC-31, "DARK CURRENT INSPECTION" . (Alternator is
normal. Do not replace.)
NO >> Replace alternator. (Alternator power generation error.)
INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION
1. ALTERNATOR VOLTAGE INSPECTION
1. Increase engine speed to 2,500 rpm.
2. Check battery voltage.
Is the inspection result 16V or less?
YES >> GO TO 2.
NO >> Replace alternator. (Excessive alternator power genera-
tion.)

MKIA0067E

2. BATTERY VOLTAGE INSPECTION

1. Turn the ignition switch OFF.
2. Disconnect alternator connector.
3. Check voltage between alternator connector terminal 3 and
ground.
3 - Ground : 12V or more
Is the inspection result 12V or more?
YES >> Replace alternator. (Alternator power generation error)
NO >> GO TO 3.
MKIB1918E

3. FUSE CHECK
Check if fuse #26 (10A) is blown.
OK or NG
OK >> Repair harness between fuse #26 (10A) and alternator harness connector terminal 4. (Alternator
is normal. Do not replace.)
NG >> Replace fuse. (Alternator is normal. Do not replace.)

SC-30
 CHARGING SYSTEM

DARK CURRENT INSPECTION

Dark Current: Small current while ignition switch is “OFF”. A
NOTE:
● If battery ground cable is disconnected from battery terminal, a large dark current may not be reproduced.
When battery discharge occurs, never disconnect battery terminal while using ammeter. B
● Do not connect CONSULT-II CONVERTER to data link connector when measuring dark current. CON-
SULT-II power should be supplied using AC adapter or internal battery.
1. Attach current measurement probe for CONSULT-II to battery C
ground cable. Refer to SC-32, "OPERATION PROCEDURE OF
CURRENT MEASUREMENT PROBE FOR CONSULT-II" .
2. Check that all electrical equipment is turned OFF. D
3. Remove key. Close and lock doors. Check that room lamp turns
off.
4. Measure dark current. Is it 50mA or less? Refer to SC-32, E
"OPERATION PROCEDURE OF CURRENT MEASUREMENT
PROBE FOR CONSULT-II" .
NOTE: MKIA0070E F
Dark current stable time is different due to equipment and use of
the vehicle. If it is not 50mA or less after leaving for 1 minute, measure dark current again after leaving for
30 minutes or more.
If YES, GO TO 7. If NO, GO TO 5. G
5. Remove and install fuses one by one. Search for the fuse that greatly changes dark current.
NOTE:
H
If dark current is greatly reduced when removing the fuse, and even if dark current is not greatly increased
when installing it again, the fuse circuit may be the cause.
6. Check that dark current changes when moving the suspect circuit harness. If dark current changes, check
harness for short. If dark current does not change, electronic unit in the circuit may not be entering the I
energy-saving mode when it turns OFF. If it does not enter the energy-saving mode, replace electronic
unit.
7. No malfunction for alternator and electrical equipment. Electric load may be larger than alternator generat- J
ing ability. Check the customer's usage.

SC

SC-31
 CHARGING SYSTEM

OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II

For details, refer to the supplied “CONSULT-II Current Probe Operation Manual”.
1. Turn current probe power supply OFF and connect to CONSULT-II. (Red: CH1, Black: Ground)
2. Touch “SUB MODE”.
3. Touch “Extending Measurement Mode” on “SUB MODE” screen.
4. CAUTION is displayed, touch “OK”.

MKIA0071E

5. Set current probe range switch at the range to measure, turn

current probe power supply ON. When measuring dark current,
set 4A range. (Check that POWER indicator turns on. Refer to
CONSULT-II Current Probe Operation Manual.)
6. Touch the same measuring range at CONSULT-II.
NOTE:
If current probe measuring range is different from CONSULT-II
measuring range, incorrect value is displayed.

MKIA0072E

7. Adjust 0 point of current probe or CONSULT-II. (Do not clamp

anything to probe.)
NOTE:
If 0 point is dislocated greatly, adjust at current probe side gen-
erally.

MKIA0073E

8. Align current direction mark, clamp harness, and measure cur-

rent. If current direction is incorrect, it is displayed negative
value.
NOTE:
● When current is measured, close probe joint securely.

● If multiple harnesses are clamped, measurement cannot be

performed. Always clamp only one.

MKIA0074E

SC-32
 CHARGING SYSTEM

Trouble Diagnoses (K9K Engine Models) EKS00K2W

DIAGNOSIS PROCEDURE A
1. Check malfunction symptoms or customer's remarks.
2. Perform pre-diagnosis inspection. Refer to SC-33, "PRE-DIAGNOSIS INSPECTION" .
3. Perform trouble diagnosis for each trouble symptom. Refer to SC-33, "DIAGNOSIS CHART BY SYMP- B
TOM"
4. Repair or replace parts indicated inspection flow based on the charge warning lamp. Refer to SC-33,
"INSPECTION FLOW BY CHARGE WARNING LAMP" . C
5. End
PRE-DIAGNOSIS INSPECTION D
1. Perform alternator belt inspection. Refer to EM-244, "DRIVE BELTS" .
2. Inspect battery.
3. Check alternator terminal B for loose or improper connection. E
4. Check alternator connector and terminals for loose connection, disconnection and bend.
5. Check connecting condition of harness for charging system harness (fusible link terminal and battery ter-
minal). F
6. After performing 1 to 5 above, go to trouble diagnosis for symptoms. Refer to SC-33, "DIAGNOSIS
CHART BY SYMPTOM" .
DIAGNOSIS CHART BY SYMPTOM G
Symptom Reference page
Battery discharge Refer to SC-33, "INSPECTION FLOW BY CHARGE WARN- H
Charge warning lamp illuminates. ING LAMP" .

Other than the above symptoms (splashing out of battery fluid, Refer to SC-37, "INSPECTION OF EXCESSIVE ALTERNA-
nasty smell and others) TOR POWER GENERATION" . I
INSPECTION FLOW BY CHARGE WARNING LAMP
1. CHARGE WARNING LAMP INSPECTION J
1. Turn ignition switch ON.
2. Check if charge warning lamp illuminates.
SC
Does charge warning lamp illuminate?
YES >> GO TO 2.
NO >> Go to SC-34, "CHARGE WARNING LAMP LINE
L
INSPECTION" .

M
MKIB0555E

2. CHARGE WARNING LAMP INSPECTION

1. Start engine.
2. Check if charge warning lamp goes off.
Does charge warning lamp goes off?
YES >> GO TO 3.
NO >> Go to SC-35, "VOLTAGE DETECTION LINE AND
CHARGE WARNING LAMP INSPECTION" .

MKIB0556E

SC-33
 CHARGING SYSTEM

3. CHARGE WARNING LAMP INSPECTION

1. Set engine speed at 2,500 rpm.
2. Check if charge warning lamp illuminates.
Does charge warning lamp illuminate?
YES >> Go to SC-37, "INSPECTION OF EXCESSIVE ALTER-
NATOR POWER GENERATION" .
NO >> Go to SC-37, "INSPECTION OF INSUFFICIENT
ALTERNATOR POWER GENERATION" .

MKIB0555E

CHARGE WARNING LAMP LINE INSPECTION

CAUTION:
If open circuit is detected in L terminal, alternator cannot start generating.
INSPECTION PROCEDURE
1. CHARGE WARNING LAMP INSPECTION
1. Turn ignition switch OFF.
2. Remove alternator connector.
3. Connect alternator connector terminal 3 to ground.

MKIB1919E

4. Turn ignition switch ON.

Does charge warning lamp illuminate?
YES >> GO TO 4.
NO >> GO TO 2.

MKIB0555E

2. CONNECTOR INSPECTION
1. Turn ignition switch OFF.
2. Check combination meter and terminals (meter side, and harness side) for damage, deformation or
improper connection.
OK or NG
OK >> GO TO 3.
NG >> Repair terminals and connectors.

SC-34
 CHARGING SYSTEM

3. CONTINUITY INSPECTION A
1. Disconnect combination meter connector.
2. Check continuity between combination meter connector terminal 38 and alternator connector terminal 3.
B
38 - 3 : Continuity should exist.
OK or NG
OK >> Replace combination meter. (Do not replace alternator, since it is normal.) C
NG >> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.)

4. CHARGE WARNING LAMP INSPECTION D

1. Turn ignition switch OFF.
2. Connect alternator connectors.
E
3. Turn ignition switch ON.
Does charge warning lamp illuminate?
YES >> Repair alternator connector. (Poor connection and inter- F
mittent problem) (Do not replace alternator, since it is
normal.)
NO >> Replace alternator. (circuit malfunction in alternator)
G
MKIB0555E

VOLTAGE DETECTION LINE AND CHARGE WARNING LAMP INSPECTION H

INSPECTION PROCEDURE
1. CHARGE WARNING LAMP INSPECTION
I
1. Turn ignition switch OFF.
2. Disconnect alternator connector.
3. Turn ignition switch ON. J
Does charge warning lamp stay ON?
YES >> GO TO 6.
NO >> GO TO 2. SC

L
MKIB0555E

2. VOLTAGE INSPECTION M
Check voltage between alternator connector terminal 4 and ground.
4 - Ground : 12V or more
Is the inspection result 12V or more?
YES >> Replace alternator.
NO >> GO TO 3.

MKIB1731E

SC-35
 CHARGING SYSTEM

3. CONNECTOR INSPECTION
1. Turn ignition switch OFF.
2. Check alternator connector and terminal 4 (alternator side, and harness side) for damage, deformation or
improper connection.
OK or NG
OK >> GO TO 4.
NG >> Repair terminals and connectors.

4. CONNECTOR INSPECTION
Check IPDM E/R and terminals (IPDM E/R side, and harness side) for damage, deformation or improper con-
nection.
OK or NG
OK >> GO TO 5.
NG >> Repair terminals and connectors.

5. CONTINUITY INSPECTION
1. Disconnect IPDM E/R connector.
2. Check continuity between IPDM E/R connector terminal 63 and alternator connector terminal 4.
63 - 4 : Continuity should exist.
OK or NG
OK >> Replace IPDM E/R. (Do not replace alternator, since it is normal.)
NG >> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.)

6. CONTINUITY INSPECTION
1. Turn ignition switch OFF.
2. Disconnect combination meter connector.
3. Check continuity between combination meter connector terminal 38 and ground, and combination meter
connector terminal 38 and alternator connector terminal 3.
38 - Ground : Continuity should not exist.
38 - 3 : Continuity should exist.
OK or NG
OK >> Replace combination meter. (Do not replace alternator, since it is normal.)
NG >> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.)

SC-36
 CHARGING SYSTEM

INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION

CAUTION: A
Check them using charged battery performed battery inspection.
1. VOLTAGE INSPECTION
B
1. Increase engine speed to 2,500 rpm.
2. Turn electrical load to ON. (Headlamp LO turns on, blower fan
motor maximum airflow amount) C
3. Check battery voltage.
Is the inspection result 12.8V to 15.1V?
YES >> GO TO 2. D
NO >> Replace alternator. (Alternator power generation error.)

E
MKIA0067E

2. CURRENT INSPECTION F
1. Turn ignition switch OFF.
2. Disconnect the battery ground cable.
G
3. Attach current measurement probe for CONSULT-II to the harness for alternator terminal B.
(If the probe can not be attached properly, then connect the sub-
harness between alternator terminal B and the vehicle side har-
ness as shown in figure, and attach the probe to sub-harness.) H
4. Connect battery ground cable.
5. Increase engine speed to 2,500 rpm.
I
6. Turn electrical load to ON. (Headlamp LO turns on, blower fan
motor maximum airflow amount, rear window defogger)
7. Check alternator terminal B current.
J
CAUTION:
Be careful of rotating parts because the engine is running. MKIA0068E

Is the inspection result 30A or more?

SC
YES >> GO TO dark current inspection. Refer to SC-38, "DARK CURRENT INSPECTION" . (Alternator is
normal. Do not replace.)
NO >> Replace alternator. (Alternator power generation error.)
L
INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION
1. ALTERNATOR VOLTAGE INSPECTION
M
1. Increase engine speed to 2,500 rpm.
2. Check battery voltage.
Is the inspection result 16V or less?
YES >> GO TO 2.
NO >> Replace alternator. (Excessive alternator power genera-
tion.)

MKIA0067E

SC-37
 CHARGING SYSTEM

2. BATTERY VOLTAGE INSPECTION

1. Turn ignition switch OFF.
2. Disconnect alternator connector.
3. Turn ignition switch ON.
4. Check voltage between alternator connector terminal 4 and
ground.
4 - Ground : 12V or more
Is the inspection result 12V or more?
YES >> Replace alternator. (Alternator power generation error)
NO >> GO TO 3. MKIB1731E

3. CONNECTOR INSPECTION
1. Turn ignition switch OFF.
2. Check IPDM E/R and terminals (IPDM E/R side, and harness side) for damage, deformation or improper
connection.
OK or NG
OK >> GO TO 4.
NG >> Repair terminals and connectors.

4. CONTINUITY INSPECTION
1. Disconnect IPDM E/R connector.
2. Check continuity between IPDM E/R connector terminal 63 and alternator connector terminal 4.
63 - 4 : Continuity should exist.
OK or NG
OK >> Replace IPDM E/R. (Do not replace alternator, since it is normal.)
NG >> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.)
DARK CURRENT INSPECTION
Dark Current: Small current while ignition switch is “OFF”.
NOTE:
● If battery ground cable is disconnected from battery terminal, a large dark current may not be reproduced.
When battery discharge occurs, never disconnect battery terminal while using ammeter.
● Do not connect CONSULT-II CONVERTER to data link connector when measuring dark current. CON-
SULT-II power should be supplied using AC adapter or internal battery.
1. Attach current measurement probe for CONSULT-II to battery
ground cable. Refer to SC-39, "OPERATION PROCEDURE OF
CURRENT MEASUREMENT PROBE FOR CONSULT-II" .
2. Check that all electrical equipment is turned OFF.
3. Remove key. Close and lock doors. Check that room lamp turns
off.
4. Measure dark current. Is it 50mA or less? Refer to SC-39,
"OPERATION PROCEDURE OF CURRENT MEASUREMENT
PROBE FOR CONSULT-II" .
NOTE: MKIA0070E
Dark current stable time is different due to equipment and use of
the vehicle. If it is not 50mA or less after leaving for 1 minute, measure dark current again after leaving for
30 minutes or more.
If YES, GO TO 7. If NO, GO TO 5.
5. Remove and install fuses one by one. Search for the fuse that greatly changes dark current.

SC-38
 CHARGING SYSTEM

NOTE:
If dark current is greatly reduced when removing the fuse, and even if dark current is not greatly increased A
when installing it again, the fuse circuit may be the cause.
6. Check that dark current changes when moving the suspect circuit harness. If dark current changes, check
harness for short. If dark current does not change, electronic unit in the circuit may not be entering the B
energy-saving mode when it turns OFF. If it does not enter the energy-saving mode, replace electronic
unit.
7. No malfunction for alternator and electrical equipment. Electric load may be larger than alternator generat-
C
ing ability. Check the customer's usage.
OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II
For details, refer to the supplied “CONSULT-II Current Probe Operation Manual”. D
1. Turn current probe power supply OFF and connect to CONSULT-II. (Red: CH1, Black: Ground)
2. Touch “SUB MODE”.
3. Touch “Extending Measurement Mode” on “SUB MODE” screen. E
4. CAUTION is displayed, touch “OK”.

MKIA0071E
H

5. Set current probe range switch at the range to measure, turn

current probe power supply ON. When measuring dark current, I
set 4A range. (Check that POWER indicator turns on. Refer to
CONSULT-II Current Probe Operation Manual.)
6. Touch the same measuring range at CONSULT-II. J
NOTE:
If current probe measuring range is different from CONSULT-II
measuring range, incorrect value is displayed.
SC

MKIA0072E

L
7. Adjust 0 point of current probe or CONSULT-II. (Do not clamp
anything to probe.)
NOTE: M
If 0 point is dislocated greatly, adjust at current probe side gen-
erally.

MKIA0073E

SC-39
 CHARGING SYSTEM

8. Align current direction mark, clamp harness, and measure cur-

rent. If current direction is incorrect, it is displayed negative
value.
NOTE:
● When current is measured, close probe joint securely.

● If multiple harnesses are clamped, measurement cannot be

performed. Always clamp only one.

MKIA0074E

Removal and Installation (CR Engine Models) EKS007ZH

REMOVAL
1. Disconnect battery ground cable.
2. Remove fender protector from RH side.
3. Remove alternator drive belt. Refer to EM-16, "Removal and
Installation" .
4. Remove idler pulley bracket mounting bolts, and remove idler
pulley assembly.

MKIA0075E

5. Disconnect alternator harness connector.

Terminal B mounting nut, ground wire mounting nut, and remove
harness clips.

MKIA0076E

6. Remove engine mounting stay from RH side.

7. Remove alternator upper bracket mounting bolts, and alterna-
tor upper mounting bolt.

MKIA0077E

SC-40
 CHARGING SYSTEM

8. Loosen alternator lower mounting bolt, and pull out from U-cut
portion on front cover. A
9. Remove alternator assembly from engine.

MKIA0078E

D
INSTALLATION
Install in the reverse order of removal, taking care of the following point.
● Install alternator, and check tension of belt. Refer to EM-14, "Tension Adjustment" . E
CAUTION:
Be sure to tighten B terminal mounting nut carefully.
B terminal nut: : 9.32 - 10.8 N·m (0.95 - 1.1 kg-m, 82 - 95 in-lb) F

Ground bolt: : 2.94 - 4.9 N·m (0.30 - 0.49 kg-m, 26 - 43 in-lb)

Alternator mounting bolt: : 33.3 - 46.1 N·m (3.4 - 4.7 kg-m, 24 - 34 ft-lb) G

Alternator upper bracket bolt: : 33.3 - 46.1 N·m (3.4 - 4.7 kg-m, 24 - 34 ft-lb)
Engine mounting stay bolt: H
: 40.0 - 50.0 N·m (4.1 - 5.1 kg-m, 30 - 37 ft-lb)
Idler pulley bracket bolt: : 16.6 - 23.5 N·m (1.7 - 2.4 kg-m, 12 - 17 ft-lb)
Idler pulley nut: I
: 25.5 - 33.3 N·m (2.6 - 3.3 kg-m, 19 - 24 ft-lb)

Removal and Installation (HR Engine Models) EKS00P1A

REMOVAL J
1. Disconnect battery ground cable.
2. Remove fender protector from RH side.
3. Remove alternator drive belt. Refer to EM-116, "Removal and Installation" . SC
4. Remove idler pulley assembly. Refer to EM-117, "Removal and Installation of Drive Belt Idler Pulley" .
5. Disconnect alternator harness connector.
L
● B terminal mounting nut, ground wire mounting nut, and
remove harness clips.

MKIB1996E

6. Remove A/C compressor. Refer to ATC-95, "Removal and Installation for Compressor" (with auto A/C) or
MTC-68, "Removal and Installation for Compressor" (with manual A/C).

SC-41
 CHARGING SYSTEM

7. Remove torque rod bolt.

MKIB1997E

8. Remove alternator mounting upper bolt.

MKIB1998E

9. Loosen alternator mounting lower bolt.

10. Remove alternator assembly from lower side the vehicle.

MKIB1999E

INSTALLATION
Install in the reverse order of removal, taking care of the following point.
● Install alternator, and check tension of belt. Refer to EM-115, "Tension Adjustment" .
CAUTION:
Be sure to tighten B terminal mounting nut carefully.
B terminal nut: : 9.32 - 10.8 N·m (0.95 - 1.1 kg-m, 82 - 95 in-lb)
Ground bolt: : 2.94 - 4.9 N·m (0.30 - 0.49 kg-m, 26 - 43 in-lb)
Alternator mounting bolt: : 21.0 - 29.0 N·m (2.2 - 2.9kg-m, 16 - 21ft-lb)
Torque rod bolt: : 40.0 - 50.0 N·m (4.1 - 5.1 kg-m, 30 - 37 ft-lb)
Idler pulley bolt: : 24.0 - 32.0 N·m (2.5 - 3.2kg-m, 18 - 23ft-lb)

SC-42
 CHARGING SYSTEM

Removal and Installation (K9K Engine Models) EKS00K2X

REMOVAL A
1. Disconnect battery ground cable.
2. Remove under cover and RH fender protector.
3. Remove front bumper. Refer to EI-5, "FRONT BUMPER" . B
4. Remove alternator drive belt. Refer to EM-244, "DRIVE BELTS"
.
5. Disconnect alternator harness connector and B terminal nut. C

D
MKIA0086E

6. Remove alternator upper mounting bolt. E

MKIA0087E H

7. Remove alternator lower mounting bolt.

8. Remove alternator assembly from engine. I

SC

MKIA0088E

INSTALLATION L
Install in the reverse order of removal, taking care of the following point.
● Install alternator, and check tension of belt. Refer to EM-244, "DRIVE BELTS" .
CAUTION: M
Be sure to tighten B terminal mounting nut carefully.
Disassembly EKS007ZJ

REAR COVER

SEL032Z

SC-43
 CHARGING SYSTEM

CAUTION:
Rear cover may be hard to remove because a ring is used to lock outer race of rear bearing. To facili-
tate removal of rear cover, heat just bearing box section with a 200W soldering iron.
Do not use a heat gun, as it can damage diode assembly.
REAR BEARING
CAUTION:
● Do not reuse rear bearing after removal. Replace with a new one.
● Do not lubricate rear bearing outer race.
Inspection EKS007ZK

ROTOR CHECK
1. Resistance test
Resistance : Refer to SC-61, "SER-
VICE DATA AND SPECIFI-
CATIONS (SDS)" .
● Not within the specified values... Replace rotor.

2. Insulator test
● Continuity exists... Replace rotor.

3. Check slip ring for wear.

Slip ring minimum : Refer to SC-61, "SER- SEL033Z

outer diameter VICE DATA AND SPECIFI-

CATIONS (SDS)" .
● Not within the specified values... Replace rotor.
BRUSH CHECK
1. Check smooth movement of brush.
● Not smooth... Check brush holder and clean.

2. Check brush for wear.

● Replace brush if it is worn down to the limit line.

SEL631DA

STATOR CHECK
1. Continuity test
● No continuity... Replace stator.

SEL108E

SC-44
 CHARGING SYSTEM

2. Ground test
● Continuity exists... Replace stator. A

SEL109E

D
Assembly EKS007ZL

RING FITTING IN REAR BEARING

● Fix ring into groove in rear bearing so that it is as close to the E
adjacent area as possible.
CAUTION:
Do not reuse rear bearing after removal.
F

SEL044Z
H
REAR COVER INSTALLATION
1. Fit brush assembly, diode assembly, regulator assembly and
stator. I

SC

SEL048Z

L
2. Push brushes up with fingers and install them to rotor.
Take care not to damage slip ring sliding surface.
M

SEL049Z

SC-45
 STARTING SYSTEM

STARTING SYSTEM PFP:00011

System Description EKS007ZM

M/T MODELS
Power is supplied at all times
● through 40A fusible link (letter H, located in the fuse and fusible link box)
● to ignition switch terminal 1.
With the ignition switch in the ON or START position, power is supplied
● through 10A fuse [No.50 located in the IPDM E/R]
● to park/neutral position switch terminal 2
● through 10A fuse [No.4, located in fuse block (J/B)]
● through IPDM E/R terminal 21
● to starter relay.
With the shift lever in the N position (under the ignition switch ON or START position)
Power is supplied
● through park/neutral position switch terminal 2 and 3
● to IPDM E/R terminal 31
and then starter relay is energized.
When ignition switch turn to START position, power is supplied
● through ignition switch terminal 1 and 5
● through IPDM E/R terminal 9 and 11
● to starter motor terminal 1.
The starter motor plunger closes and provides a closed circuit between the battery and starter motor. The
starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the
engine starts.
A/T MODELS
Power is supplied at all times
● through 40A fusible link (letter H, located in the fuse and fusible link box)
● to ignition switch terminal 1.
With the ignition switch in the ON or START position, power is supplied
● through 10A fuse [No. 50 located in the IPDM E/R]
● to park/neutral position switch terminal 1.
With the selector lever in the P or N position (under the ignition switch ON or START position)
Power is supplied
● through park/neutral position switch terminal 1 and 2
● through IPDM E/R terminal 21
● to starter relay.
● through park/neutral position switch terminal 1 and 2
● to IPDM E/R terminal 31.
and then starter relay is energized.
When ignition switch turn to START position, power is supplied
● through ignition switch terminal 1 and 5
● through IPDM E/R terminal 9 and 11
● to starter motor terminal 1
The starter motor plunger closes and provides a closed circuit between the battery and starter motor. The
starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the
engine starts.

SC-46
 STARTING SYSTEM

Wiring Diagram — START — /CR and HR Engine Models EKS007ZN

SC

MKWA4066E

SC-47
STARTING SYSTEM

MKWA4067E

SC-48
 STARTING SYSTEM

Wiring Diagram — START — /K9K Engine Models EKS00K2Z

SC

MKWA3477E

SC-49
STARTING SYSTEM

MKWA4231E

SC-50
 STARTING SYSTEM

Trouble Diagnoses EKS007ZQ

A
If any abnormality is found, immediately disconnect battery negative terminal.

SC

SEL761W

SC-51
 STARTING SYSTEM

Removal and Installation (CR Engine Models) EKS007ZR

REMOVAL
1. Disconnect negative battery cable.
2. Remove starter motor mounting bolt from upper side.
3. Disconnect S terminal and B terminal from starter motor.
4. Remove starter motor mounting bolt from lower side.
5. Remove starter motor from lower side the vehicle.

MKIA0080E

INSTALLATION
Install in the reverse order of removal.
Removal and Installation (HR Engine Models) EKS00P1B

PKIC0987E

1. Cylinder block 2. B terminal harness 3. S terminal harness

4. Starter motor : N·m (kg-m, ft-lb) : N·m (kg-m, in-lb)

: Engine front

REMOVAL
1. Disconnect the battery cable from the negative terminal.
2. Remove air duct (inlet). Refer to EM-119, "AIR CLEANER AND AIR DUCT" .
3. Remove reservoir tank. Refer to.CO-38, "RADIATOR" .

SC-52
 STARTING SYSTEM

4. Disconnect “S” terminal nut.

5. Remove “B” terminal nut. A
6. Remove starter motor mounting bolts.
7. Remove starter motor upward from the vehicle.
B
INSTALLATION
Installation is the reverse order of removal.
CAUTION: C
Be sure to tighten “B” terminal nut carefully.
Removal and Installation (K9K Engine Models) EKS00K30

REMOVAL D
1. Disconnect negative battery cable.
2. Remove starter motor mounting bolt from upper side.
3. Disconnect S terminal and B terminal from starter motor. E
4. Remove starter motor mounting bolt from lower side.
5. Remove starter motor from lower side the vehicle.
F

G
MKIA0089E

INSTALLATION H
Install in the reverse order of removal.
Disassembly and Assembly EKS007ZS

SC

MKIB1994E

1. Gear case 2. Sleeve bearing 3. Shift lever

4. Plate 5. Packing 6. Adjusting plate
7. Magnetic switch assembly 8. Stopper clip 9. Pinion stopper

SC-53
 STARTING SYSTEM

10. Pinion assembly 11. Internal gear 12. Pinion shaft

13. Planetary gear 14. Ball 15. Packing
16. Yoke 17. Armature 18. Brush holder assembly
19. Rear bearing 20. Rear cover

Through-bolt:
M0T84585
: 4.1 - 7.1 N·m (0.45 - 0.72 kg-m, 39.1 - 62.5 in-lb)

MKIA0082E

1. Bushing 2. Gear case 3. Magnetic switch assembly

4. Stopper clip 5. Pinion stopper 6. Bushing
7. Pinion assembly 8. Shift lever 9. Armature
10. Packing 11. Yoke 12. Brush holder
13. Rear cover 14. Bushing 15. Cap

SC-54
 STARTING SYSTEM

MKIB1995E

1. Gear case 2. Shift lever 3. Plate I

4. Packing 5. Magnetic switch assembly 6. Ring
7. Stopper 8. Clutch gear assembly 9. Internal gear assembly
J
10. Shaft assembly gear 11. Gear assembly 12. Packing
13. Though-bolt 14. Yoke assembly 15. Armature
16. Brush holder assembly 17. E-ring 18. Rear cover assembly
SC

SC-55
 STARTING SYSTEM

Inspection EKS007ZT

MAGNETIC SWITCH CHECK

● Before starting to check, disconnect battery ground cable.
● Disconnect “M” terminal of starter motor.
1. Continuity test (between “S” terminal and switch body).
● No continuity... Replace.

SEL555E

2. Continuity test (between “S” terminal and “M” terminal).

● No continuity... Replace.

SEL556E

PINION/CLUTCH CHECK
1. Inspect pinion teeth.
● Replace pinion if teeth are worn or damaged. (Also check
condition of ring gear teeth.)
2. Inspect reduction gear teeth (If equipped).
● Replace reduction gear if teeth are worn or damaged. (Also
check condition of armature shaft gear teeth.)
3. Check to see if pinion locks in one direction and rotates
smoothly in the opposite direction.
● If it locks or rotates in both directions, or unusual resistance is
evident.... Replace. MEL139L

BRUSH CHECK
Brush
Check wear of brush.
Wear limit length : Refer to SC-61, "SER-
VICE DATA AND SPECIFI-
CATIONS (SDS)" .
● Excessive wear... Replace.

SEL014Z

SC-56
 STARTING SYSTEM

Brush Spring Check

Check brush spring pressure with brush spring detached from brush. A
Spring pressure (with : Refer to SC-61, "SER-
new brush) VICE DATA AND SPECIFI-
CATIONS (SDS)" . B

● Not within the specified values... Replace.

C

SEL015Z
D

Brush Holder
1. Perform insulation test between brush holder (positive side) and E
its base (negative side).
● Continuity exists.... Replace.

2. Check brush to see if it moves smoothly. F

● If brush holder is bent, replace it; if sliding surface is dirty,
clean.
G

SC
SEL016Z

SC-57
 STARTING SYSTEM

YOKE CHECK
Magnet is secured to yoke by bonding agent. Check magnet to see
that it is secured to yoke and for any cracks. Replace malfunctioning
parts as an assembly.
CAUTION:
Do not clamp yoke in a vice or strike it with a hammer.

SEL018Z

ARMATURE CHECK
1. Continuity test (between two segments side by side).
● No continuity... Replace.

2. Insulation test (between each commutator bar and shaft).

● Continuity exists.... Replace.

SEL019Z

3. Check commutator surface.

● Rough... Sand lightly with No. 500 - 600 emery paper.

SEL020Z

SC-58
 STARTING SYSTEM

4. Check diameter of commutator.

Commutator minimum : Refer to SC-61, "SER- A
diameter VICE DATA AND SPECIFI-
CATIONS (SDS)" .
B
● Less than specified value... Replace.
5. Check depth of insulating mold from commutator surface.
C

SEL021Z

SEL022Z

SC
● Less than 0.2 mm (0.008 in)... Undercut to 0.5 to 0.8 mm (0.020 to 0.031 in)
Assembly EKS007ZU

Apply high-temperature grease to lubricate the bearing, gears and frictional surface when assembling the L
starter.
Carefully observe the following instructions.
PINION PROTRUSION LENGTH ADJUSTMENT M
Clearance
With pinion driven out by magnetic switch, push pinion back to
remove slack and measure clearance “ ” between the front edge of
the pinion and the pinion stopper.
Clearance “ ” : Refer to SC-61, "SER-
VICE DATA AND SPECIFI-
CATIONS (SDS)" .

SEL026Z

SC-59
 STARTING SYSTEM

● Not in the specified value... Adjust by adjusting plate.

SEL633BA

SC-60
 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

A
Battery EKS007ZV

Applied model CR, HR, K9K

FULMEN type code B
Type
LB1 (FCM 047 620) LB2 (FCM 055 622) LB2 (FCM 050 622)
Capacity V-AH 12 - 47 12 - 55 12 - 50
C
Starter EKS007ZW

M0T84585 0 001 116 009 M0T32171

D
Type MITSUBISHI make BOSCH make MITSUBISHI make
Reduction gear type Non reduction Reduction gear type
Applied model CR HR E
System voltage V 12.0
Terminal
11.0 11.5 11.0
voltage V F
No-load
Current A Less than 90 Less than 48 Less than 90
Revolution rpm More than 2,800 More than 5,800 More than 3,000
G
Minimum diameter of commutator mm (in) — 33.5 (1.319) —
Minimum length of brush mm (in) — 3.5 (0.138) —
Brush spring tension H
— — —
N (kg, lb)
Less than 0.2
Clearance between bearing metal and armature shaft mm (in) — —
(0.008)
I
0.3 - 2.5 0.0 - 3.9
Clearance “ ” between pinion front edge and pinion stopper mm (in) —
(0.012 - 0.098) (0 - 0.154)

Alternator EKS007ZX J

2542927 A002TJ0291ZE
Type
VALEO make MITSUBISHI make SC
Applied model CR HR
Nominal rating V-A 12 - 77 12 - 120
Ground polarity Negative L
Minimum revolutions under no-load (When 13.5V is applied) rpm — —
More than 39 / 1,800
More than 60 / 2,500
More than 27 / 1,300 M
Hot output current (When 13.5V is applied) A/rpm More than 95 / 2,500
More than 76 / 5,000
More than 116 / 5,000
More than 77 / 6,000
Regulated output voltage V 14.55 14.1 - 14.7
Minimum length of brush mm (in) — —
Brush spring pressure N (g, oz.) — —
Slip ring minimum diameter mm (in) — —
Rotor coil resistance at 20° (68°F) Ω — —

SC-61
SERVICE DATA AND SPECIFICATIONS (SDS)

SC-62