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STARTING & CHARGING SYSTEM
K ELECTRICAL
SECTION
STARTING & CHARGING SYSTEM
SC
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CONTENTS
APPLICATION NOTICE ............................................. 3 . How to Check Vehicle Type .................................... 3 . PRECAUTIONS ......................................................... 4 . Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" ................................................................. 4 . PREPARATION .......................................................... 5 . Special Service Tools .............................................. 5 . BATTERY ................................................................... 6 . How to Handle Battery ............................................ 6 . METHODS OF PREVENTING OVER-DISCHARGE .............................................................. 6 . CHECKING ELECTROLYTE LEVEL ................... 6 . SPECIFIC GRAVITY CHECK .............................. 7 . Battery Test and Charging Chart ............................. 8 . CHART I ............................................................... 8 . CHART II .............................................................. 9 . A: SLOW CHARGE ............................................ 10 . B: STANDARD CHARGE ................................... 12 . C: QUICK CHARGE ........................................... 13 . Removal and Installation ....................................... 15 . CHARGING SYSTEM .............................................. 16 . System Description (CR Engine Models) .............. 16 . System Description (HR Engine Models) .............. 16 . System Description (K9K Engine Models) ............ 16 . Wiring Diagram -- CHARGE -- /CR Engine Models.. 17 . Wiring Diagram -- CHARGE -- /HR Engine Models.. 18 . Wiring Diagram -- CHARGE -- /K9K Engine Models .......................................................................... 19 . Trouble Diagnoses (CR Engine Models) ............... 21 . DIAGNOSIS PROCEDURE ............................... 21 . PRE-DIAGNOSIS INSPECTION ........................ 21 . DIAGNOSIS CHART BY SYMPTOM ................. 21 . INSPECTION FLOW BY CHARGE WARNING LAMP ................................................................. 21 . CHARGE WARNING LAMP LINE INSPECTION 22 ... INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION ............................. 23 . INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION ..................................... 24 . DARK CURRENT INSPECTION ........................ 24 . OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II .... 25 . Trouble Diagnoses (HR Engine Models) ............... 26 . DIAGNOSIS PROCEDURE ............................... 26 . PRE-DIAGNOSIS INSPECTION ........................ 26 . DIAGNOSIS CHART BY SYMPTOM ................. 26 . INSPECTION FLOW BY CHARGE WARNING LAMP .................................................................. 26 . CHARGE WARNING LAMP LINE INSPECTION 27 ... VOLTAGE DETECTION LINE AND CHARGE WARNING LAMP INSPECTION ........................ 28 . INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION ............................. 29 . INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION ..................................... 30 . DARK CURRENT INSPECTION ........................ 31 . OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II .... 32 . Trouble Diagnoses (K9K Engine Models) ............. 33 . DIAGNOSIS PROCEDURE ............................... 33 . PRE-DIAGNOSIS INSPECTION ........................ 33 . DIAGNOSIS CHART BY SYMPTOM ................. 33 . INSPECTION FLOW BY CHARGE WARNING LAMP .................................................................. 33 . CHARGE WARNING LAMP LINE INSPECTION 34 ... VOLTAGE DETECTION LINE AND CHARGE WARNING LAMP INSPECTION ........................ 35 . INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION ............................. 37 . INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION ..................................... 37 . DARK CURRENT INSPECTION ........................ 38 . OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II .... 39 . Removal and Installation (CR Engine Models) ...... 40 . REMOVAL .......................................................... 40 . INSTALLATION .................................................. 41 . Removal and Installation (HR Engine Models) ...... 41 . REMOVAL .......................................................... 41 .
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INSTALLATION ................................................... 42 . Removal and Installation (K9K Engine Models) .... 43 . REMOVAL .......................................................... 43 . INSTALLATION ................................................... 43 . Disassembly .......................................................... 43 . REAR COVER .................................................... 43 . REAR BEARING ................................................ 44 . Inspection .............................................................. 44 . ROTOR CHECK ................................................. 44 . BRUSH CHECK ................................................. 44 . STATOR CHECK ................................................ 44 . Assembly ............................................................... 45 . RING FITTING IN REAR BEARING ................... 45 . REAR COVER INSTALLATION .......................... 45 . STARTING SYSTEM ................................................ 46 . System Description ................................................ 46 . M/T MODELS ..................................................... 46 . A/T MODELS ...................................................... 46 . Wiring Diagram -- START -- /CR and HR Engine Models ................................................................... 47 . Wiring Diagram -- START -- /K9K Engine Models 49 ... Trouble Diagnoses ................................................. 51 . Removal and Installation (CR Engine Models) ...... 52 .
REMOVAL ...........................................................52 . INSTALLATION ...................................................52 . Removal and Installation (HR Engine Models) ......52 . REMOVAL ...........................................................52 . INSTALLATION ...................................................53 . Removal and Installation (K9K Engine Models) .....53 . REMOVAL ...........................................................53 . INSTALLATION ...................................................53 . Disassembly and Assembly ...................................53 . Inspection ...............................................................56 . MAGNETIC SWITCH CHECK ............................56 . PINION/CLUTCH CHECK ..................................56 . BRUSH CHECK ..................................................56 . YOKE CHECK ....................................................58 . ARMATURE CHECK ..........................................58 . Assembly ...............................................................59 . PINION PROTRUSION LENGTH ADJUSTMENT ..................................................................59 . SERVICE DATA AND SPECIFICATIONS (SDS) .....61 . Battery ....................................................................61 . Starter ....................................................................61 . Alternator ...............................................................61 .
SC-2
APPLICATION NOTICE APPLICATION NOTICE How to Check Vehicle Type
PFP:00000
A
EKS00Q77
Confirm K9K engine type with Model written on identification plate (refer to GI-44, "IDENTIFICATION INFORMATION" ), then refer to service information in SC section.
Vehicle type xTKxxxxK12Vxx xTKxxxxK12Yxx xTKxxxxK12Txx xTKxxxxK12Uxx Engine type Euro3 48kW Euro3 60kW Euro4 50kW Euro4 63kW
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PRECAUTIONS
PFP:00011 PRECAUTIONS Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
EKS007Z9
The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: q 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 performed by an authorized NISSAN/INFINITI dealer. q 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 SRS section. q Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors.
SC-4
PREPARATION PREPARATION Special Service Tools
Tool number Tool name Description
PFP:00002
A
EKS007ZY
B
EG1187 1900 Current measurement probe for CONSULT-II
MKIA0065E
C
System diagnose and inspection
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SC-5
BATTERY BATTERY How to Handle Battery
PFP:00011
EKS007ZB
CAUTION: q If it becomes necessary to start the engine with a booster battery and jumper cables, use a 12-volt booster battery. q After connecting battery cables, ensure that they are tightly clamped to battery terminals for good contact. q 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. q The battery surface (particularly its top) should always be kept clean and dry. q The terminal connections should be clean and tight. q At every routine maintenance, check the electrolyte level. This also applies to batteries designated as "low maintenance" and "maintenance-free".
MEL040F
q
When the vehicle is not going to be used over a long period of time, disconnect the negative battery terminal. (If the vehicle has an extended storage switch, turn it off.)
MEL041F
q
Check the charge condition of the battery. Periodically check the specific gravity of the electrolyte. Keep a close check on charge condition to prevent over-discharge.
MEL042F
CHECKING ELECTROLYTE LEVEL
WARNING: Do not allow battery fluid to come in contact with skin, eyes, fabrics, or painted surfaces. After 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.
SC-6
BATTERY
q q
Remove the cell plug using a suitable tool. Add distilled water up to the MAX level.
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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 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.
SEL709E
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SPECIFIC GRAVITY CHECK
1. Read hydrometer and thermometer indications at eye level. 2. Convert into specific gravity at 20°C (68°F). Example: q 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. q 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
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SEL007Z
SC-7
BATTERY Battery Test and Charging Chart
CHART I
EKS007ZC
SEL754W
*1. SC-7, "SPECIFIC GRAVITY CHECK" *4. SC-12, "B: STANDARD CHARGE"
*2. SC-9, "CHART II" *5. SC-13, "C: QUICK CHARGE"
*3. SC-10, "A: SLOW CHARGE"
SC-8
BATTERY
CHART II
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SEL755W
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SC-8, "CHART I"
Check battery type and determine the specified current using the following table.
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Fig. 1 Discharging Current (Load Tester)
Type 28B19R(L) 34B19R(L) 46B24R(L) 55B24R(L) 50D23R(L) 55D23R(L) 65D26R(L) 80D26R(L) 75D31R(L) 063 [YUASA type code] 95D31R(L) 115D31R(L) 025 [YUASA type code] 065 [YUASA type code] 027 [YUASA type code] 075 [YUASA type code] 110D26R(L) 95E41R(L) 067 [YUASA type code] Current (A) 90 99 135 135 150 180 195 195 210 210 240 240 240 255 285 300 300 300 325
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SC-9
BATTERY
Type 130E41R(L) 096 [YUASA type code] 096 [YUASA type code] 010S [YUASA type code] LB1 FCM 047 620 [FULMAN type code] LB2 FCM 055 622 [FULMAN type code] LB2 FCM 050 622 [FULMAN type code] Current (A) 330 375 375 360 420 510 600
A: SLOW CHARGE
SEL756W
*1. SC-7, "SPECIFIC GRAVITY CHECK"
*2. SC-9, "CHART II"
SC-10
BATTERY
Fig. 2 Initial Charging Current Setting (Slow Charge)
A
CON-VERTED SPECIFIC GRAVITY
BATTERY TYPE 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
BL1 FCM 047 620 [FULMEN type code]
LB2 FCM 050 622 [FULMEN type code]
LB2 FCM 055 622 [FULMEN type code]
115D31R(L)
110D26R(L)
130E41R(L) 14.0 (A)
C
50D23R(L)
55D23R(L)
65D26R(L)
80D26R(L)
75D31R(L)
95D31R(L)
28B19R(L)
34B19R(L)
46B24R(L)
55B24R(L)
95E41R(L)
D
Below 1.100
E
8.5 (A) 9.0 (A) 2.55 (A) 2.75 (A) 3.0 (A) 4.0 (A) 5.0 (A) 7.0 (A) 8.0 (A) 10.0 (A) 11.0 (A)
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Check battery type and determine the specified current using the table shown above. After starting charging, adjustment of charging current is not necessary.
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Fig. 3 Additional Charge (Slow Charge)
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SEL757W
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SC-9, "CHART II"
CAUTION: q 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. q Keep battery away from open flame while it is being charged. q When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as this may cause a spark. q If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its temperature is below 60°C (140°F).
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SC-11
1.190 - 1.220 28B19R(L) 34B19R(L) LB1 FCM 047 620 [FULMEN type code] LB2 FCM 050 622 [FULMEN type code] 46B24R(L) 55B24R(L) LB2 FCM 055 622 [FULMEN type code] 50D23R(L) 55D23R(L) 025 [YUASA type code] 027 [YUASA type code] 65D26R(L) 80D26R(L) 7.0 (A) 063 [YUASA type code] 067 [YUASA type code] 096 [YUASA type code] 8.0 (A) 95D31R(L) 115D31R(L) 110D26R(L) 95E41R(L) 065 [YUASA type code] 075 [YUASA type code] 096L [YUASA type code]
SEL758W
1.160 - 1.190 4.0 (A)
1.130 - 1.160
1.100 - 1.130 CON-VERTED SPECIFIC GRAVITY
2.1(A) 4.8(A) 5.0 (A)
2.3(A)
B: STANDARD CHARGE
*1. SC-7, "SPECIFIC GRAVITY CHECK"
2.4(A)
2.0 (A) 4.1(A) 2.0(A) *2. SC-9, "CHART II" 6.0 (A)
2.8(A)
3.3(A)
2.0 (A)
3.4(A)
4.0(A)
3.0 (A)
4.0 (A)
2.0 (A)
3.3(A)
3.0 (A)
4.2(A)
3.0 (A)
4.0 (A)
5.0 (A)
BATTERY
Fig. 4 Initial Charging Current Setting (Standard Charge)
BATTERY TYPE
SC-12
75D31R(L) 9.0 (A) 10.0 (A) 010S [YUASA type code] 130E41R(L) 13.0 (A)
5.0 (A)
7.0 (A)
4.0 (A)
6.0 (A)
5.0 (A)
7.0 (A)
6.0 (A)
5.0 (A)
7.0 (A)
8.0 (A)
6.0 (A)
9.0 (A)
8.0 (A)
11.0 (A)
9.0 (A)
BATTERY
q q
Check battery type and determine the specified current using the table shown above. After starting charging, adjustment of charging current is not necessary.
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Fig. 5 Additional Charge (Standard Charge)
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SEL759W
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SC-9, "CHART II"
CAUTION: q Do not use standard charge method on a battery whose specific gravity is less than 1.100. q 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. q Keep battery away from open flame while it is being charged. q When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as this may cause a spark. q If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its temperature is below 60°C (140°F).
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C: QUICK CHARGE
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SEL760W
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SC-9, "CHART II"
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SC-13
BATTERY
Fig. 6 Initial Charging Current Setting and Charging Time (Quick Charge)
LB1 FCM 047 620 [FULMEN type code] BL2 FCM 050 622 [FULMEN type code] LB2 FCM 055 622 [FULMEN type code]
010S [YUASA type code]
096L [YUASA type code]
025 [YUASA type code]
027 [YUASA type code]
063 [YUASA type code]
067 [YUASA type code]
096 [YUASA type code]
065 [YUASA type code]
075 [YUASA type code]
BATTERY TYPE
115D31R(L)
110D26R(L)
CURRENT [A]
10 (A)
15 (A)
20 (A)
25 (A)
30 (A)
1.100 - 1.130
2.5 hours
1.130 - 1.160
2.0 hours
1.160 - 1.190
1.5 hours
CONVERTED SPECIFIC GRAVITY
1.190 - 1.220
1.0 hours
Above 1.220
0.75 hours (45 min.)
Check battery type and determine the specified current using the table shown above. q After starting charging, adjustment of charging current is not necessary. CAUTION: q Do not use quick charge method on a battery whose specific gravity is less than 1.100. q Set initial charging current to value specified in Fig. 6. If charger is not capable of producing specified current value, set its charging current as close to that value as possible. q Keep battery away from open flame while it is being charged. q When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as this may cause a spark. q Be careful of a rise in battery temperature because a large current flow is required during quickcharge operation. If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its temperature is below 60°C (140°F).
q
SC-14
40 (A)
21(A)
23(A)
24(A)
130E41R(L)
50D23R(L)
55D23R(L)
65D26R(L)
80D26R(L)
75D31R(L)
95D31R(L)
28B19R(L)
34B19R(L)
46B24R(L)
55B24R(L)
95E41R(L)
BATTERY
q
Do not exceed the charging time specified in Fig. 6, because charging battery over the charging time can cause deterioration of the battery.
EKS007ZD
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Removal and Installation
Observe the following to ensure proper servicing. CAUTION: q When removing, remove negative terminal first. But for installation, install positive terminal first. q Tighten parts to the specified torque shown below. Battery bracket mounting bolt: : 12.7 - 15.7 N·m (1.3 - 1.6 kg-m, 10 - 11 ft-lb) Battery cable tightening nut: : 3.0 - 5.0 N·m (0.31 - 0.51 kg-m, 27 - 44 in-lb)
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CHARGING SYSTEM CHARGING SYSTEM System Description (CR Engine Models)
PFP:00011
EKS007ZE
The alternator provides DC voltage to operate the vehicle's electrical system and to keep the battery charged. The voltage output is controlled by the IC regulator. Terminal B supplies power to charge the battery and operate the vehicle's electrical system. The charging circuit is protected by the 100A link. The alternator is grounded to the body. With the ignition switch in the ON or START position, power is supplied q 10A fuse [No. 2, located in the fuse block (J/B)] q to combination meter terminal 28 for the charge warning lamp. Ground is supplied q to terminal 38 of the combination meter q through terminal 4 (L) of the alternator. The charge warning lamp will illuminate. When the alternator is providing sufficient voltage with the engine running, the ground is opened and the charge warning lamp will go off. If the charge warning lamp illuminates with the engine running, a fault is indicated.
System Description (HR Engine Models)
EKS00P17
The alternator provides DC voltage to operate the vehicle's electrical system and to keep the battery charged. The voltage output is controlled by the IC regulator. Power is supplied at all times to alternator terminal 3 through: q 10A fuse [No. 26, located in the fuse block (J/B)]. Terminal B supplies power to charge the battery and operate the vehicle's electrical system. Output voltage is controlled by the IC regulator at terminal 4 detecting the input voltage. The charging circuit is protected by the 100A link. The alternator is grounded to the body. With the ignition switch in the ON or START position, power is supplied q 10A fuse [No. 2, located in the fuse block (J/B)] q to combination meter terminal 28 for the charge warning lamp. Ground is supplied q to terminal 38 of the combination meter q through terminal 2 (L) of the alternator. The charge warning lamp will illuminate. When the alternator is providing sufficient voltage with the engine running, the ground is opened and the charge warning lamp will go off. If the charge warning lamp illuminates with the engine running, a fault is indicated.
System Description (K9K Engine Models)
EKS00K2U
The alternator provides DC voltage to operate the vehicle's electrical system and to keep the battery charged. The voltage output is controlled by the IC regulator. With the ignition switch in the ON or START position, power is supplied to alternator terminal 4 (S) through: q IPDM E/R (Intelligent Power Distribution Module Engine Room) Terminal B supplies power to charge the battery and operate the vehicle's electrical system. Output voltage is controlled by the IC regulator at terminal 4 (S) detecting the input voltage. The charging circuit is protected by the 100A link. The alternator is grounded to the body. With the ignition switch in the ON or START position, power is supplied q 10A fuse [No. 2, located in the fuse block (J/B)] q to combination meter terminal 28 for the charge warning lamp. Ground is supplied q to terminal 38 of the combination meter q through terminal 3 (L) of the alternator. The charge warning lamp will illuminate. When the alternator is providing sufficient voltage with the engine running, the ground is opened and the charge warning lamp will go off. If the charge warning lamp illuminates with the engine running, a fault is indicated.
SC-16
CHARGING SYSTEM Wiring Diagram -- CHARGE -- /CR Engine Models
EKS007ZF
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MKWA4064E
SC-17
CHARGING SYSTEM Wiring Diagram -- CHARGE -- /HR Engine Models
EKS00P18
MKWA4065E
SC-18
CHARGING SYSTEM Wiring Diagram -- CHARGE -- /K9K Engine Models
EKS00K2V
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B
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MKWA4230E
SC-19
CHARGING SYSTEM
MKWA3474E
SC-20
CHARGING SYSTEM Trouble Diagnoses (CR Engine Models)
DIAGNOSIS PROCEDURE
1. 2. 3. 4. 5. 1. 2. 3. 4. 5. 6. Check malfunction symptoms or customer's remarks. Perform pre-diagnosis inspection. Refer to SC-21, "PRE-DIAGNOSIS INSPECTION" . Perform trouble diagnosis for each trouble symptom. Refer to SC-21, "DIAGNOSIS CHART BY SYMPTOM" Repair or replace parts indicated inspection flow based on the charge warning lamp. Refer to SC-21, "INSPECTION FLOW BY CHARGE WARNING LAMP" . End Perform alternator belt inspection. Refer to EM-14, "DRIVE BELTS" . Inspect battery. Check alternator terminal B for loose or improper connection. Check alternator connector and terminals for loose connection, disconnection and bend. Check connecting condition of harness for charging system harness (fusible link terminal and battery terminal). After performing 1 to 5 above, go to trouble diagnosis for symptoms. Refer to SC-21, "DIAGNOSIS CHART BY SYMPTOM" .
EKS007ZG
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PRE-DIAGNOSIS INSPECTION
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DIAGNOSIS CHART BY SYMPTOM
Symptom Battery discharge Charge warning lamp illuminates. Other than the above symptoms (splashing out of battery fluid, nasty smell and others) Reference page Refer to SC-21, "INSPECTION FLOW BY CHARGE WARNING LAMP" . Refer to SC-24, "INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION" .
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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-22, "CHARGE WARNING LAMP LINE INSPECTION" .
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MKIB0555E
2. CHARGE WARNING LAMP INSPECTION
1. Set engine speed at 2,500 rpm. 2. Check if charge warning lamp illuminates. Does charge warning lamp illuminate? YES >> Go to SC-24, "INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION" . NO >> Go to SC-23, "INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION" .
MKIB0555E
SC-21
CHARGING SYSTEM
CHARGE WARNING LAMP LINE INSPECTION
CAUTION: If open circuit is detected in L terminal, alternator cannot start generating.
INSPECTION PROCEDURE
1. CHARGE WARNING LAMP INSPECTION
1. 2. 3. Turn ignition switch OFF. Disconnect alternator connector Connect alternator connector terminal 4 to ground.
MKIB1916E
4. Turn ignition switch ON. Does charge warning lamp illuminate? YES >> GO TO 4. NO >> GO TO 2.
MKIB0555E
2. CONNECTOR INSPECTION
Turn ignition switch OFF. Check 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. 1. 2.
3. CONTINUITY INSPECTION
1. 2. Disconnect combination meter connector. Check continuity between combination meter connector terminal 38 and ground, and combination meter connector terminal 38 and alternator connector terminal 4. 38 - Ground 38 - 4 : Continuity should not exist. : Continuity should exist.
OK or NG OK >> Replace combination meter. (Do not replace alternator, since it is normal.) NG >> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.)
SC-22
CHARGING SYSTEM
4. CHARGE WARNING LAMP INSPECTION
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 intermittent problem) (Do not replace alternator, since it is normal.) NO >> Replace alternator. (circuit malfunction in alternator)
MKIB0555E
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B
C
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INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION
CAUTION: Check them using charged battery performed battery inspection.
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1. VOLTAGE INSPECTION
1. 2. Increase engine speed to 2,500 rpm. 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.)
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MKIA0067E
2. CURRENT INSPECTION
1. 2. 3.
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Turn the ignition switch OFF. Disconnect the battery ground cable. SC 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 subharness between alternator terminal B and the vehicle side harL ness as shown in figure, and attach the probe to sub-harness.) 4. Connect battery ground cable. 5. Increase engine speed to 2,500 rpm. M 6. Turn electrical load to ON. (Headlamp LO turns on, blower fan motor maximum airflow amount, rear window defogger) 7. Check alternator terminal B current. CAUTION: Be careful of rotating parts because the engine is running. MKIA0068E Is the inspection result 30A or more? YES >> GO TO dark current inspection. Refer to SC-24, "DARK CURRENT INSPECTION" . (Alternator is normal. Do not replace.) NO >> Replace alternator. (Alternator power generation error.)
SC-23
CHARGING SYSTEM
INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION
1. ALTERNATOR VOLTAGE INSPECTION
1. Increase engine speed to 2,500 rpm. 2. Check battery voltage. Is the inspection result 16V or less? YES >> Replace alternator. (Alternator power generation error.) NO >> Replace alternator. (Excessive alternator power generation.)
MKIA0067E
DARK CURRENT INSPECTION
Dark Current: Small current while ignition switch is "OFF". NOTE: q 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. q Do not connect CONSULT-II CONVERTER to data link connector when measuring dark current. CONSULT-II power should be supplied using AC adapter or internal battery. 1. Attach current measurement probe for CONSULT-II to battery ground cable. Refer to SC-25, "OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II" . 2. Check that all electrical equipment is turned OFF. 3. Remove key. Close and lock doors. Check that room lamp turns off. 4. Measure dark current. Is it 50mA or less? Refer to SC-25, "OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II" . NOTE: MKIA0070E Dark current stable time is different due to equipment and use of the vehicle. If it is not 50mA or less after leaving for 1 minute, measure dark current again after leaving for 30 minutes or more. If YES, GO TO 7. If NO, GO TO 5. 5. Remove and install fuses one by one. Search for the fuse that greatly changes dark current. NOTE: If dark current is greatly reduced when removing the fuse, and even if dark current is not greatly increased when installing it again, the fuse circuit may be the cause. 6. Check that dark current changes when moving the suspect circuit harness. If dark current changes, check harness for short. If dark current does not change, electronic unit in the circuit may not be entering the energy-saving mode when it turns OFF. If it does not enter the energy-saving mode, replace electronic unit. 7. No malfunction for alternator and electrical equipment. Electric load may be larger than alternator generating ability. Check the customer's usage.
SC-24
CHARGING SYSTEM
OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II
For details, refer to the supplied "CONSULT-II Current Probe Operation Manual". 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".
A
B
C
D
E
MKIA0071E
5.
6.
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.) 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.
F
G
H
MKIA0072E
I
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 generally.
J
SC
L
MKIA0073E
8.
Align current direction mark, clamp harness, and measure current. If current direction is incorrect, it is displayed negative value. NOTE: q When current is measured, close probe joint securely. q If multiple harnesses are clamped, measurement cannot be performed. Always clamp only one.
M
MKIA0074E
SC-25
CHARGING SYSTEM Trouble Diagnoses (HR Engine Models)
DIAGNOSIS PROCEDURE
1. 2. 3. 4. 5. 1. 2. 3. 4. 5. 6. Check malfunction symptoms or customer's remarks. Perform pre-diagnosis inspection. Refer to SC-26, "PRE-DIAGNOSIS INSPECTION" . Perform trouble diagnosis for each trouble symptom. Refer to SC-26, "DIAGNOSIS CHART BY SYMPTOM" . Repair or replace parts indicated inspection flow based on the charge warning lamp. Refer to SC-26, "INSPECTION FLOW BY CHARGE WARNING LAMP" . End Perform alternator belt inspection. Refer to EM-115, "DRIVE BELTS" . Inspect battery. Check alternator terminal B for loose or improper connection. Check alternator connector and terminals for loose connection, disconnection and bend. Check connecting condition of harness for charging system harness (fusible link terminal and battery terminal). After performing 1 to 5 above, go to trouble diagnosis for symptoms. Refer to SC-26, "DIAGNOSIS CHART BY SYMPTOM" .
EKS00P19
PRE-DIAGNOSIS INSPECTION
DIAGNOSIS CHART BY SYMPTOM
Symptom Battery discharge Charge warning lamp illuminates. Other than the above symptoms (splashing out of battery fluid, nasty smell and others) Reference page Refer to SC-26, "INSPECTION FLOW BY CHARGE WARNING LAMP" . Refer to SC-30, "INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION" .
INSPECTION FLOW BY CHARGE WARNING LAMP
1. CHARGE WARNING LAMP INSPECTION
1. Turn ignition switch ON. 2. Check if charge warning lamp illuminates. Does charge warning lamp illuminate? YES >> GO TO 2. NO >> Go to SC-27, "CHARGE WARNING LAMP LINE INSPECTION" .
MKIB0555E
2. CHARGE WARNING LAMP INSPECTION
1. Start engine. 2. Check if charge warning lamp goes off. Does charge warning lamp goes off? YES >> GO TO 3. NO >> Go to SC-28, "VOLTAGE DETECTION LINE AND CHARGE WARNING LAMP INSPECTION" .
MKIB0556E
SC-26
CHARGING SYSTEM
3. CHARGE WARNING LAMP INSPECTION
1. Set engine speed at 2,500 rpm. 2. Check if charge warning lamp illuminates. Does charge warning lamp illuminate? YES >> Go to SC-30, "INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION" . NO >> Go to SC-29, "INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION" .
A
B
C
D
MKIB0555E
CHARGE WARNING LAMP LINE INSPECTION
CAUTION: If open circuit is detected in L terminal, alternator cannot start generating.
E
INSPECTION PROCEDURE
1. CHARGE WARNING LAMP INSPECTION
1. 2. 3. Turn ignition switch OFF. Disconnect alternator connector Connect alternator connector terminal 2 to ground.
F
G
H
I
MKIB1917E
J
4. Turn ignition switch ON. Does charge warning lamp illuminate? YES >> GO TO 4. NO >> GO TO 2.
SC
L
M
MKIB0555E
2. CONNECTOR INSPECTION
Turn ignition switch OFF. Check 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. 1. 2.
SC-27
CHARGING SYSTEM
3. CONTINUITY INSPECTION
1. 2. Disconnect combination meter connector. Check continuity between combination meter connector terminal 38 and alternator connector terminal 2. 38 - 2 : Continuity should exist.
OK or NG OK >> Replace combination meter. (Do not replace alternator, since it is normal.) NG >> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.)
4. CHARGE WARNING LAMP INSPECTION
1. Turn ignition switch OFF. 2. Connect alternator connector. 3. Turn ignition switch ON. Does charge warning lamp illuminate? YES >> Repair alternator connector. (Poor connection and intermittent problem) (Do not replace alternator, since it is normal.) NO >> Replace alternator. (circuit malfunction in alternator)
MKIB0555E
VOLTAGE DETECTION LINE AND CHARGE WARNING LAMP INSPECTION INSPECTION PROCEDURE
1. CHARGE WARNING LAMP INSPECTION
1. Turn ignition switch OFF. 2. Disconnect alternator connector. 3. Turn ignition switch ON. Does charge warning lamp stay ON? YES >> GO TO 5. NO >> GO TO 2.
MKIB0555E
2. VOLTAGE INSPECTION
Check voltage between alternator connector terminal 3 and ground. 3 - Ground : 12V or more Is the inspection result 12V or more? YES >> Replace alternator. NO >> GO TO 3.
MKIB1918E
SC-28
CHARGING SYSTEM
3. CONNECTOR INSPECTION
Turn ignition switch OFF. Check alternator connector and terminal 3 (alternator side, and harness side) for damage, deformation or improper connection. OK or NG OK >> GO TO 4. NG >> Repair terminals and connectors. 1. 2.
A
B
C
4. CHECK FUSE
Check if alternator S terminal fuse #26 (10A) is blown. OK or NG OK >> Repair harness between fuse #26 (10A) and alternator connector terminal 4. (Do not replace alternator, since it is normal.) NG >> Replace fuse. (Do not replace alternator, since it is normal.)
D E
5. CONTINUITY INSPECTION
1. 2. 3. Turn ignition switch OFF. Disconnect combination meter connector. Check continuity between combination meter connector terminal 38 and ground, and combination meter connector terminal 38 and alternator connector terminal 2. 38 - Ground 38 - 2 : Continuity should not exist. : Continuity should exist.
F
G
H
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.)
I
INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION
CAUTION: Check them using charged battery performed battery inspection.
J
1. VOLTAGE INSPECTION
1. 2. Increase engine speed to 2,500 rpm. 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.)
SC
L
M
MKIA0067E
SC-29
CHARGING SYSTEM
2. CURRENT INSPECTION
Turn the ignition switch OFF. Disconnect the battery ground cable. 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 subharness between alternator terminal B and the vehicle side harness as shown in figure, and attach the probe to sub-harness.) 4. Connect battery ground cable. 5. Increase engine speed to 2,500 rpm. 6. Turn electrical load to ON. (Headlamp LO turns on, blower fan motor maximum airflow amount, rear window defogger) 7. Check alternator terminal B current. CAUTION: Be careful of rotating parts because the engine is running. MKIA0068E Is the inspection result 30A or more? YES >> GO TO dark current inspection. Refer to SC-31, "DARK CURRENT INSPECTION" . (Alternator is normal. Do not replace.) NO >> Replace alternator. (Alternator power generation error.) 1. 2. 3.
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 generation.)
MKIA0067E
2. BATTERY VOLTAGE INSPECTION
1. 2. 3. Turn the ignition switch OFF. Disconnect alternator connector. Check voltage between alternator connector terminal 3 and ground. 3 - Ground : 12V or more
Is the inspection result 12V or more? YES >> Replace alternator. (Alternator power generation error) NO >> GO TO 3.
MKIB1918E
3. FUSE CHECK
Check if fuse #26 (10A) is blown. OK or NG OK >> Repair harness between fuse #26 (10A) and alternator harness connector terminal 4. (Alternator is normal. Do not replace.) NG >> Replace fuse. (Alternator is normal. Do not replace.)
SC-30
CHARGING SYSTEM
DARK CURRENT INSPECTION
Dark Current: Small current while ignition switch is "OFF". NOTE: q 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. q Do not connect CONSULT-II CONVERTER to data link connector when measuring dark current. CONSULT-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-32, "OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II" . 2. Check that all electrical equipment is turned OFF. 3. Remove key. Close and lock doors. Check that room lamp turns off. 4. Measure dark current. Is it 50mA or less? Refer to SC-32, "OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II" . NOTE: MKIA0070E Dark current stable time is different due to equipment and use of the vehicle. If it is not 50mA or less after leaving for 1 minute, measure dark current again after leaving for 30 minutes or more. If YES, GO TO 7. If NO, GO TO 5. 5. Remove and install fuses one by one. Search for the fuse that greatly changes dark current. NOTE: If dark current is greatly reduced when removing the fuse, and even if dark current is not greatly increased when installing it again, the fuse circuit may be the cause. 6. Check that dark current changes when moving the suspect circuit harness. If dark current changes, check harness for short. If dark current does not change, electronic unit in the circuit may not be entering the energy-saving mode when it turns OFF. If it does not enter the energy-saving mode, replace electronic unit. 7. No malfunction for alternator and electrical equipment. Electric load may be larger than alternator generating ability. Check the customer's usage.
A
B
C
D
E
F
G
H
I
J
SC
L
M
SC-31
CHARGING SYSTEM
OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II
For details, refer to the supplied "CONSULT-II Current Probe Operation Manual". 1. Turn current probe power supply OFF and connect to CONSULT-II. (Red: CH1, Black: Ground) 2. Touch "SUB MODE". 3. Touch "Extending Measurement Mode" on "SUB MODE" screen. 4. CAUTION is displayed, touch "OK".
MKIA0071E
5.
6.
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.) 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 generally.
MKIA0073E
8.
Align current direction mark, clamp harness, and measure current. If current direction is incorrect, it is displayed negative value. NOTE: q When current is measured, close probe joint securely. q If multiple harnesses are clamped, measurement cannot be performed. Always clamp only one.
MKIA0074E
SC-32
CHARGING SYSTEM Trouble Diagnoses (K9K Engine Models)
DIAGNOSIS PROCEDURE
1. 2. 3. 4. 5. 1. 2. 3. 4. 5. 6. Check malfunction symptoms or customer's remarks. Perform pre-diagnosis inspection. Refer to SC-33, "PRE-DIAGNOSIS INSPECTION" . Perform trouble diagnosis for each trouble symptom. Refer to SC-33, "DIAGNOSIS CHART BY SYMPTOM" Repair or replace parts indicated inspection flow based on the charge warning lamp. Refer to SC-33, "INSPECTION FLOW BY CHARGE WARNING LAMP" . End Perform alternator belt inspection. Refer to EM-244, "DRIVE BELTS" . Inspect battery. Check alternator terminal B for loose or improper connection. Check alternator connector and terminals for loose connection, disconnection and bend. Check connecting condition of harness for charging system harness (fusible link terminal and battery terminal). After performing 1 to 5 above, go to trouble diagnosis for symptoms. Refer to SC-33, "DIAGNOSIS CHART BY SYMPTOM" .
EKS00K2W
A
B
C
PRE-DIAGNOSIS INSPECTION
D
E
F
DIAGNOSIS CHART BY SYMPTOM
Symptom Battery discharge Charge warning lamp illuminates. Other than the above symptoms (splashing out of battery fluid, nasty smell and others) Reference page Refer to SC-33, "INSPECTION FLOW BY CHARGE WARNING LAMP" . Refer to SC-37, "INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION" .
G
H
I
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-34, "CHARGE WARNING LAMP LINE INSPECTION" .
J
SC
L
M
MKIB0555E
2. CHARGE WARNING LAMP INSPECTION
1. Start engine. 2. Check if charge warning lamp goes off. Does charge warning lamp goes off? YES >> GO TO 3. NO >> Go to SC-35, "VOLTAGE DETECTION LINE AND CHARGE WARNING LAMP INSPECTION" .
MKIB0556E
SC-33
CHARGING SYSTEM
3. CHARGE WARNING LAMP INSPECTION
1. Set engine speed at 2,500 rpm. 2. Check if charge warning lamp illuminates. Does charge warning lamp illuminate? YES >> Go to SC-37, "INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION" . NO >> Go to SC-37, "INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION" .
MKIB0555E
CHARGE WARNING LAMP LINE INSPECTION
CAUTION: If open circuit is detected in L terminal, alternator cannot start generating.
INSPECTION PROCEDURE
1. CHARGE WARNING LAMP INSPECTION
1. 2. 3. Turn ignition switch OFF. Remove alternator connector. Connect alternator connector terminal 3 to ground.
MKIB1919E
4. Turn ignition switch ON. Does charge warning lamp illuminate? YES >> GO TO 4. NO >> GO TO 2.
MKIB0555E
2. CONNECTOR INSPECTION
1. 2. Turn ignition switch OFF. Check combination meter and terminals (meter side, and harness side) for damage, deformation or improper connection. OK or NG OK >> GO TO 3. NG >> Repair terminals and connectors.
SC-34
CHARGING SYSTEM
3. CONTINUITY INSPECTION
1. 2. Disconnect combination meter connector. Check continuity between combination meter connector terminal 38 and alternator connector terminal 3. 38 - 3 : Continuity should exist.
A
B
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.)
C
4. CHARGE WARNING LAMP INSPECTION
1. Turn ignition switch OFF. 2. Connect alternator connectors. 3. Turn ignition switch ON. Does charge warning lamp illuminate? YES >> Repair alternator connector. (Poor connection and intermittent problem) (Do not replace alternator, since it is normal.) NO >> Replace alternator. (circuit malfunction in alternator)
MKIB0555E
D
E
F
G
VOLTAGE DETECTION LINE AND CHARGE WARNING LAMP INSPECTION INSPECTION PROCEDURE
H
1. CHARGE WARNING LAMP INSPECTION
1. Turn ignition switch OFF. 2. Disconnect alternator connector. 3. Turn ignition switch ON. Does charge warning lamp stay ON? YES >> GO TO 6. NO >> GO TO 2.
I J
SC
L
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.
M
MKIB1731E
SC-35
CHARGING SYSTEM
3. CONNECTOR INSPECTION
Turn ignition switch OFF. Check alternator connector and terminal 4 (alternator side, and harness side) for damage, deformation or improper connection. OK or NG OK >> GO TO 4. NG >> Repair terminals and connectors. 1. 2.
4. CONNECTOR INSPECTION
Check IPDM E/R and terminals (IPDM E/R side, and harness side) for damage, deformation or improper connection. OK or NG OK >> GO TO 5. NG >> Repair terminals and connectors.
5. CONTINUITY INSPECTION
1. 2. Disconnect IPDM E/R connector. Check continuity between IPDM E/R connector terminal 63 and alternator connector terminal 4. 63 - 4 : Continuity should exist.
OK or NG OK >> Replace IPDM E/R. (Do not replace alternator, since it is normal.) NG >> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.)
6. CONTINUITY INSPECTION
1. 2. 3. Turn ignition switch OFF. Disconnect combination meter connector. Check continuity between combination meter connector terminal 38 and ground, and combination meter connector terminal 38 and alternator connector terminal 3. 38 - Ground 38 - 3 : Continuity should not exist. : Continuity should exist.
OK or NG OK >> Replace combination meter. (Do not replace alternator, since it is normal.) NG >> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.)
SC-36
CHARGING SYSTEM
INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION
CAUTION: Check them using charged battery performed battery inspection.
A
1. VOLTAGE INSPECTION
1. 2. Increase engine speed to 2,500 rpm. 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.)
B
C
D
E
MKIA0067E
2. CURRENT INSPECTION
1. 2. 3.
F
INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION
Turn ignition switch OFF. Disconnect the battery ground cable. G 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 subharness between alternator terminal B and the vehicle side harH 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. I 6. Turn electrical load to ON. (Headlamp LO turns on, blower fan motor maximum airflow amount, rear window defogger) 7. Check alternator terminal B current. J CAUTION: Be careful of rotating parts because the engine is running. MKIA0068E Is the inspection result 30A or more? SC YES >> GO TO dark current inspection. Refer to SC-38, "DARK CURRENT INSPECTION" . (Alternator is normal. Do not replace.) NO >> Replace alternator. (Alternator power generation error.) L
1. ALTERNATOR VOLTAGE INSPECTION
M
1. Increase engine speed to 2,500 rpm. 2. Check battery voltage. Is the inspection result 16V or less? YES >> GO TO 2. NO >> Replace alternator. (Excessive alternator power generation.)
MKIA0067E
SC-37
CHARGING SYSTEM
2. BATTERY VOLTAGE INSPECTION
1. 2. 3. 4. Turn ignition switch OFF. Disconnect alternator connector. Turn ignition switch ON. Check voltage between alternator connector terminal 4 and ground. 4 - Ground : 12V or more
Is the inspection result 12V or more? YES >> Replace alternator. (Alternator power generation error) NO >> GO TO 3.
MKIB1731E
3. CONNECTOR INSPECTION
1. 2. Turn ignition switch OFF. Check IPDM E/R and terminals (IPDM E/R side, and harness side) for damage, deformation or improper connection. OK or NG OK >> GO TO 4. NG >> Repair terminals and connectors.
4. CONTINUITY INSPECTION
1. 2. Disconnect IPDM E/R connector. Check continuity between IPDM E/R connector terminal 63 and alternator connector terminal 4. 63 - 4 : Continuity should exist.
OK or NG OK >> Replace IPDM E/R. (Do not replace alternator, since it is normal.) NG >> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.)
DARK CURRENT INSPECTION
Dark Current: Small current while ignition switch is "OFF". NOTE: q 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. q Do not connect CONSULT-II CONVERTER to data link connector when measuring dark current. CONSULT-II power should be supplied using AC adapter or internal battery. 1. Attach current measurement probe for CONSULT-II to battery ground cable. Refer to SC-39, "OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II" . 2. Check that all electrical equipment is turned OFF. 3. Remove key. Close and lock doors. Check that room lamp turns off. 4. Measure dark current. Is it 50mA or less? Refer to SC-39, "OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II" . NOTE: MKIA0070E Dark current stable time is different due to equipment and use of the vehicle. If it is not 50mA or less after leaving for 1 minute, measure dark current again after leaving for 30 minutes or more. If YES, GO TO 7. If NO, GO TO 5. 5. Remove and install fuses one by one. Search for the fuse that greatly changes dark current.
SC-38
CHARGING SYSTEM
NOTE: If dark current is greatly reduced when removing the fuse, and even if dark current is not greatly increased when installing it again, the fuse circuit may be the cause. 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. No malfunction for alternator and electrical equipment. Electric load may be larger than alternator generating ability. Check the customer's usage.
A
6.
B
7.
C
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".
D
E
F
G
MKIA0071E
H
5.
6.
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.) 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.
I
J
SC
MKIA0072E
L
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 generally.
M
MKIA0073E
SC-39
CHARGING SYSTEM
8. Align current direction mark, clamp harness, and measure current. If current direction is incorrect, it is displayed negative value. NOTE: q When current is measured, close probe joint securely. q If multiple harnesses are clamped, measurement cannot be performed. Always clamp only one.
MKIA0074E
Removal and Installation (CR Engine Models)
REMOVAL
1. 2. 3. 4. Disconnect battery ground cable. Remove fender protector from RH side. Remove alternator drive belt. Refer to EM-16, "Removal and Installation" . Remove idler pulley bracket mounting bolts, and remove idler pulley assembly.
EKS007ZH
MKIA0075E
5.
Disconnect alternator harness connector. Terminal B mounting nut, ground wire mounting nut, and remove harness clips.
MKIA0076E
6. 7.
Remove engine mounting stay from RH side. Remove alternator upper bracket mounting bolts, and alternator upper mounting bolt.
MKIA0077E
SC-40
CHARGING SYSTEM
8. 9. Loosen alternator lower mounting bolt, and pull out from U-cut portion on front cover. Remove alternator assembly from engine.
A
B
C
MKIA0078E
INSTALLATION
Install in the reverse order of removal, taking care of the following point. q Install alternator, and check tension of belt. Refer to EM-14, "Tension Adjustment" . CAUTION: Be sure to tighten B terminal mounting nut carefully. B terminal nut: Ground bolt: Alternator mounting bolt: Alternator upper bracket bolt: Engine mounting stay bolt: Idler pulley bracket bolt: Idler pulley nut: : 9.32 - 10.8 N·m (0.95 - 1.1 kg-m, 82 - 95 in-lb) : 2.94 - 4.9 N·m (0.30 - 0.49 kg-m, 26 - 43 in-lb) : 33.3 - 46.1 N·m (3.4 - 4.7 kg-m, 24 - 34 ft-lb) : 33.3 - 46.1 N·m (3.4 - 4.7 kg-m, 24 - 34 ft-lb) : 40.0 - 50.0 N·m (4.1 - 5.1 kg-m, 30 - 37 ft-lb) : 16.6 - 23.5 N·m (1.7 - 2.4 kg-m, 12 - 17 ft-lb) : 25.5 - 33.3 N·m (2.6 - 3.3 kg-m, 19 - 24 ft-lb)
EKS00P1A
D
E
F
G
H
I
Removal and Installation (HR Engine Models)
REMOVAL
1. 2. 3. 4. 5.
J
Disconnect battery ground cable. Remove fender protector from RH side. Remove alternator drive belt. Refer to EM-116, "Removal and Installation" . Remove idler pulley assembly. Refer to EM-117, "Removal and Installation of Drive Belt Idler Pulley" . Disconnect alternator harness connector. q B terminal mounting nut, ground wire mounting nut, and remove harness clips.
SC
L
M
MKIB1996E
6.
Remove A/C compressor. Refer to ATC-95, "Removal and Installation for Compressor" (with auto A/C) or MTC-68, "Removal and Installation for Compressor" (with manual A/C).
SC-41
CHARGING SYSTEM
7. Remove torque rod bolt.
MKIB1997E
8.
Remove alternator mounting upper bolt.
MKIB1998E
9. Loosen alternator mounting lower bolt. 10. Remove alternator assembly from lower side the vehicle.
MKIB1999E
INSTALLATION
Install in the reverse order of removal, taking care of the following point. q Install alternator, and check tension of belt. Refer to EM-115, "Tension Adjustment" . CAUTION: Be sure to tighten B terminal mounting nut carefully. B terminal nut: Ground bolt: Alternator mounting bolt: Torque rod bolt: Idler pulley bolt: : 9.32 - 10.8 N·m (0.95 - 1.1 kg-m, 82 - 95 in-lb) : 2.94 - 4.9 N·m (0.30 - 0.49 kg-m, 26 - 43 in-lb) : 21.0 - 29.0 N·m (2.2 - 2.9kg-m, 16 - 21ft-lb) : 40.0 - 50.0 N·m (4.1 - 5.1 kg-m, 30 - 37 ft-lb) : 24.0 - 32.0 N·m (2.5 - 3.2kg-m, 18 - 23ft-lb)
SC-42
CHARGING SYSTEM Removal and Installation (K9K Engine Models)
REMOVAL
1. 2. 3. 4. 5. Disconnect battery ground cable. Remove under cover and RH fender protector. Remove front bumper. Refer to EI-5, "FRONT BUMPER" . Remove alternator drive belt. Refer to EM-244, "DRIVE BELTS" . Disconnect alternator harness connector and B terminal nut.
EKS00K2X
A
B
C
D
MKIA0086E
6.
Remove alternator upper mounting bolt.
E
F
G
MKIA0087E
H
7. 8.
Remove alternator lower mounting bolt. Remove alternator assembly from engine.
I
J
SC
MKIA0088E
INSTALLATION
Install in the reverse order of removal, taking care of the following point. q Install alternator, and check tension of belt. Refer to EM-244, "DRIVE BELTS" . CAUTION: Be sure to tighten B terminal mounting nut carefully.
L
M
Disassembly
REAR COVER
EKS007ZJ
SEL032Z
SC-43
CHARGING SYSTEM
CAUTION: Rear cover may be hard to remove because a ring is used to lock outer race of rear bearing. To facilitate 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: q Do not reuse rear bearing after removal. Replace with a new one. q Do not lubricate rear bearing outer race.
Inspection
ROTOR CHECK
1. Resistance test Resistance : Refer to SC-61, "SERVICE DATA AND SPECIFICATIONS (SDS)" .
EKS007ZK
2. 3.
q Not within the specified values... Replace rotor. Insulator test q Continuity exists... Replace rotor. Check slip ring for wear.
Slip ring minimum outer diameter
q
: Refer to SC-61, "SERVICE DATA AND SPECIFICATIONS (SDS)" .
SEL033Z
Not within the specified values... Replace rotor.
BRUSH CHECK
1. 2. Check smooth movement of brush. q Not smooth... Check brush holder and clean. Check brush for wear. q Replace brush if it is worn down to the limit line.
SEL631DA
STATOR CHECK
1. Continuity test q No continuity... Replace stator.
SEL108E
SC-44
CHARGING SYSTEM
2. Ground test q Continuity exists... Replace stator.
A
B
C
SEL109E
Assembly
RING FITTING IN REAR BEARING
q
D
EKS007ZL
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.
E
F
G
SEL044Z
H
REAR COVER INSTALLATION
1. Fit brush assembly, diode assembly, regulator assembly and stator.
I
J
SC
SEL048Z
L
2. Push brushes up with fingers and install them to rotor. Take care not to damage slip ring sliding surface.
M
SEL049Z
SC-45
STARTING SYSTEM STARTING SYSTEM System Description
M/T MODELS
Power is supplied at all times q through 40A fusible link (letter H, located in the fuse and fusible link box) q to ignition switch terminal 1. With the ignition switch in the ON or START position, power is supplied q through 10A fuse [No.50 located in the IPDM E/R] q to park/neutral position switch terminal 2 q through 10A fuse [No.4, located in fuse block (J/B)] q through IPDM E/R terminal 21 q to starter relay. With the shift lever in the N position (under the ignition switch ON or START position) Power is supplied q through park/neutral position switch terminal 2 and 3 q to IPDM E/R terminal 31 and then starter relay is energized. When ignition switch turn to START position, power is supplied q through ignition switch terminal 1 and 5 q through IPDM E/R terminal 9 and 11 q to starter motor terminal 1. The starter motor plunger closes and provides a closed circuit between the battery and starter motor. The starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the engine starts.
PFP:00011
EKS007ZM
A/T MODELS
Power is supplied at all times q through 40A fusible link (letter H, located in the fuse and fusible link box) q to ignition switch terminal 1. With the ignition switch in the ON or START position, power is supplied q through 10A fuse [No. 50 located in the IPDM E/R] q to park/neutral position switch terminal 1. With the selector lever in the P or N position (under the ignition switch ON or START position) Power is supplied q through park/neutral position switch terminal 1 and 2 q through IPDM E/R terminal 21 q to starter relay. q through park/neutral position switch terminal 1 and 2 q to IPDM E/R terminal 31. and then starter relay is energized. When ignition switch turn to START position, power is supplied q through ignition switch terminal 1 and 5 q through IPDM E/R terminal 9 and 11 q to starter motor terminal 1 The starter motor plunger closes and provides a closed circuit between the battery and starter motor. The starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the engine starts.
SC-46
STARTING SYSTEM Wiring Diagram -- START -- /CR and HR Engine Models
EKS007ZN
A
B
C
D
E
F
G
H
I
J
SC
L
M
MKWA4066E
SC-47
STARTING SYSTEM
MKWA4067E
SC-48
STARTING SYSTEM Wiring Diagram -- START -- /K9K Engine Models
EKS00K2Z
A
B
C
D
E
F
G
H
I
J
SC
L
M
MKWA3477E
SC-49
STARTING SYSTEM
MKWA4231E
SC-50
STARTING SYSTEM Trouble Diagnoses
If any abnormality is found, immediately disconnect battery negative terminal.
EKS007ZQ
A
B
C
D
E
F
G
H
I
J
SC
L
M
SEL761W
SC-51
STARTING SYSTEM Removal and Installation (CR Engine Models)
REMOVAL
1. 2. 3. 4. 5. Disconnect negative battery cable. Remove starter motor mounting bolt from upper side. Disconnect S terminal and B terminal from starter motor. Remove starter motor mounting bolt from lower side. Remove starter motor from lower side the vehicle.
EKS007ZR
MKIA0080E
INSTALLATION
Install in the reverse order of removal.
Removal and Installation (HR Engine Models)
EKS00P1B
PKIC0987E
1. 4.
Cylinder block Starter motor : Engine front
2.
B terminal harness : N·m (kg-m, ft-lb)
3.
S terminal harness : N·m (kg-m, in-lb)
REMOVAL
1. 2. 3. Disconnect the battery cable from the negative terminal. Remove air duct (inlet). Refer to EM-119, "AIR CLEANER AND AIR DUCT" . Remove reservoir tank. Refer to.CO-38, "RADIATOR" .
SC-52
STARTING SYSTEM
4. 5. 6. 7. Disconnect "S" terminal nut. Remove "B" terminal nut. Remove starter motor mounting bolts. Remove starter motor upward from the vehicle.
A
INSTALLATION
Installation is the reverse order of removal. CAUTION: Be sure to tighten "B" terminal nut carefully.
B
C
EKS00K30
Removal and Installation (K9K Engine Models)
REMOVAL
1. 2. 3. 4. 5. Disconnect negative battery cable. Remove starter motor mounting bolt from upper side. Disconnect S terminal and B terminal from starter motor. Remove starter motor mounting bolt from lower side. Remove starter motor from lower side the vehicle.
D
E
F
G
MKIA0089E
INSTALLATION
Install in the reverse order of removal.
H
EKS007ZS
Disassembly and Assembly
I
J
SC
L
M
MKIB1994E
1. 4. 7.
Gear case Plate Magnetic switch assembly
2. 5. 8.
Sleeve bearing Packing Stopper clip
3. 6. 9.
Shift lever Adjusting plate Pinion stopper
SC-53
STARTING SYSTEM
10. Pinion assembly 13. Planetary gear 16. Yoke 19. Rear bearing 11. Internal gear 14. Ball 17. Armature 20. Rear cover 12. Pinion shaft 15. Packing 18. Brush holder assembly
Through-bolt: M0T84585 : 4.1 - 7.1 N·m (0.45 - 0.72 kg-m, 39.1 - 62.5 in-lb)
MKIA0082E
1. 4. 7.
Bushing Stopper clip Pinion assembly
2. 5. 8.
Gear case Pinion stopper Shift lever
3. 6. 9.
Magnetic switch assembly Bushing Armature
10. Packing 13. Rear cover
11. Yoke 14. Bushing
12. Brush holder 15. Cap
SC-54
STARTING SYSTEM
A
B
C
D
E
F
G
H
MKIB1995E
1. 4. 7.
Gear case Packing Stopper
2. 5. 8.
Shift lever Magnetic switch assembly Clutch gear assembly
3. 6. 9.
Plate Ring Internal gear assembly
I
10. Shaft assembly gear 13. Though-bolt 16. Brush holder assembly
11. Gear assembly 14. Yoke assembly 17. E-ring
12. Packing 15. Armature 18. Rear cover assembly
J
SC
L
M
SC-55
STARTING SYSTEM Inspection
MAGNETIC SWITCH CHECK
q q
EKS007ZT
1.
Before starting to check, disconnect battery ground cable. Disconnect "M" terminal of starter motor. Continuity test (between "S" terminal and switch body). q No continuity... Replace.
SEL555E
2.
Continuity test (between "S" terminal and "M" terminal). q No continuity... Replace.
SEL556E
PINION/CLUTCH CHECK
1. Inspect pinion teeth. q Replace pinion if teeth are worn or damaged. (Also check condition of ring gear teeth.) Inspect reduction gear teeth (If equipped). q 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. q If it locks or rotates in both directions, or unusual resistance is evident.... Replace.
2.
3.
MEL139L
BRUSH CHECK Brush
Check wear of brush. Wear limit length : Refer to SC-61, "SERVICE DATA AND SPECIFICATIONS (SDS)" .
q
Excessive wear... Replace.
SEL014Z
SC-56
STARTING SYSTEM
Brush Spring Check
Check brush spring pressure with brush spring detached from brush. Spring pressure (with new brush)
q
A
: Refer to SC-61, "SERVICE DATA AND SPECIFICATIONS (SDS)" .
B
Not within the specified values... Replace.
C
SEL015Z
D
Brush Holder
1. Perform insulation test between brus