STARTING & CHARGING SYSTEM SECTION

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GI MA EM LC EC

CONTENTS
PRECAUTIONS ...............................................................2 Supplemental Restraint System (SRS) AIR BAG and SEAT BELT PRE-TENSIONER ...............2 Wiring Diagrams and Trouble Diagnosis.....................2 PREPARATION ...............................................................3 Special Service Tool ....................................................3 BATTERY.........................................................................4 How to Handle Battery ................................................4 METHODS OF PREVENTING OVER-DISCHARGE ......4 CHECKING ELECTROLYTE LEVEL ............................4 SPECIFIC GRAVITY CHECK ......................................5 CHARGING THE BATTERY ........................................6 Trouble Diagnoses with Battery/Starting/Charging System Tester ..............................................................7 DIAGNOSTIC RESULT ITEM CHART ..........................9 STARTING SYSTEM .....................................................10 System Description....................................................10 M/T MODELS ..........................................................10 A/T MODELS ...........................................................10 Wiring Diagram - START -.........................................11 A/T MODELS ...........................................................12 Trouble Diagnoses with Battery/Starting/Charging System Tester ............................................................13 DIAGNOSTIC RESULT ITEM CHART ........................14 WORK FLOW ..........................................................15 DIAGNOSTIC PROCEDURE 1 ..................................16 DIAGNOSTIC PROCEDURE 2 ..................................18
MINIMUM SPECIFICATION OF CRANKING VOLTAGE REFERENCING COOLANT TEMPERATURE ......................................................19

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Construction...............................................................19 Removal and Installation ...........................................19 REMOVAL ...............................................................19 INSTALLATION........................................................20 Pinion/Clutch Check ..................................................20 CHARGING SYSTEM ....................................................21 System Description....................................................21 Wiring Diagram - CHARGE -.....................................22 Trouble Diagnoses with Battery/Starting/Charging System Tester ............................................................23 DIAGNOSTIC RESULT ITEM CHART ........................25 WORK FLOW ..........................................................26 DIAGNOSTIC PROCEDURE 1 ..................................27 DIAGNOSTIC PROCEDURE 2 ..................................28 DIAGNOSTIC PROCEDURE 3 ..................................29 MALFUNCTION INDICATOR ....................................29 Construction...............................................................30 Removal and Installation ...........................................30 REMOVAL ...............................................................30 INSTALLATION........................................................30 SERVICE DATA AND SPECIFICATIONS (SDS) .........31 Battery........................................................................31 Starter ........................................................................31 Alternator ...................................................................31

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PRECAUTIONS
Supplemental Restraint System (SRS) AIR BAG and SEAT BELT PRE-TENSIONER

Supplemental Restraint System (SRS) AIR BAG and SEAT BELT PRE-TENSIONER

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The Supplemental Restraint System such as AIR BAG and SEAT BELT PRE-TENSIONER used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. The SRS system composition which is available to INFINITI I35 is as follows (The composition varies according to optional equipment.): For a frontal collision The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt pre-tensioners, a diagnosis sensor unit, crash zone sensor, warning lamp, wiring harness and spiral cable. For a side collision The Supplemental Restraint System consists of front side air bag module (located in the outer side of front seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision). Information necessary to service the system safely is included in the RS 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 should be performed by an authorized INFINITI dealer. Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the RS 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 harness connector (and by yellow harness protector or yellow insulation tape before the harness connectors).

Wiring Diagrams and Trouble Diagnosis

When you read wiring diagrams, refer to the following: GI-11, HOW TO READ WIRING DIAGRAMS EL-11, POWER SUPPLY ROUTING for power distribution circuit When you perform trouble diagnosis, refer to the following: GI-35, HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES GI-24, HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT

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PREPARATION
Special Service Tool

Special Service Tool

Tool number Tool name J-44373 Model 620 Battery/Starting/Charging system tester Description

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BATTERY
How to Handle Battery

How to Handle Battery

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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

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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.
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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.)

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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.

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CHECKING ELECTROLYTE LEVEL

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

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BATTERY
How to Handle Battery (Contd)

Remove the cell plug using a suitable tool. Add distilled water up to the MAX level.

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Sulphation

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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 current and higher voltage are observed in the initial stage of charging sulphated batteries. A sulphated battery may sometimes be brought back into service by means of a long, slow charge, 12 hours or more, followed by a battery capacity test.

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SPECIFIC GRAVITY CHECK

1.

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Read hydrometer and thermometer indications at eye level.

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2.

Use the chart below to correct your hydrometer reading according to electrolyte temperature.
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Hydrometer Temperature Correction

Battery electrolyte temperature C (F) 71 (160) 66 (150) 60 (140) 54 (130) 49 (120) 43 (110) 38 (100) 32 (90) 27 (80) 21 (70) 16 (60) 10 (50)

Add to specific gravity reading 0.032 0.028 0.024 0.020 0.016 0.012 0.008 0.004 0 0.004 0.008 0.012

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BATTERY
How to Handle Battery (Contd)
Battery electrolyte temperature C (F) 4 (40) 1 (30) 7 (20) 12 (10) 18 (0) Add to specific gravity reading 0.016 0.020 0.024 0.028 0.032

Corrected specific gravity 1.260 - 1.280 1.230 - 1.250 1.200 - 1.220 1.170 - 1.190 1.140 - 1.160 1.110 - 1.130

Approximate charge condition Fully charged 3/4 charged 1/2 charged 1/4 charged Almost discharged Completely discharged

CHARGING THE BATTERY

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CAUTION: Do not quick charge a fully discharged battery. Keep the battery away from open flame while it is being charged. When connecting the charger, connect the leads first, then turn on the charger. Do not turn on the charger first, as this may cause a spark. If battery electrolyte temperature rises above 60C (140F), stop charging. Always charge battery at a temperature below 60C (140F).

Charging Rates
Amps 50 25 10 5 Time 1 hour 2 hours 5 hours 10 hours

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Do not charge at more than 50 ampere rate. NOTE: The ammeter reading on your battery charger will automatically decrease as the battery charges. This indicates that the voltage of the battery is increasing normally as the state of charge improves. The charging amps indicated above refer to initial charge rate. If, after charging, the specific gravity of any two cells varies more than .050, the battery should be replaced.

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BATTERY
Trouble Diagnoses with Battery/Starting/Charging System Tester

Trouble Diagnoses with Battery/Starting/Charging System Tester

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CAUTION: When working with batteries, always wear appropriate eye protection. NOTE: To ensure a complete and thorough diagnosis, the battery, starter and alternator test segments must be done as a set from start to finish. If battery surface charge is detected while testing, the tester will prompt you to turn on the headlights to remove the surface charge. If necessary, the tester will prompt you to determine if the battery temperature is above or below 0C (32F). Choose the appropriate selection by pressing the up or down arrow button, then press ENTER to make the selection.

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1.

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Turn off all loads on the vehicle electrical system. Clean or repair as necessary. 2. Visually inspect the battery, battery terminals and cable ends with ignition switch in OFF position. NOTE: The contact surface between the battery terminals, cable ends and tester leads must be clean for a valid test. A poor connection will prevent testing and a CHECK CONNECTION message will appear during the test procedures. If this occurs, clean the battery post and terminals, reconnect them and restart the test. 3. Connect the red tester lead clamp to the positive battery terminal, and the black to the negative terminal.

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4. The tester will turn on automatically. Using the arrow keys, select IN VEHICLE on the tester and then press the ENTER key.

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SEL405X

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BATTERY
Trouble Diagnoses with Battery/Starting/Charging System Tester (Contd)

5.

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Locate the battery type and rating stamped or written on the top case of the battery to be tested. NOTE: The battery type and rating will have either of the following. CCA: Cold Cranking Amps (490 CCA, 550 CCA, etc.) JIS: Japanese Industrial Standard. Battery is stamped with a number such as: 80D26L: 80 (rank of output), D (physical size-depth), 26 (width in cm). The last character L (post configuration) is not input into the tester. The tester requires the rating for the battery be entered exactly as it is written or stamped on the battery. Do not attempt a CCA conversion for JIS stamped batteries. JIS must be input directly. 6. Using the arrow and ENTER keys alternately, select the battery type and rating. NOTE: The tester lists five choices; CCA, JIS, IEC, DIN, and EN. Only use CCA or JIS.

7.

Press ENTER to begin the test. Diagnosis results are displayed on the tester. Refer to DIAGNOSTIC RESULT ITEM CHART, SC-9.

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8.

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Press ENTER, then test output code is displayed. Record the test output code on the repair order. 9. Toggle back to the DIAGNOSTIC SCREEN for test results. NOTE: If necessary, the tester will ask the user to determine if the battery has just been charged. Choose the appropriate selection by pressing the up or down arrow button and then press the ENTER button to make the selection. When testing a battery installed in a vehicle that has recently been driven, select BEFORE CHANGE. If the battery has just been slow charged due to a CHARGE & RETEST decision by the tester, and the tester asks the user BEFORE CHARGE/AFTER CHARGE, select AFTER CHARGE.

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BATTERY
Trouble Diagnoses with Battery/Starting/Charging System Tester (Contd)

DIAGNOSTIC RESULT ITEM CHART

Diagnostic item GOOD BATTERY Service procedure Battery is OK, go to Trouble Diagnoses, STARTING SYSTEM. Refer to SC-13.

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REPLACE BATTERY

Replace battery. Before replacing battery, clean the battery cable clamps and battery posts. Perform battery test again with Battery/Starting/Charging system tester. If second test result is Replace Battery, then do so. Perform battery test again to confirm repair. Replace the battery. Perform battery test again with Battery/Starting/Charging system tester to confirm repair. Perform the slow battery charging procedure. (Initial rate of charge is 10A for 12 hours.) Perform battery test again with Battery/Starting/Charging system tester. Perform the slow battery charging. (Initial rate of charge is 10A for 12 hours.) Perform battery test again with Battery/Starting/Charging system tester to confirm repair. NOTE: If the tester asks the user BEFORE CHARGE/AFTER CHARGE, select AFTER CHARGE.

BAD CELL-REPLACE GOOD-RECHARGE

CHARGE & RETEST

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STARTING SYSTEM
System Description

System Description
M/T MODELS

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Power is supplied at all times through 40A fusible link (letter C, located in the fuse and fusible link box) to ignition switch terminal 1. With the ignition switch in the START position, power is supplied through terminal 5 of the ignition switch to clutch interlock relay terminal 5. With the ignition switch in the START position, power is supplied through 10A fuse [No. 21, located in the fuse block (J/B)] to clutch interlock relay terminal 1. When the clutch pedal is depressed, ground is supplied to clutch interlock relay terminal 2 through the clutch interlock switch and body grounds E11, E22 and E53. The clutch interlock relay is energized and power is supplied from terminal 3 of the clutch interlock relay to terminal 2 of the starter motor windings. 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.

A/T MODELS

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Power is supplied at all times through 40A fusible link (letter C, 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 15A fuse [No. 20, located in the fuse block (J/B)] to park/neutral position relay terminal 1. Also, with the ignition switch in the START position, power is supplied from ignition switch terminal 5 to park/neutral position relay terminal 6. Ground is supplied, with the selector lever in the P or N position to park/neutral position relay terminal 2 through park/neutral position switch. The park/neutral position relay is energized and power is supplied from ignition switch terminal 5 through park/neutral position relay terminals 6 and 7 to terminal 2 of the starter motor windings. 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.

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STARTING SYSTEM
Wiring Diagram START

Wiring Diagram START

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MEL397O

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STARTING SYSTEM
Wiring Diagram START (Contd)

A/T MODELS

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MEL209K

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STARTING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester

Trouble Diagnoses with Battery/Starting/Charging System Tester

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NOTE: To ensure a complete and thorough diagnosis, the battery, starter and alternator test segments must be done as a set from start to finish.

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1. 2. 3.

Turn off all loads on the vehicle electrical system. Perform battery test with Battery/Starting/Charging system tester. Refer to SC-7. Press ENTER to begin the starting system test.

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4.

Start the engine.

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5.

Diagnosis result is displayed on the tester. Refer to DIAGNOSTIC RESULT ITEM CHART, SC-14. NOTE: If the starter performs normally but the engine does not start, perform engine diagnosis. For intermittent NO CRANK or NO STARTER OPERATION incidents, go to DIAGNOSTIC PROCEDURE 2.

RS BT HA

SEL410X

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STARTING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester (Contd)

DIAGNOSTIC RESULT ITEM CHART

Diagnostic item CRANKING VOLTAGE NORMAL CRANKING VOLTAGE LOW CHARGE BATTERY Go to WORK FLOW, SC-15. Go to WORK FLOW, SC-15. Service procedure

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Perform the slow battery charging procedure. (Initial rate of charge is 10A for 12 hours.) Perform battery test again with Battery/Starting/Charging system tester. Refer to SC-7. Before replacing battery, clean the battery cable clamps and battery posts. Perform battery test again with Battery/Starting/Charging system tester. Refer to SC-7. If second test result is REPLACE BATTERY, then do so. Perform battery test again to confirm repair.

REPLACE BATTERY

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STARTING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester (Contd)

WORK FLOW

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*1 *2

SC-7 SC-19

*3

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*4

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STARTING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester (Contd)

DIAGNOSTIC PROCEDURE 1 Check B Terminal Circuit

1
1. 2. 3. 4. 5.

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CHECK POWER SUPPLY FOR STARTER MOTOR B TERMINAL

Remove the fuel pump fuse. Crank or start the engine (where possible) until the fuel pressure is released. Turn the ignition OFF. Check that the starter motor connector E202 terminal 1 (B/R) connection is clean and tight. Check voltage between starter motor connector E202 terminal 1 (B/R) and ground using a digital circuit tester.

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OK or NG OK NG GO TO 2. Check harness between the battery and the starter motor for open circuit.

CHECK BATTERY CABLE CONNECTION QUALITY (VOLTAGE DROP TEST)

1. Check voltage between starter motor connector E202 terminal 1 (B/R) and battery positive terminal using a digital circuit tester.

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OK or NG OK NG GO TO 3. Check harness between the battery and the starter motor for poor continuity.

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STARTING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester (Contd)

CHECK STARTER MOTOR GROUND CIRCUIT (VOLTAGE DROP TEST)

1. Check voltage between starter motor case and battery negative terminal using a digital circuit tester.

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OK or NG OK NG Starter motor B terminal circuit is OK. Further inspection necessary. Refer to WORK FLOW, SC-15. Check the starter motor case and ground for poor continuity.

AX SU BR ST RS BT HA

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STARTING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester (Contd)

DIAGNOSTIC PROCEDURE 2 Check S Terminal Circuit

1
1. 2. 3. 4. 5.

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CHECK POWER SUPPLY FOR STARTER MOTOR S TERMINAL

Remove the fuel pump fuse. Crank or start the engine (where possible) until the fuel pressure is released. Turn the ignition OFF. Disconnect starter motor connector. Check voltage between starter motor connector E203 terminal 2 (B/R) (M/T models) or E201 terminal 2 (B/R) (A/T models) and ground using a digital circuit tester.

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OK or NG OK NG GO TO 2. Check the following. 40A fusible link (letter C, located in fuse and fusible link box) Park/neutral position relay Harness for open or short

CHECK S TERMINAL CONNECTION QUALITY (VOLTAGE DROP TEST)

1. Connect starter motor connector. 2. Check voltage between starter motor connector E203 terminal 2 (B/R) (M/T models) or E201 terminal 2 (B/R) (A/T models) and battery positive terminal using a digital tester.

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OK or NG OK NG Starter motor S terminal circuit is OK. Further inspection necessary. Refer to WORK FLOW, SC-15. Check harness between the battery and the starter motor S terminal for poor continuity.

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STARTING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester (Contd)

MINIMUM SPECIFICATION OF CRANKING VOLTAGE REFERENCING COOLANT TEMPERATURE NHSC0019S05

Engine coolant temperature 30C to 20C (22F to 4F) 19C to 10C (2F to 14F) 9C to 0C (16F to 32F) More than 1C (More than 34F) Voltage V 8.2 8.7 9.1 9.4

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Construction

LC EC FE AT AX SU BR ST RS BT

MEL209O

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Removal and Installation

REMOVAL
1. 2. 3. 4. 5. Remove air duct assembly. Remove harness protector from engine room harness. Disconnect starter harness. Remove starter bolts (two). Remove starter.

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STARTING SYSTEM
Removal and Installation (Contd)

INSTALLATION
To install, reverse the removal procedure.

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Pinion/Clutch Check
1. 2. 3.

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Inspect pinion teeth. Replace pinion if teeth are worn or damaged. (Also check condition of ring gear teeth.) Inspect reduction gear teeth. Replace reduction gear if teeth are worn or damaged. (Also check condition of armature shaft gear teeth.) 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.

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CHARGING SYSTEM
System Description

System Description

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The alternator provides DC voltage to operate the vehicles 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 (S) through: 120A fusible link (letter A, located in the fuse and fusible link box), and 10A fuse (No. 70, located in the fuse and fusible link box). Terminal B supplies power to charge the battery and operate the vehicles electrical system. Output voltage is controlled by the IC regulator at terminal 3 (S) detecting the input voltage. The charging circuit is protected by the 120A fusible link. The alternator is grounded to the engine block. With the ignition switch in the ON or START position, power is supplied through 10A fuse [No. 30, located in the fuse block (J/B)] to combination meter terminal 24 for the charge warning lamp. Ground is supplied to terminal 68 of the combination meter through terminal 2 (L) of the alternator. With power and ground supplied, 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.

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CHARGING SYSTEM
Wiring Diagram CHARGE

Wiring Diagram CHARGE

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MEL396O

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CHARGING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester

Trouble Diagnoses with Battery/Starting/Charging System Tester

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NOTE: To ensure a complete and thorough diagnosis, the battery, starter and alternator test segments must be done as a set from start to finish.

GI MA EM

1. 2. 3. 4.

Turn off all loads on the vehicle electrical system. Perform battery and starting system test with Battery/Starting/ Charging system tester. Press ENTER to begin the charging system test. Start engine.

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5.

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Press ENTER until LOADS OFF REV ENGINE 5 SEC is displayed. 6. Raise and hold the engine speed at 1,500 to 2,000 rpm for about 5 seconds, then return to the engine to idle. Once the increase in engine rpm is detected, press ENTER to continue. NOTE: If after 30 seconds an increase in engine idle speed is not detected, RPM NOT DETECTED will display. Some engines may have a higher idle initially after starting, particularly when the engine is cold. The tester may detect this without any other action being taken. If this occurs, continue on with the testing process. The final results will not be affected.

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7. The tester now checks the engine at idle and performs the DIODE/RIPPLE check. 8. When complete, the tester will prompt you to turn on the following electrical loads. Heater fun set to highest. Do not run the A/C or windshield defroster. Headlamp high beam Rear window defogger NOTE: Do not run the windshield wipers or any other cyclical loads.
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CHARGING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester (Contd)

9.

Press ENTER to continue.

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10. Raise and hold the engine speed at 1,500 to 2,000 rpm for about 5 seconds, then return the engine to idle. Once the increase in engine rpm is detected, press ENTER to continue. NOTE: If after 30 seconds an increase in engine idle speed is not detected, RPM NOT DETECTED will be displayed. Press ENTER to restart the test.

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11. Diagnostic result is displayed on the tester. Refer to DIAGNOSTIC RESULT ITEM CHART, SC-25.

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12. Press ENTER then test output code is displayed. Record the test output code on the repair order. 13. Toggle back to the DIAGNOSTIC SCREEN for test results.

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CHARGING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester (Contd)

DIAGNOSTIC RESULT ITEM CHART

Diagnostic item CHARGING SYSTEM NORMAL NO CHARGING VOLTAGE LOW CHARGING VOLTAGE HIGH CHARGING VOLTAGE DIODE RIPPLE NORMAL EXCESS RIPPLE DETECTED DIODE RIPPLE NOT DETECTED Service procedure Charging system is normal and will also show DIODE RIPPLE test result. Go to WORK FLOW, SC-26. Go to WORK FLOW, SC-26. Go to WORK FLOW, SC-26. Diode ripple is OK and will also show CHARGING VOLTAGE test result. Replace the alternator. Perform DIODE RIPPLE test again using Battery/Starting/ Charging system tester to confirm repair. Go to WORK FLOW, SC-26.

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CHARGING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester (Contd)

WORK FLOW

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CHARGING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester (Contd)

DIAGNOSTIC PROCEDURE 1 Check L Terminal Circuit

1 CHECK L TERMINAL CONNECTION
Check to see if L terminal is clean and tight. OK or NG OK NG GO TO 2.

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SEL966X

Repair L terminal connection. Confirm repair by performing complete Battery/Starting/ Charging system test.

CHECK L TERMINAL CIRCUIT

1. Disconnect alternator connector. 2. Apply ground to alternator connector A2 terminal 2 (BR) with the ignition switch in the ON position.

OK or NG OK NG Replace the alternator. Confirm repair by performing complete Battery/Starting/Charging system test. Check the following. 10A fuse [No. 30, located in fuse block (J/B)] CHARGE lamp Harness for open or short between combination meter and fuse Harness for open or short between combination meter and alternator

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CHARGING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester (Contd)

DIAGNOSTIC PROCEDURE 2 Check B Terminal Circuit

1 CHECK B TERMINAL CONNECTION
Check to see if B terminal is clean and tight. OK or NG OK NG

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GO TO 2. Confirm repair by performing complete Battery/Starting/Charging system test. Repair B terminal connection.

CHECK ALTERNATOR B TERMINAL CIRCUIT

Check voltage between alternator connector E46 terminal B (B/R) and ground using a digital circuit tester.

SEL967X

OK or NG OK NG GO TO 3. Check the following. 120A fusible link (letter A, located in fuse and fusible link box) Harness for open or short between alternator and fusible link

CHECK B TERMINAL CONNECTION QUALITY (VOLTAGE DROP TEST)

Check voltage between alternator connector E46 terminal B (B/R) and battery positive terminal using a digital tester.

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OK or NG OK NG Replace the alternator. Confirm repair by performing complete Battery/Starting/Charging system test. Check harness between the battery and the alternator for poor continuity.

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CHARGING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester (Contd)

DIAGNOSTIC PROCEDURE 3 Check S Terminal Circuit

1 CHECK S TERMINAL CONNECTION
Check to see if S terminal is clean and tight. OK or NG OK NG GO TO 2.

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GI MA EM LC EC FE AT AX
SEL969X

Repair S terminal connection. Confirm repair by performing complete Battery/Starting/ Charging system test.

CHECK ALTERNATOR S TERMINAL CIRCUIT

Check voltage between alternator connector A2 terminal 3 (B/P) and ground using a digital circuit tester.

OK or NG OK NG GO TO 3. Check the following. 10A fuse (No. 70, located in fuse and fusible link box) Harness for open or short between alternator and fuse

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CHECK S TERMINAL CONNECTION QUALITY (VOLTAGE DROP TEST)

Check voltage between alternator connector A2 terminal 3 (B/P) and battery positive terminal using a digital tester.

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SEL970X

OK or NG OK NG Replace the alternator. Confirm repair by performing complete Battery/Starting/Charging system test. Check harness between the battery and the alternator for poor continuity.

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MALFUNCTION INDICATOR

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The IC regulator warning function activates to illuminate CHARGE warning lamp, if any of the following symptoms occur while alternator is operating: Excessive voltage is produced. No voltage is produced.

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CHARGING SYSTEM
Construction

Construction

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MEL210O

Removal and Installation

REMOVAL
1. 2. 3. 4. 5. 6. 7. 8. Remove engine undercover RH. Remove side inspection cover RH. Loosen belt idler pulley. Remove drive belt. Remove A/C compressor mounting bolts (four). Slide A/C compressor forward. Disconnect alternator harness connector. Remove alternator upper bolt and lower bolt.

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SEL460T

INSTALLATION
To install, reverse the removal procedure.

NHSC0013S02

MEL384KA

SC-30

SERVICE DATA AND SPECIFICATIONS (SDS)

Battery

Battery
Type Capacity V-AH A 80D26L 12-55 582

NHSC0014

GI MA

Cold cranking current (For reference value)

Starter
M0T87181 Type MITSUBISHI make Reduction gear type Applied model System voltage Terminal voltage No-load Current Revolution Minimum diameter of commutator Minimum length of brush Brush spring tension Clearance between bearing metal and armature shaft Clearance between pinion front edge and pinion stopper A/T 12V 11.0V Less than 90A More than 2,800 rpm 28.8 mm (1.134 in) 7.0 mm (0.276 in) 18.3 - 24.8 N (18.3 - 2.53 kg, 4.11 - 5.58 lb) Less than 0.2 mm (0.008 in) 0.5 - 2.0 mm (0.020 - 0.079 in)

NHSC0015

EM LC EC FE AT AX SU
NHSC0016

Alternator
LR1110-720 Type HITACHI make Nominal rating Ground polarity Minimum revolution under no-load (When 13.5 volts is applied) 12V-110A Negative Less than 1,200 rpm (More than 24A/1,300 rpm) More than 67A/1,800 rpm More than 87A/2,500 rpm More than 105A/5,000 rpm 14.1 - 14.7V More than 6.00 mm (0.2362 in) 1.000 - 3.432 N (102 - 350 g, 3.60 - 12.34 oz) More than 26.0 mm (1.024 in) 2.16 - 2.46

BR ST RS BT HA

Hot output current (When 13.5 volts is applied)

Regulated output voltage Minimum length of brush Brush spring pressure Slip ring minimum outer diameter Rotor (Field coil) resistance

EL IDX

SC-31

NOTES