STARTING & CHARGING SYSTEM

K ELECTRICAL

B
SECTION
STARTING & CHARGING SYSTEM C

E
CONTENTS
PRECAUTIONS .......................................................... 2 Inspection ............................................................... 18 F
Precautions for Supplemental Restraint System ROTOR CHECK .................................................. 18
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN- BRUSH CHECK .................................................. 18
SIONER” .................................................................. 2 PULLEY CHECK(WITH CLUTCH TYPE) ............ 18 G
Wiring Diagrams and Trouble Diagnosis .................. 2 STATOR CHECK ................................................. 18
BATTERY .................................................................... 3 Assembly ................................................................ 19
How to Handle Battery ............................................. 3 RING FITTING IN REAR BEARING .................... 19
H
METHODS OF PREVENTING OVER-DIS- REAR COVER INSTALLATION ........................... 19
CHARGE ............................................................... 3 STARTING SYSTEM ................................................. 20
CHECKING ELECTROLYTE LEVEL .................... 3 System Description ................................................. 20
SPECIFIC GRAVITY CHECK ............................... 4 M/T MODELS ...................................................... 20 I
Battery Test and Charging Chart .............................. 5 A/T MODELS ....................................................... 20
CHART I ................................................................ 5 Wiring Diagram — START —/M/T models ............. 21
CHART II ............................................................... 6 Wiring Diagram — START —/A/T models .............. 22 J
A: SLOW CHARGE ............................................... 7 Trouble Diagnoses ................................................. 23
B: STANDARD CHARGE ...................................... 8 Removal and Installation ........................................ 24
C: QUICK CHARGE ............................................ 10 REMOVAL ........................................................... 24
SC
Removal and Installation .........................................11 INSTALLATION ................................................... 24
CHARGING SYSTEM ............................................... 12 Disassembly and Assembly .................................... 25
System Description ................................................ 12 Inspection ............................................................... 28
Wiring Diagram — CHARGE — ............................. 13 MAGNETIC SWITCH CHECK ............................. 28 L
Trouble Diagnoses ................................................. 14 PINION/CLUTCH CHECK ................................... 28
WITH IC REGULATOR ....................................... 14 BRUSH CHECK .................................................. 28
MALFUNCTION INDICATOR .............................. 14 YOKE CHECK ..................................................... 29 M
Removal and Installation ........................................ 15 ARMATURE CHECK ........................................... 30
REMOVAL (QR ENGINE MODELS) ................... 15 Assembly ................................................................ 31
REMOVAL (YD ENGINE MODELS) ................... 15 PINION PROTRUSION LENGTH ADJUST-
INSTALLATION ................................................... 15 MENT .................................................................. 31
Disassembly and Assembly ................................... 16 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 33
Disassembly ........................................................... 17 Battery .................................................................... 33
REAR COVER .................................................... 17 Starter ..................................................................... 33
REAR BEARING ................................................. 18 Alternator ................................................................ 33

SC-1
 PRECAUTIONS

PRECAUTIONS PFP:00011

Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER” EKS007AR

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 harness connec-
tors.
Wiring Diagrams and Trouble Diagnosis EKS00312

When you read wiring diagrams, refer to the followings:

● Refer to GI-13, "How to Read Wiring Diagrams" in GI section
● Refer to PG-2, "POWER SUPPLY ROUTING" for power distribution circuit in PG section
When you perform trouble diagnosis, refer to the followings:
● Refer to GI-10, "HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES" in GI section
● Refer to GI-23, "How to Perform Efficient Diagnosis for an Electrical Incident" in GI section

SC-2
 BATTERY

BATTERY PFP:00011
A
How to Handle Battery EKS00313

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-3
 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-4
 BATTERY

Battery Test and Charging Chart EKS00314

CHART I A

SC

SEL754W

*1: SC-4 *2: SC-6 *3: SC-7

*4: SC-8 *5: SC-10

SC-5
 BATTERY

CHART II

SEL755W

*: SC-5

● 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
95D31R(L) 240
115D31R(L) 240
025 [YUASA type code] 240
027 [YUASA type code] 285
110D26R(L) 300
95E41R(L) 300
067 [YUASA type code] 325
130E41R(L) 330
096 [YUASA type code] 375

SC-6
 BATTERY

A: SLOW CHARGE
A

SEL756W
I
*1: SC-4 *2: SC-6

Fig. 2 INITIAL CHARGING CURRENT SETTING (Slow charge) J

BATTERY TYPE
096 [YUASA type code ]
025 [YUASA type code]

027 [YUASA type code]

067 [YUASA type code]

SC

130E41R(L)
115D31R(L)

110D26R(L)

CON-VERTED
50D23R(L)

55D23R(L)

65D26R(L)

80D26R(L)

75D31R(L)

95D31R(L)
28B19R(L)

34B19R(L)

46B24R(L)

55B24R(L)

SPECIFIC 95E41R(L)
GRAVITY
L

M
14.
8.5 9.0
Below 1.100 4.0 (A) 5.0 (A) 7.0 (A) 8.0 (A) 10.0 (A) 0
(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-7
 BATTERY

Fig. 3 ADDITIONAL CHARGE (Slow charge)

SEL757W

*: SC-6

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 60°C (140°F), stop charging. Always charge battery when its
temperature is below 60°C (140°F).
B: STANDARD CHARGE

SEL758W

*1: SC-4 *2: SC-6

SC-8
 BATTERY

Fig. 4 INITIAL CHARGING CURRENT SETTING (Standard charge)

BATTERY TYPE
A

025 [YUASA type code]

027 [YUASA type code]

067 [YUASA type code]

096 [YUASA type code]

B

115D31R(L)

110D26R(L)

130E41R(L)
CON-VERTED

50D23R(L)

55D23R(L)

65D26R(L)

80D26R(L)

75D31R(L)

95D31R(L)
28B19R(L)

34B19R(L)

46B24R(L)

55B24R(L)

95E41R(L)
SPECIFIC GRAV-
ITY
C

13. D
8.0
1.100 - 1.130 4.0 (A) 5.0 (A) 6.0 (A) 7.0 (A) 9.0 (A) 0
(A)
(A)
11. E
7.0
1.130 - 1.160 3.0 (A) 4.0 (A) 5.0 (A) 6.0 (A) 8.0 (A) 0
(A)
(A)
6.0 9.0
1.160 - 1.190 2.0 (A) 3.0 (A) 4.0 (A) 5.0 (A)
(A)
7.0 (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)
(A) (A)
G
● Check battery type and determine the specified current using the table shown above.
● After starting charging, adjustment of charging current is not necessary.
Fig. 5 ADDITIONAL CHARGE (Standard charge) H

SC
SEL759W

*: SC-6
L
CAUTION:
● 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 M
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 60°C (140°F), stop charging. Always charge battery when its
temperature is below 60°C (140°F).

SC-9
 BATTERY

C: QUICK CHARGE

SEL760W

*: SC-6

Fig. 6 INITIAL CHARGING CURRENT SETTING AND CHARGING TIME (Quick charge)

025 [YUASA type code]

027 [YUASA type code]

067 [YUASA type code]

096 [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)
BATTERY TYPE

40
CURRENT [A] 10 (A) 15 (A) 20 (A) 25 (A) 30 (A)
(A)
1.100 -
CONVERTED SPECIFIC GRAVITY

2.5 hours
1.130
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 60°C (140°F), stop charging. Always charge battery when its
temperature is below 60°C (140°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-10
 BATTERY

Removal and Installation EKS00315

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 shown below.
Battery fix frame mounting nut: C
: 3.5 - 5.3 N·m (0.36 - 0.54 kg-m, 31 - 46 in-lb)
Battery cable tightening nut: D
SKIA0068E
: 3.0 - 5.0 N·m (0.31 - 0.51 kg-m, 27 - 44 in-lb)

SC

SC-11
 CHARGING SYSTEM

CHARGING SYSTEM PFP:00011

System Description EKS00316

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 (S)
● through 10A fuse (No.34, located in the fuse and fusible link box)
● to alternator terminal B
● through 120A (Gasoline engine models) or 100A (Diesel engine models) fusible link (letter A, located in
the fuse and fusible link box).
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 120A (Gasoline engine models) or 100A (Diesel engine models) 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. 11, located in the fuse block (J/B)]
● to combination meter terminal 46 (LHD models) or terminal 59 (RHD models) for the charge warning
lamp.
Ground is supplied with power and ground supplied
● to terminal 64 (LHD models) or terminal 54 ( RHD models) of the combination meter
● through terminal 3 (L) of the alternator
● to terminal E of the alternator
● through body ground E30.
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 malfunction is indicated.

SC-12
 CHARGING SYSTEM

Wiring Diagram — CHARGE — EKS00317

SC

TKWA0058E

SC-13
 CHARGING SYSTEM

Trouble Diagnoses EKS00319

Before conducting an alternator test, make sure that the battery is fully charged. A 30-volt voltmeter and suit-
able test probes are necessary for the test. The alternator can be checked easily by referring to the Inspection
Table.
● Before starting, inspect the fusible link.
● Use fully charged battery.
WITH IC REGULATOR

SEL338V

NOTE:
● If the inspection result is OK even though the charging system is malfunctioning, check the B terminal
connection. (Check the tightening torque.)
● When field circuit is open, check condition of rotor coil, rotor slip ring and brush. If necessary, replace
faulty parts with new ones.
MALFUNCTION INDICATOR
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.

SC-14
 CHARGING SYSTEM

Removal and Installation EKS0031A

REMOVAL (QR ENGINE MODELS) A

1. Disconnect negative battery cable.
2. Remove alternator drive belt. Refer to EM-12, "Checking Drive Belts" in EM section.
3. Remove alternator harness mounting bolt, ground mounting B
bolt, alternator connector and B terminal mounting nut.
4. Remove alternator mounting bolts.
5. Remove alternator assembly from vehicle upper side. C

E
PKIA2496E

REMOVAL (YD ENGINE MODELS)

1. Disconnect negative battery cable. F
2. Remove alternator harness mounting bolt, alternator connector
and B terminal mounting nut.
3. Remove drive belt.Refer to EM-118, "Checking Drive Belts" in G
EM section.
4. Remove alternator bracket mounting bolts and alternator
bracket. H
5. Remove alternator mounting bolts.
6. Remove alternator assembly from vehicle upper side.
I
MEL948N

INSTALLATION
J
Install in the reverse order of removal, taking care of the following point.
● Install alternator, and check tension of belt. Refer to EM-12, "Tension Adjustment" (QR engine models) or
EM-118, "Tension Adjustment" (YD engine models) in “ENGINE MECHANICAL (EM)” section.
SC
CAUTION:
Be sure to tighten B terminal mounting nut carefully.
QR engine models L
B terminal nut: : 7.9 - 11.0 N·m (0.8 - 1.11 kg-m, 6.0 - 8.0 ft-lb)
Ground bolt: : 2.3 - 2.6 N·m (0.23 - 0.27 kg-m, 20 - 23 in-lb) M
Alternator mounting bolt: : 59 - 69 N·m (6.1 - 7.1 kg-m, 45 - 51 ft-lb)
YD engine models
B terminal nut: : 7.9 - 11.0 N·m (0.8 - 1.11 kg-m, 6.0 -8.0 ft-lb)
Ground bolt: : 2.3 - 2.6 N·m (0.23 - 0.27 kg-m, 20 - 23 in-lb)
Alternator mounting bolt (upper side): : 16 - 20 N·m (1.6 - 2.1 kg-m, 12 - 15 ft-lb)
Alternator mounting bolt (lower side): : 38 - 50 N·m (3.8 - 5.1 kg-m, 28 - 36 ft-lb)

SC-15
 CHARGING SYSTEM

Disassembly and Assembly EKS0031B

PKIA0460E

1. Pulley 2. Front cover 3. Front bearing

4. Retainer 5. Rotor 6. Slip ring
7. Stator 8. Fan guide 9. IC voltage regulator assembly
10. Diode assembly 11. Rear cover

Through-bolt:
: 3.2 - 3.9 N·m (0.33 - 0.40kg-m, 29 - 35 in-lb)

SC-16
 CHARGING SYSTEM

PKIA0461E
I
1. Pulley 2. Front cover 3. Front bearing
4. Retainer 5. Rotor 6. Rear bearing
7. Stator 8. IC voltage regulator assembly 9. Diode assembly J
10. Rear cover

Through-bolt
SC
: 3.5 - 5.3 N·m(0.36 - 0.54 kg-m, 31.0 - 46.9 in-lb)
Pulley nut:
L
: 99 - 137 N·m(10.1 - 14.0 kg-m, 73.0 - 101.1 ft-lb)

Disassembly EKS0031C

REAR COVER M

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.

SC-17
 CHARGING SYSTEM

REAR BEARING
CAUTION:
● Do not reuse rear bearing after removal. Replace with a new one.
● Do not lubricate rear bearing outer race.
Inspection EKS0031D

ROTOR CHECK
1. Resistance test
Resistance : Refer to SDS.SC-33,
"Alternator"
● 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 SDS.SC-33,
outer diameter "Alternator" SEL033Z

● 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

PULLEY CHECK(WITH CLUTCH TYPE)

1. Check for locking (Outer ring is turned counterclockwise when
viewed from the rear).
● If it rotates in both directions... Replace pulley.

2. Check for dragging (Outer ring is turned clockwise when viewed

from the rear).
● If it locks or unusual resistance is felt... Replace pulley.

PKIA0458E

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

SEL108E

SC-18
 CHARGING SYSTEM

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

SEL109E

D
Assembly EKS0031E

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-19
 STARTING SYSTEM

STARTING SYSTEM PFP:00011

System Description EKS0031F

M/T MODELS
Power is supplied at all times
● through 30A 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
● from ignition switch terminal 5
● to starter motor harness connector 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 30A 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
● from ignition switch terminal 5
● to park/neutral position relay terminal 5.
With the ignition switch in the ON or START position, power is supplied
● through 10A fuse [No,13 located in the fuse block (J/B)]
● to park/neutral position relay terminal 1.
With the selector lever in the P or N position, ground is supplied
● to park/neutral position relay terminal 2
● through the park/neutral position switch terminals 1 and 2,and
● through body grounds F9 and F10.
Then park/neutral position relay is energized and power is supplied
● from park/neutral position relay terminal 3
● to starter motor harness connector 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-20
 STARTING SYSTEM

Wiring Diagram — START —/M/T models EKS0031G

SC

TKWA0056E

SC-21
 STARTING SYSTEM

Wiring Diagram — START —/A/T models EKS0031H

TKWA0057E

SC-22
 STARTING SYSTEM

Trouble Diagnoses EKS0031I

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

SC

SEL761W

SC-23
 STARTING SYSTEM

Removal and Installation EKS0031J

REMOVAL
M/T models
1. Disconnect negative battery cable.
2. Remove air duct. Refer to EM-14, "AIR CLEANER AND AIR
DUCT" (QR engine models) or EM-120, "AIR CLEANER AND
AIR DUCT" (YD engine models).
3. Disconnect S connector and B terminal from starter motor.
4. Remove starter motor mounting bolts.
5. Remove starter motor from upper side the vehicle.

PKIA2741E

A/T models
1. Disconnect negative battery cable.
2. Remove air duct and air cleaner assembly. Refer to EM-14, "AIR
CLEANER AND AIR DUCT" (QR engine models) or EM-120,
"AIR CLEANER AND AIR DUCT" (YD engine models).
3. Remove A/T selector cable and harness from bracket.
4. Disconnect S connector and B terminal from starter motor.
5. Remove starter motor from upper side the vehicle.

PKIA2742E

INSTALLATION
Install in the reverse order of removal.
QR engine models (M/T)
B terminal nut: :9.81 - 11.8 N·m (1.0 - 1.2 kg-m, 87 - 112 in-lb)
Starter motor mounting bolt: : 98.1 - 127.0 N·m (10.0 - 13.0 kg-m, 73 - 94 ft-lb)
QR engine models (A/T)
B terminal nut: : 7.3 - 9.8 N·m (0.75 - 1.00 kg-m, 65 - 87 in-lb)
Starter motor mounting bolt:
Upper side : : 41.2 - 52.0 N·m (4.2 - 5.3 kg-m, 31 - 38 ft - lb)
Lower side : : 98.1 - 127.0 N·m (10.0 -13.0 kg-m, 73 -94 ft-lb)
YD22 engine models
B terminal nut: : 9.81 - 11.8 N·m (1.0 - 1.2 kg-m, 87 - 112 in-lb)
Starter motor mounting bolt: : 41.2 - 52.0 N·m (4.2 - 5.3 kg-m, 31 - 38 ft-lb)

SC-24
 STARTING SYSTEM

Disassembly and Assembly EKS0031K

I
PKIA0464E

1. Sleeve bearing 2. Gear case 3. Stopper clip

4. Pinion stopper 5. Pinion assembly 6. Internal gear
J
7. Plate 8. Packing 9. Adjusting plate
10. Magnetic switch assembly 11. Planetary gear 12. Ball
13. Packing 14. Yoke 15. Armature
SC
16. Brushholder assembly 17. Rear bearing 18. Rear cover

Through-bolt :
L
: 4.1 - 7.4N·m (0.45 - 0.72kg-m, 39.1 - 62.5 in-lb)

SC-25
 STARTING SYSTEM

PKIA0465E

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

Through-bolt :
: 5.6 - 10.4N·m (0.57 - 1.06kg-m, 49.5 - 92.0 in-lb)

SC-26
 STARTING SYSTEM

PKIA0466E

1. Pinion stopper clip 2. Pinion stopper 3. Pinion I

4. Pinion spring 5. Gear case assembly 6. Shift lever set
7. Dust cover kit 8. Magnetic switch assembly 9. Clutch assembly
J
10. E-ring 11. Thrust washer 12. Center bracket(P)
13. Packing 14. Planetary gear 15. Internal gear
16. Center bracket (A) 17. Yoke assembly 18. Armature assembly
SC
19. Brush holder assembly 20. Brush(-) 21. Brush spring
22. Thrust washer 23. Rear cover assembly

Through-bolt: L

: 4.9 - 6.4 N·m (0.50 - 0.65 kg-m,43.4 - 56.4 in-lb)

M

SC-27
 STARTING SYSTEM

Inspection EKS0031L

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 SDS.SC-33,
"Starter" .
● Excessive wear ... Replace.

SEL014Z

SC-28
 STARTING SYSTEM

Brush Spring Check

Check brush spring pressure with brush spring detached from brush. A
Spring pressure (with :Refer to SDS.SC-33,
new brush) "Starter" .
B
● Not within the specified values ... Replace.

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

YOKE CHECK L
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.
M
CAUTION:
Do not clamp yoke in a vice or strike it with a hammer.

SEL019Z

SC-29
 STARTING SYSTEM

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

4. Check diameter of commutator.

Commutator minimum :Refer to SDS.SC-33,
diameter "Starter" .
● Less than specified value ... Replace.

SEL021Z

SC-30
 STARTING SYSTEM

5. Check depth of insulating mold from commutator surface.

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

G
SEL022Z

Assembly EKS0031M

H
Apply high-temperature grease to lubricate the bearing, gears and frictional surface when assembling the
starter.
Carefully observe the following instructions.
I
PINION PROTRUSION LENGTH ADJUSTMENT
Clearance (QR engine models)
With pinion driven out by magnetic switch, push pinion back to J
remove slack and measure clearance “l” between the front edge of
the pinion and the pinion stopper.
Clearance “ ” :Refer to SDS.SC-33, SC
"Starter" .

SEL026Z M

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

SEL633BA

SC-31
 STARTING SYSTEM

Movement ( YD engine models)

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 SDS.SC-33,
"Starter" .

MEL140L

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

SEL633BA

SC-32
 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

A
Battery EKS0031Q

Applied model QR20, QR25 engine

Except for Northern Europe YD22 engine B
For Northern Europe
Standard Option
Type 55D23L 80D26L 110D26L
C
Capacity V-AH 12-48 12-55 12-64

Starter EKS0031R
D
S114-844 M0T87081 M8T71471
Type HITACHI make MITSUBISHI make
Reduction E
QR20, QR25 engine
Applied model YD22 engine
A/T M/T
F
System voltage V 12
Terminal voltage V 11.0
No-load Current A Less than 90 Less than 90 Less than 145 G
Revolution rpm More than 2,700 More than 2,500 More than 3,300
Minimum diameter of commutator mm (in) 28.0 (1.102) 28.8 (1.134) 31.4 (1.236)
H
Minimum length of brush mm (in) 10.5 (0.413) 7.0 (0.276) 11.0 (0.433)
15.0 - 20.4(1.5 - 2.1, 3.4 26.7 - 36.1(2.7 - 3.7, 6.0
Brush spring tension N (kg, lb) 16.2(1.65, 3.64)
- 4.6) - 8.2)
I
Clearance between bearing metal and armature
Less than 0.2 (0.008) —
shaft mm (in)
Clearance “l” between pinion front edge and pinion
0.3 - 2.5 (0.012 - 0.098) 0.5 - 2.0(0.020 - 0.079) — J
stopper mm (in)
Movement “l” in height of pinion assembly mm (in) — 0.5 - 2.0(0.020 - 0.079)

Alternator EKS0031S
SC

LR1110-713 A3TB0771
Type
HITACHI make MITSUBISHI make L
Applied model QR20, QR25 engine YD22 engine
Nominal rating V-A 12-110 12-90
Ground polarity Negative
M

Minimum revolutions under no-load (When 13.5V is

Less than 1,100 Less than 1,300
applied) rpm
More than35/1,300 More than29/1,300
Hot output current (When 13.5V is applied) A/rpm More than91/2,500 More than76/2,500
More than110/5,000 More than88/5,000
Regulated output voltage V 14.1 - 14.7
Minimum length of brush mm (in) More than 6.0 (0.236) More than 5.0 (0.197)
Brush spring pressure N (g, oz) 1.0 - 3.43 (102 - 350, 3.60 - 12.34) 4.8 - 6.0 (490 - 610, 17.28 - 21.51)
Slip ring minimum diameter mm (in) More than 26.0 (1.024) More than 22.1 (0.870)
Rotor coil resistance at 20° (68°F) Ω 2.31 2.1 - 2.5

SC-33
SERVICE DATA AND SPECIFICATIONS (SDS)

SC-34