STARTING & CHARGING SYSTEM

K ELECTRICAL

STARTING & CHARGING SYSTEM

SECTION SC B

E
CONTENTS
PRECAUTIONS .......................................................... 3 REMOVAL ........................................................... 23 F
Precautions for Supplemental Restraint System INSTALLATION ................................................... 23
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN- Disassembly and Assembly .................................... 23
SIONER” .................................................................. 3 LHD MODELS ..................................................... 23 G
Wiring Diagrams and Trouble Diagnosis .................. 3 RHD MODELS .................................................... 24
PREPARATION ........................................................... 4 Disassembly ........................................................... 24
Special Service Tools ............................................... 4 REAR COVER ..................................................... 24
H
BATTERY .................................................................... 5 REAR BEARING ................................................. 24
How to Handle Battery ............................................. 5 Inspection ............................................................... 25
METHODS OF PREVENTING OVER-DIS- ROTOR CHECK .................................................. 25
CHARGE ............................................................... 5 BRUSH CHECK .................................................. 25 I
CHECKING ELECTROLYTE LEVEL .................... 5 PULLEY CHECK (WITH CLUTCH TYPE) ........... 25
SPECIFIC GRAVITY CHECK ............................... 6 STATOR CHECK ................................................. 25
Battery Test and Charging Chart .............................. 7 Assembly ................................................................ 26 J
CHART I ................................................................ 7 RING FITTING IN REAR BEARING .................... 26
CHART II ............................................................... 8 REAR COVER INSTALLATION ........................... 26
A: SLOW CHARGE ............................................... 9 STARTING SYSTEM ................................................. 27
SC
B: STANDARD CHARGE .................................... 10 System Description ................................................. 27
C: QUICK CHARGE ............................................ 12 A/T MODELS ....................................................... 27
Removal and Installation ........................................ 13 M/T MODELS ...................................................... 27
CHARGING SYSTEM ............................................... 14 Wiring Diagram — START — ................................. 28 L
System Description ................................................ 14 A/T MODELS ....................................................... 28
Wiring Diagram — CHARGE — ............................. 15 M/T MODELS ...................................................... 29
Trouble Diagnosis .................................................. 16 Trouble Diagnoses ................................................. 30 M
DIAGNOSIS PROCEDURE ................................ 16 Removal and Installation ........................................ 31
PRE-DIAGNOSIS INSPECTION ......................... 16 REMOVAL ........................................................... 31
DIAGNOSIS CHART BY SYMPTOM .................. 16 INSTALLATION ................................................... 31
INSPECTION FLOW BY CHARGE WARNING Disassembly and Assembly .................................... 32
LAMP .................................................................. 16 Inspection ............................................................... 32
CHARGE WARNING LAMP LINE INSPECTION... 17 MAGNETIC SWITCH CHECK ............................. 32
VOLTAGE DETECTION LINE AND CHARGE PINION/CLUTCH CHECK ................................... 33
WARNING LAMP INSPECTION ......................... 18 BRUSH CHECK .................................................. 33
INSPECTION OF INSUFFICIENT ALTERNA- YOKE CHECK ..................................................... 34
TOR POWER GENERATION .............................. 20 ARMATURE CHECK ........................................... 35
INSPECTION OF EXCESSIVE ALTERNATOR Assembly ................................................................ 36
POWER GENERATION ...................................... 20 PINION PROTRUSION LENGTH ADJUST-
DARK CURRENT INSPECTION ......................... 21 MENT .................................................................. 36
OPERATION PROCEDURE OF CURRENT SERVICE DATA AND SPECIFICATIONS (SDS) ...... 37
MEASUREMENT PROBE FOR CONSULT-II ..... 22 Battery .................................................................... 37
Removal and Installation ........................................ 23

SC-1
Starter ..................................................................... 37
Alternator ................................................................ 37

SC-2
 PRECAUTIONS

PRECAUTIONS PFP:00011
A
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER” EKS00MZ4

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along B
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. C
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. D
● 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. E
● 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. F
Wiring Diagrams and Trouble Diagnosis EKS00MZ5

When you read wiring diagrams, refer to the followings: G

● GI-15, "How to Read Wiring Diagrams" in GI section
● PG-4, "POWER SUPPLY ROUTING CIRCUIT" for power distribution circuit in PG section
When you perform trouble diagnosis, refer to the followings: H
● GI-11, "How to Follow Trouble Diagnoses" in GI section
● GI-24, "How to Perform Efficient Diagnosis for an Electrical Incident" in GI section
I

SC

SC-3
 PREPARATION

PREPARATION PFP:00002

Special Service Tools EKS00MZ6

Tool name Description

CONSULT-II unit, and

Program card

PBIA3527J

CONSULT-II CONVERTER
System diagnose and inspection

PBIA3526J

Current measurement probe for

CONSULT-II
EG1187 1900

MKIA0065E

SC-4
 BATTERY

BATTERY PFP:00011
A
How to Handle Battery EKS00MZ7

CAUTION:
● If it becomes necessary to start the engine with a booster battery and jumper cables, use a 12-volt B
booster battery.
● After connecting battery cables, ensure that they are tightly clamped to battery terminals for good
contact. C
● 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. D
● The battery surface (particularly its top) should always be kept
clean and dry.
● The terminal connections should be clean and tight. E
● At every routine maintenance, check the electrolyte level.
This also applies to batteries designated as “low maintenance”
and “maintenance-free”. F

G
MEL040F

H
● 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.)
I

SC
MEL041F

● Check the charge condition of the battery. L

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-5
 BATTERY

● Remove the cell plug using a suitable tool.

● Add distilled water up to the MAX level.

MEL043F

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.
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
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.
SEL709E

SPECIFIC GRAVITY CHECK

1. Read hydrometer and thermometer indications at eye level.
2. Convert into specific gravity at 20°C (68°F).
Example:
● 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.
● 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.
MEL042FA

SEL007Z

SC-6
 BATTERY

Battery Test and Charging Chart EKS00MZ8

CHART I A

SC

SEL754W

*1. SC-6 *2. SC-8 *3. SC-9

*4. SC-10 *5. SC-12

SC-7
 BATTERY

CHART II

SEL755W

*. SC-7

● Check battery type and determine the specified current using the following table.
Fig. 1 Discharging Current (Load Tester)
Type Current (A)
28B19R(L) 90
34B19R(L) 99
46B24R(L) 135
55B24R(L) 135
50D23R(L) 150
55D23R(L) 180
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-8
 BATTERY

Type Current (A)

A
130E41R(L) 330
L2/580L [EXIDE type code] 350
096 [YUASA type code] 375 B
096 [YUASA type code] 375
010S [YUASA type code] 360
L3/760L [EXIDE type code] 420 C

A: SLOW CHARGE
D

SC

SEL756W L
*1. SC-6 *2. SC-8

Fig. 2 Initial Charging Current Setting (Slow Charge)

M
BATTERY TYPE
L2/580L [EXIDE type code]

L3/760L [EXIDE 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]

CON-
130E41R(L)
115D31R(L)

110D26R(L)
50D23R(L)

55D23R(L)

65D26R(L)

80D26R(L)

75D31R(L)

95D31R(L)
28B19R(L)

34B19R(L)

46B24R(L)

55B24R(L)

95E41R(L)

VERTED
SPECIFIC
GRAVITY

8. 9. 14
Below
4.0 (A) 5.0 (A) 7.0 (A) 8.0 (A) 5 0 10.0 (A) 11.0 (A) .0
1.100
(A) (A) (A)

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

SC-9
 BATTERY

Fig. 3 Additional Charge (Slow Charge)

SEL757W

*. SC-8

CAUTION:
● Set charging current to value specified in Fig. 2. 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.
● 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 55°C (131°F), stop charging. Always charge battery when its
temperature is below 55°C (131°F).
B: STANDARD CHARGE

SEL758W

*1. SC-6 *2. SC-8

SC-10
 BATTERY

Fig. 4 Initial Charging Current Setting (Standard Charge)

BATTERY TYPE
A

L2/580L [EXIDE type code]

L3/760L [EXIDE 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]

B

115D31R(L)

110D26R(L)

130E41R(L)
CONVERTED

50D23R(L)

55D23R(L)

65D26R(L)
80D26R(L)

75D31R(L)

95D31R(L)
28B19R(L)

34B19R(L)

46B24R(L)

55B24R(L)

95E41R(L)
SPECIFIC
GRAVITY
C

D
8.0 13.0
1.100 - 1.130 4.0 (A) 5.0 (A) 6.0 (A) 7.0 (A) 9.0 (A) 10.0 (A)
(A) (A)
7.0 11.0 E
1.130 - 1.160 3.0 (A) 4.0 (A) 5.0 (A) 6.0 (A) 8.0 (A) 9.0 (A)
(A) (A)
6.0 9.0
1.160 - 1.190 2.0 (A) 3.0 (A) 4.0 (A) 5.0 (A) 7.0 (A) 8.0 (A)
(A) (A)
F
5.0 7.0
1.190 - 1.220 2.0 (A) 2.0 (A) 3.0 (A) 4.0 (A) 5.0 (A) 6.0 (A)
(A) (A)

● Check battery type and determine the specified current using the table shown above. G
● After starting charging, adjustment of charging current is not necessary.
Fig. 5 Additional Charge (Standard Charge)
H

SC
SEL759W

*. SC-8

CAUTION: L
● Do not use standard charge method on a battery whose specific gravity is less than 1.100.
● 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. M
● 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.
● If battery temperature rises above 55°C (131°F), stop charging. Always charge battery when its
temperature is below 55°C (131°F).

SC-11
 BATTERY

C: QUICK CHARGE

SEL760W

*. SC-8

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

L2/580L [EXIDE type code]

L3/760L [EXIDE 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]

130E41R(L)
115D31R(L)

110D26R(L)
50D23R(L)

55D23R(L)

65D26R(L)

80D26R(L)

75D31R(L)

95D31R(L)
28B19R(L)

34B19R(L)

46B24R(L)

55B24R(L)

95E41R(L)
BAT-
TERY
TYPE

CUR- 40
10 (A) 15 (A) 20 (A) 25 (A) 30 (A)
RENT [A] (A)
1.100
- 2.5 hours
1.130
CONVERTED SPECIFIC GRAVITY

1.130
- 2.0 hours
1.160
1.160
- 1.5 hours
1.190
1.190
- 1.0 hours
1.220
Above
0.75 hours (45 min.)
1.220

● 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 55°C (131°F), stop charging. Always charge battery when its
temperature is below 55°C (131°F).
● Do not exceed the charging time specified in Fig. 6, because charging battery over the charging
time can cause deterioration of the battery.

SC-12
 BATTERY

Removal and Installation EKS00MZ9

A
Observe the following to ensure proper servicing.
CAUTION:
● When removing, remove negative terminal first. But for installation, install positive terminal first.
B
● Tighten parts to the specified torque as shown in figure.

H
MKIB1993E

1. Battery fixing type 1 2. Battery fixing type 2 3. Battery 4. Battery tray

SC

SC-13
 CHARGING SYSTEM

CHARGING SYSTEM PFP:00011

System Description EKS00MZA

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 4 through:
● 15A fuse (No. 30, located in the fuse and fusible link box).
Terminal 1 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
140A fusible link (letter "A", located in the fuse and fusible link box) .
The alternator is grounded to the engine block.
With the ignition switch in the ON or START position, power is supplied
● 10A fuse [No. 14, located in the fuse block (J/B)]
● to combination meter terminal 16 for the charge warning lamp.
Ground is supplied With power and ground supplied
● to terminal 2 of the combination meter
● through terminal 3 of the alternator.
If the charge warning lamp illuminates with the engine running, a fault is indicated.
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.

SC-14
 CHARGING SYSTEM

Wiring Diagram — CHARGE — EKS00MZB

SC

MKWA3624E

SC-15
 CHARGING SYSTEM

Trouble Diagnosis EKS00MZD

DIAGNOSIS PROCEDURE
1. Check malfunction symptoms or customer's remarks.
2. Perform pre-diagnosis inspection. Refer to SC-16, "PRE-DIAGNOSIS INSPECTION" .
3. Perform trouble diagnosis for each trouble symptom. Refer to SC-16, "DIAGNOSIS CHART BY SYMP-
TOM"
4. Repair or replace parts indicated inspection flow based on the charge warning lamp. Refer to SC-16,
"INSPECTION FLOW BY CHARGE WARNING LAMP" .
5. End
PRE-DIAGNOSIS INSPECTION
1. Perform alternator belt inspection. Refer to EM-12, "DRIVE BELTS" .
2. Inspect battery.
3. Check alternator terminal 1 for loose or improper connection.
4. Check alternator connector 4 and 3 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-16, "DIAGNOSIS
CHART BY SYMPTOM" .
DIAGNOSIS CHART BY SYMPTOM
Symptom Reference page
Refer to SC-16, "INSPECTION FLOW BY CHARGE WARN-
Battery discharge
ING LAMP" .
Refer to SC-16, "INSPECTION FLOW BY CHARGE WARN-
Charge warning lamp illuminates.
ING LAMP" .
Other than the above symptoms (splashing out of battery fluid, SC-20, "INSPECTION OF EXCESSIVE ALTERNATOR
nasty smell and others) 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-17, "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-18, "VOLTAGE DETECTION LINE AND
CHARGE WARNING LAMP INSPECTION" .

MKIB0556E

SC-16
 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-20, "INSPECTION OF EXCESSIVE ALTER-
NATOR POWER GENERATION" .
NO >> Go to SC-20, "INSPECTION OF INSUFFICIENT C
ALTERNATOR POWER GENERATION" .

D
MKIB0555E

CHARGE WARNING LAMP LINE INSPECTION

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

MKIB1725E 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 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-17
 CHARGING SYSTEM

3. CONTINUITY INSPECTION
1. Disconnect combination meter connector.
2. Check continuity between combination meter connector terminal 2 and alternator connector terminal 3.
2-3 : 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.)

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. Remove alternator connector.
3. Turn ignition switch ON.
Does charge warning lamp stay ON?
YES >> GO TO 6.
NO >> GO TO 2.

MKIB0555E

2. VOLTAGE INSPECTION
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.

MKIB1726E

SC-18
 CHARGING SYSTEM

3. CONNECTOR INSPECTION A
1. Turn ignition switch OFF.
2. Check alternator connector and terminal 4 (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 any of the following fuses in the alternator are blown.
● Check 15A fuse
OK or NG E
OK >> GO TO 5.
NG >> If fuse is blownout, be sure to eliminate cause of malfunction befer installing new fuse.

5. CONTINUITY INSPECTION F

1. Turn ignition switch OFF.

2. Disconnect combination meter connector. G
3. Check continuity between combination meter connector terminal 2 and ground, and combination meter
connector terminal 2 and alternator terminal 3.
H
2 - Ground : Continuity should not exist.
2-3 : 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.)
J

SC

SC-19
 CHARGING SYSTEM

INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION

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

MKIA0067E

2. CURRENT INSPECTION
1. Turn 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-21, "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

SC-20
 CHARGING SYSTEM

2. BATTERY VOLTAGE INSPECTION A

1. Turn ignition switch OFF.
2. Disconnect alternator connector.
3. Turn ignition switch ON. B
4. Check voltage between alternator connector terminal 4 and
ground.
C
4 - Ground : 12V or more
Is the inspection result 12V or more?
YES >> Replace alternator. (Alternator power generation error) D
NO >> GO TO 3. MKIB1726E

3. CHECK FUSE E

Check if any of the following fuses in the alternator are blown.

● Check 15A fuse
F
OK or NG
OK >> Repair the harnesses.
NG >> If fuse is blownout, be sure to eliminate cause of malfunction befer installing new fuse. G
DARK CURRENT INSPECTION
Dark Current: Small current while ignition switch is “OFF”.
NOTE: H
● 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- I
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-22, "OPERATION PROCEDURE OF J
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 SC
off.
4. Measure dark current. Is it 50mA or less? Refer to SC-22,
"OPERATION PROCEDURE OF CURRENT MEASUREMENT L
PROBE FOR CONSULT-II" .
NOTE: MKIA0070E
Dark current stable time is different due to equipment and use of M
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-21
 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-22
 CHARGING SYSTEM

Removal and Installation EKS00MZE

REMOVAL A
1. Disconnect negative battery cable.
2. Remove intercooler hose and duct
3. Disconnect alternator harness. B
4. Remove drive belt. Refer to EM-12, "Checking Drive Belts" .
5. Remove alternator upper mounting bolt.
C
6. Remove alternator lower mounting nut and bolt .
7. Remove alternator.
D
MKIB1992E

INSTALLATION E
Install in the reverse order of removal, taking care of the following point.
● Install alternator, and check tension of drive belt. Refer to EM-13, "Deflection Adjustment" .
F
CAUTION:
Be sure to tighten alternator terminal 1 mounting nut carefully.
YD engine models - B terminal nut: : 7.9 - 11.0 N·m (0.8 - 1.11 kg-m, 70 - 97 in-lb) G

Disassembly and Assembly EKS00PD1

LHD MODELS H

SC

MKIB2000E

1. Rear bearing 2. Rotor 3. Retainer

4. Front bearing 5. Through bolt 6. Front cover
7. Washer 8. Pulley 9. Stator
10. IC voltage regulator assembly 11. Diode assembly 12. Rear cover
13. B terminal

SC-23
 CHARGING SYSTEM

RHD MODELS

MKIB2001E

1. Rear bearing 2. Rotor 3. Retainer

4. Front bearing 5. Through bolt 6. Front cover
7. Washer 8. Pulley 9. Stator
10. IC voltage regulator assembly 11. Diode assembly 12. Rear cover
13. B terminal

Disassembly EKS00MZG

REAR COVER

SEL032Z

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.

SC-24
 CHARGING SYSTEM

Inspection EKS00MZH

ROTOR CHECK A
1. Resistance test
Resistance : Refer to SDS. SC-37,
"Alternator" B

● Not within the specified values... Replace rotor.

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

3. Check slip ring for wear.

Slip ring minimum : Refer to SDS. SC-37, D
outer diameter "Alternator" SEL033Z

● Not within the specified values... Replace rotor.

E
BRUSH CHECK
1. Check smooth movement of brush.
● Not smooth... Check brush holder and clean. F
2. Check brush for wear.
● Replace brush if it is worn down to the limit line.
G

SEL631DA

PULLEY CHECK (WITH CLUTCH TYPE) I

1. Check for locking (Outer ring is turned counterclockwise when
viewed from the rear).
● If it rotates in both directions... Replace pulley. J
2. Check for dragging (Outer ring is turned clockwise when viewed
from the rear).
● If it locks or unusual resistance is felt... Replace pulley.
SC

L
PKIA0458E

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

SEL108E

SC-25
 CHARGING SYSTEM

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

SEL109E

Assembly EKS00MZI

RING FITTING IN REAR BEARING

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

SEL044Z

REAR COVER INSTALLATION

1. Fit brush assembly, diode assembly, regulator assembly and
stator.

SEL048Z

2. Push brushes up with fingers and install them to rotor.

Take care not to damage slip ring sliding surface.

SEL049Z

SC-26
 STARTING SYSTEM

STARTING SYSTEM PFP:00011

A
System Description EKS00MZJ

A/T MODELS
Power is supplied at all times: B
● to starter motor terminal 1 and
● through 40A fusible link (letter J , located in the fuse and fusible link box)
● to ignition switch terminal 1. C
with the ignition switch in the START position, power is supplied:
● from ignition switch terminal 5
● to IPDM E/R terminal 21. D
With the ignition switch in the ON or START position, power is supplied to IPDM E/R CPU, and
the selector lever in the P or N position, power is supplied:
● through A/T assembly terminal 9 E
● to IPDM E/R terminal 48.
Ground is supplied at all times:
F
● to IPDM E/R terminals 38 and 59
● from body grounds E21, E41 and E61.
Then the starter relay is turned ON. G
The IPDM E/R starter relay is energized and power is supplied:
● from terminal 19 of IPDM E/R
● to terminal 2 of the starter motor. H
The starter motor plunger closes and provides a closed circuit between the battery and the starter motor. The
starter motor is grounded to the cylinder block. With power and ground supplied, the starter motor operates.
M/T MODELS I
Power is supplied at all times:
● to starter motor terminal 1 and
J
● through 40A fusible link (letter J , located in the fuse and fusible link box)
● to ignition switch terminal 1.
with the ignition switch in the START position, power is supplied: SC
● from ignition switch terminal 5
● to IPDM E/R terminal 21.
With the start signal is input to IPDM E/R CPU, power is supplied: L
● through IPDM E/R terminal 14
● to IPDM E/R terminal 48.
Ground is supplied at all times: M
● to IPDM E/R terminals 38 and 59
● from body grounds E21, E41 and E61.
Then the starter relay is turned ON.
The IPDM E/R starter relay is energized and power is supplied:
● from terminal 19 of IPDM E/R
● to terminal 2 of the starter motor.
The starter motor plunger closes and provides a closed circuit between the battery and the starter motor. The
starter motor is grounded to the cylinder block. With power and ground supplied, the starter motor operates.

SC-27
 STARTING SYSTEM

Wiring Diagram — START — EKS00MZN

A/T MODELS

MKWA2946E

SC-28
 STARTING SYSTEM

M/T MODELS
A

SC

MKWA3623E

SC-29
 STARTING SYSTEM

Trouble Diagnoses EKS00MZO

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

SEL761W

SC-30
 STARTING SYSTEM

Removal and Installation EKS00MZP

REMOVAL A

I
MKIB1991E

1. Starter motor assembly 2. Rear plate 3. Transmission case

J
1. Disconnect negative battery cable.
2. Remove engine under covers.
3. Disconnect S terminal and B terminal from starter motor. SC
4. Remove starter motor mounting bolts (two).
5. Remove starter motor from bottom side the vehicle.
L
INSTALLATION
Install in the reverse order of removal.
M
(M8T76071ZE)
B terminal nut : : 7.35 - 9.81 N·m (0.75 - 1.0 kg-m, 65 - 87 in-lb)
S terminal nut : : 3.0 - 5.0 N·m (0.3 - 0.5 kg-m, 27 - 44 in-lb)

SC-31
 STARTING SYSTEM

Disassembly and Assembly EKS00PD2

MKIB2003E

1. Stopper clip 2. Pinion stopper 3. Pinion

4. Spring 5. Gear case 6. Plate
7. Packing 8. Adjusting plate 9. Magnetic switch assembly
10. Snap ring 11. Retainer ring 12. Over running clutch
13. Internal gear 14. Planetary gear 15. Ball
16. Packing 17. Cover 18. Yoke
19. Armature 20. Washer 21. Rear bearing
22. Brush holder assembly 23. Brush spring 24. Brush (-)
25. Rear cover 26. Through bolt (H): High-temperature grease point

Inspection EKS00MZR

MAGNETIC SWITCH CHECK

● Before starting to check, disconnect battery ground cable.
● Disconnect “M” terminal of starter motor.

SC-32
 STARTING SYSTEM

1. Continuity test (between “S” terminal and switch body).

● No continuity... Replace. A
2. Continuity test (between “S” terminal and “M” terminal).
● No continuity... Replace.
B

G
MKIA0011E

PINION/CLUTCH CHECK
1. Inspect pinion teeth. H
● Replace pinion if teeth are worn or damaged. (Also check
condition of ring gear teeth.)
2. Inspect reduction gear teeth (If equipped). I
● 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 J
smoothly in the opposite direction.
● If it locks or rotates in both directions, or unusual resistance is
evident.... Replace. MEL139L SC
BRUSH CHECK
Brush
L
Check wear of brush.
Wear limit length : Refer to SDS. SC-37,
"Starter" . M
● Excessive wear... Replace.

SEL014Z

SC-33
 STARTING SYSTEM

Brush Spring Check

Check brush spring pressure with brush spring detached from brush.
Spring pressure (with : Refer to SDS. SC-37,
new brush) "Starter" .
● Not within the specified values... Replace.

SEL015Z

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

2. Check brush to see if it moves smoothly.

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

SEL016Z

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.

SEL305H

SC-34
 STARTING SYSTEM

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

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

B
● Continuity exists.... Replace.

SEL019Z
D

3. Check commutator surface.

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

SEL020Z
H
4. Check diameter of commutator.
Commutator minimum : Refer to SDS. SC-37, I
diameter "Starter" .
● Less than specified value... Replace.

5. Check depth of insulating mold from commutator surface. J

SC

SEL021Z

SC-35
 STARTING SYSTEM

SEL022Z

● Less than 0.2 mm (0.008 in)... Undercut to 0.5 to 0.8 mm (0.020 to 0.031 in)
Assembly EKS00MZS

Apply high-temperature grease to lubricate the bearing, gears and frictional surface when assembling the
starter.
Carefully observe the following instructions.
PINION PROTRUSION LENGTH ADJUSTMENT
Movement
Compare movement “ ” in height of pinion when it is pushed out
with magnetic switch energized and when it is pulled out by hand
until it touches stopper.
Movement “ ” : Refer to SC-37, "Starter" .

MEL140L

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

MKIB0870E

SC-36
 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

A
Battery EKS00MZT

Applied model YD25 engine

Type L3/760L B
Capacity V-AH 12-75

Starter EKS00MZU C
M8T76071ZE
Type MITSUBISHI
D
Reduction
Applied model YD25 engine
System voltage V 12 E
Terminal voltage V 11.0
No-load Current A Less than 145
F
Revolution rpm More than 3,400
Minimum diameter of commutator mm (in) 31.4 (1.236)
Minimum length of brush mm (in) 11.0 (0.433) G
26.7 - 36.1
Brush spring tension N (kg, lb)
(2.72 - 3.68, 6.0 - 8.12)
Clearance between bearing metal and armature shaft mm (in) — H
Clearance “ ” between pinion front edge and pinion stopper mm (in) —

Movement “ ” in height of pinion assembly mm (in) 0 (0, 0) I

Alternator EKS00MZV

A3TJ0781 A3TG2681ZE J
Type
MITSUBISHI
YD25 engine
Applied model SC
LHD models RHD models
Nominal rating V-A 12-150 12-130
Ground polarity Negative L
Minimum revolutions under no-load
Less than 1,000
(When 13.5V is applied) rpm
More than 35/1,300 More than 33/1,300 M
Hot output current (When 13.5V is applied) A/rpm More than 105/2,500 More than 105/2,500
More than 136/5,000 More than 122/5,000
Regulated output voltage V 14.1 - 14.7
Minimum length of brush mm (in) More than 5.0 (0.197)
4.1 - 5.3 4.8 - 6.0
Brush spring pressure N (g, oz.)
(418 - 520, 14.74 - 18.34) (490 - 610, 17.28 - 21.51)
Slip ring minimum diameter mm (in) More than 22.1 (0.870)
Rotor coil resistance at 20° (68°F) Ω 1.6 - 2.0 1.7 - 2.1

SC-37
SERVICE DATA AND SPECIFICATIONS (SDS)

SC-38