STARTING & CHARGING SYSTEM GI

SECTION SC MA

EM

LC

EC

CONTENTS FE

PRECAUTIONS ...............................................................2 Assembly ...................................................................26

CL
Supplemental Restraint System (SRS) ″AIR PINION PROTRUSION LENGTH ADJUSTMENT ........26
BAG″ and ″SEAT BELT PRE-TENSIONER″...............2 CHARGING SYSTEM ....................................................28 MT
Wiring Diagrams and Trouble Diagnoses....................2 System Description....................................................28
BATTERY.........................................................................3 SEDAN ...................................................................28
How to Handle Battery ................................................3 HATCHBACK...........................................................28 AT
METHODS OF PREVENTING OVER-DISCHARGE ......3 Wiring Diagram - CHARGE -/Sedan .........................29
CHECKING ELECTROLYTE LEVEL ............................3 GASOLINE ENGINE MODELS EXCEPT FOR
SPECIFIC GRAVITY CHECK ......................................4 EUROPE .................................................................29 AX
Battery Test and Charging Chart.................................6 GASOLINE ENGINE MODELS FOR EUROPE ...........30
CHART I ...................................................................6 DIESEL ENGINE MODELS .......................................31
CHART II ..................................................................7 Wiring Diagram - CHARGE -/Hatchback...................32 SU
A: SLOW CHARGE ....................................................8 Trouble Diagnoses.....................................................33
B: STANDARD CHARGE ..........................................10 WITH IC REGULATOR .............................................33
C: QUICK CHARGE .................................................11 MALFUNCTION INDICATOR ....................................33 BR
STARTING SYSTEM .....................................................13 Construction...............................................................34
System Description....................................................13 Removal and Installation ...........................................37
ST
M/T MODELS ..........................................................13 REMOVAL (QG ENGINE) .........................................37
A/T MODELS ...........................................................13 REMOVAL (YD ENGINE)..........................................37
Wiring Diagram - START -/Sedan .............................15 INSTALLATION........................................................38
RS
M/T MODELS ..........................................................15 Disassembly...............................................................38
A/T MODELS EXCEPT FOR EUROPE ......................16 REAR COVER .........................................................38
A/T MODELS FOR EUROPE ....................................17 REAR BEARING ......................................................38 BT
Wiring Diagram - START -/Hatchback.......................18 Inspection...................................................................38
Trouble Diagnoses.....................................................19 ROTOR CHECK ......................................................38
Construction...............................................................20 BRUSH CHECK .......................................................39 HA
Removal and Installation ...........................................23 STATOR CHECK .....................................................39
REMOVAL ...............................................................23 Assembly ...................................................................39
INSTALLATION........................................................23 RING FITTING IN REAR BEARING ...........................39
Inspection...................................................................23 REAR COVER INSTALLATION .................................40
MAGNETIC SWITCH CHECK ...................................23 SERVICE DATA AND SPECIFICATIONS (SDS) .........41
PINION/CLUTCH CHECK .........................................23 Battery........................................................................41 EL
BRUSH CHECK .......................................................24 Starter ........................................................................41
YOKE CHECK .........................................................25 Alternator ...................................................................42
ARMATURE CHECK ................................................25
IDX
 PRECAUTIONS
Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

Supplemental Restraint System (SRS) “AIR

BAG” and “SEAT BELT PRE-TENSIONER” NJSC0001
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of
collision. The SRS system composition which is available to NISSAN MODEL N16 is as follows (The compo-
sition varies according to the destination and optional equipment.):
I For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the steer-
ing wheel), front passenger air bag module (located on the instrument panel on passenger side), front seat
belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
I For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of front
seat), side air bag (satellite) sensor, diagnosis sensor unit (one of components of air bags for a frontal
collision), wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
I To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance should be per-
formed by an authorized NISSAN dealer.
I 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 RS section.
I 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 harness connector.
Wiring Diagrams and Trouble Diagnoses NJSC0002
When you read wiring diagrams, refer to the following:
I GI-12, “HOW TO READ WIRING DIAGRAMS”
I EL-11, “POWER SUPPLY ROUTING” for power distribution circuit
When you perform trouble diagnoses, refer to the following:
I GI-33, “HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES”
I GI-22, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”

SC-2
 BATTERY
How to Handle Battery

How to Handle Battery NJSC0003

CAUTION:
If it becomes necessary to start the engine with a booster GI
battery and jumper cables,
1) Use a 12-volt booster battery.
MA
2) After connecting battery cables, ensure that they are
tightly clamped to battery terminals for good contact.
3) Never add distilled water through the hole used to check EM
specific gravity.

LC
METHODS OF PREVENTING OVER-DISCHARGE NJSC0003S01
The following precautions must be taken to prevent over-discharg- EC
ing a battery.
I The battery surface (particularly its top) should always be kept
clean and dry. FE
I The terminal connections should be clean and tight.
I At every routine maintenance, check the electrolyte level.
This also applies to batteries designated as “low maintenance” CL
and “maintenance-free”.

MEL040F
MT
I When the vehicle is not going to be used over a long period of
time, disconnect the negative battery terminal. AT

AX

SU

BR
MEL041F

I Check the charge condition of the battery.

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

BT

HA
MEL042F

CHECKING ELECTROLYTE LEVEL NJSC0003S02

WARNING:
Do not allow battery fluid to come in contact with skin, eyes,
fabrics, or painted surfaces. After touching a battery, do not EL
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. IDX

SC-3
 BATTERY
How to Handle Battery (Cont’d)
I Remove the cell plug using a suitable tool.
I Add distilled water up to the MAX level.

MEL043F

Sulphation NJSC0003S0201
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 volt-
age 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 ser-
vice by means of a long, slow charge, 12 hours or more, fol-
lowed by a battery capacity test.
SEL709E

SPECIFIC GRAVITY CHECK NJSC0003S03

1. Read hydrometer and thermometer indications at eye level.

MEL042FA

2. Convert into specific gravity at 20°C (68°F).

Example:
I When electrolyte temperature is 35°C (95°F) and specific grav-
ity of electrolyte is 1.230, converted specific gravity at 20°C
(68°F) is 1.240.
I When electrolyte temperature is 0°C (32°F) and specific grav-
ity of electrolyte is 1.210, converted specific gravity at 20°C
(68°F) is 1.196.

SC-4
BATTERY
How to Handle Battery (Cont’d)

GI

MA

EM

LC

EC

FE

SEL007Z CL

MT

AT

AX

SU

BR

ST

RS

BT

HA

EL

IDX

SC-5
 BATTERY
Battery Test and Charging Chart

Battery Test and Charging Chart NJSC0017

CHART I NJSC0017S01

SEL754W

*1: SC-4 *3: SC-8 *5: SC-11

*2: SC-7 *4: SC-10

SC-6
 BATTERY
Battery Test and Charging Chart (Cont’d)
CHART II NJSC0017S02

GI

MA

EM

LC

EC

FE

CL

MT

AT

SEL755W
AX

*: SC-6
SU
I Check battery type and determine the specified current using the following table.
Fig. 1 DISCHARGING CURRENT (Load Tester)
BR
Type Current (A)
ST
28B19R(L) 90

34B19R(L) 99
RS
46B24R(L) 135

55B24R(L) 135
BT
50D23R(L) 150

55D23R(L) 180 HA
65D26R(L) 195

80D26R(L) 195

75D31R(L) 210

95D31R(L) 240 EL
115D31R(L) 240

025 [YUASA type code (Hatchback)] 240 IDX

027 [YUASA type code (Hatchback)] 285

110D26R(L) 300

SC-7
 BATTERY
Battery Test and Charging Chart (Cont’d)

Type Current (A)

95E41R(L) 300

067 [YUASA type code (Hatchback)] 325

130E41R(L) 330

096 [YUASA type code (Hatchback)] 375

A: SLOW CHARGE NJSC0017S03

SEL756W

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

SC-8
 BATTERY
Battery Test and Charging Chart (Cont’d)
Fig. 2 INITIAL CHARGING CURRENT SETTING (Slow charge)
BATTERY TYPE
GI

025 [YUASA type code (Hatchback)]

027 [YUASA type code (Hatchback)]

067 [YUASA type code (Hatchback)]

096 [YUASA type code (Hatchback)]

MA

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)

95E41R(L)
SPECIFIC EM
GRAVITY

LC

EC

8.5 9.0 14.0

Below 1.100 4.0 (A) 5.0 (A) 7.0 (A) 8.0 (A)
(A) (A)
10.0 (A)
(A) FE

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

Fig. 3 ADDITIONAL CHARGE (Slow charge) MT

AT

AX

SU

SEL757W
BR
*: SC-7
ST
CAUTION:
I Set charging current to value specified in Fig. 2. If charger is not capable of producing specified RS
current value, set its charging current as close to that value as possible.
I Keep battery away from open flame while it is being charged.
I When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, BT
as this may cause a spark.
I If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its
temperature is below 60°C (140°F). HA

EL

IDX

SC-9
 BATTERY
Battery Test and Charging Chart (Cont’d)
B: STANDARD CHARGE NJSC0017S04

SEL758W

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

Fig. 4 INITIAL CHARGING CURRENT SETTING (Standard charge)

BATTERY TYPE
025 YUASA type code (Hatchback)

027 YUASA type code (Hatchback)

067 YUASA type code (Hatchback)

096 YUASA type code (Hatchback)

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)

95E41R(L)
SPECIFIC
GRAVITY

8.0 13.0
1.100 - 1.130 4.0 (A) 5.0 (A) 6.0 (A) 7.0 (A) 9.0 (A)
(A) (A)

7.0 11.0
1.130 - 1.160 3.0 (A) 4.0 (A) 5.0 (A) 6.0 (A) 8.0 (A)
(A) (A)

6.0 9.0
1.160 - 1.190 2.0 (A) 3.0 (A) 4.0 (A) 5.0 (A) 7.0 (A)
(A) (A)

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)

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

SC-10
 BATTERY
Battery Test and Charging Chart (Cont’d)
Fig. 5 ADDITIONAL CHARGE (Standard charge)

GI

MA

EM

LC
SEL759W

*: SC-7 EC

CAUTION: FE
I Do not use standard charge method on a battery whose specific gravity is less than 1.100.
I 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. CL
I Keep battery away from open flame while it is being charged.
I When connecting charger, connect leads first, then turn on charger. Do not turn on charger first,
as this may cause a spark. MT
I If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its
temperature is below 60°C (140°F).
AT
C: QUICK CHARGE NJSC0017S05

AX

SU

BR

ST
SEL760W

*: SC-7 RS

BT

HA

EL

IDX

SC-11
 BATTERY
Battery Test and Charging Chart (Cont’d)
Fig. 6 INITIAL CHARGING CURRENT SETTING AND CHARGING TIME (Quick charge)

025 [YUASA type code (Hatchback)]

027 [YUASA type code (Hatchback)]

067 [YUASA type code (Hatchback)]

096 [YUASA type code (Hatchback)]

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)
CONVERTED SPECIFIC GRAVITY

1.100 -
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

I Check battery type and determine the specified current using the table shown above.
I After starting charging, adjustment of charging current is not necessary.
CAUTION:
I Do not use quick charge method on a battery whose specific gravity is less than 1.100.
I 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.
I Keep battery away from open flame while it is being charged.
I When connecting charger, connect leads first, then turn on charger. Do not turn on charger first,
as this may cause a spark.
I 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).
I Do not exceed the charging time specified in Fig. 6, because charging battery over the charging
time can cause deterioration of the battery.

SC-12
 STARTING SYSTEM
System Description

System Description NJSC0004

M/T MODELS
Power is supplied at all times
NJSC0004S01
GI
I through 40A fusible link (letter B, located in the fuse and fusible link box)
I to ignition switch terminal 1. MA
Models with Theft Warning System NJSC0004S0101
With the ignition switch in the START position, power is supplied EM
I from ignition switch terminal 5
I to theft warning relay terminal 3.
If the theft warning system is triggered, ground is supplied LC
I through smart entrance control unit terminal 19
I to theft warning relay terminal 2. EC
Then power to the starter motor is interrupted.
If the theft warning system is not triggered, power is supplied
I through theft warning relay terminal 4 FE
I to starter motor harness connector terminal 1.
Models without Theft Warning System CL
NJSC0004S0102
With the ignition switch in START position, power is supplied
I from ignition switch terminal 5 MT
I 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 AT
starts.
A/T MODELS NJSC0004S02 AX
Power is supplied at all times
I through 40A fusible link (letter B, located in the fuse and fusible link box)
I to ignition switch terminal 1. SU
With the ignition switch in the START position, power is supplied
I from ignition switch terminal 5 BR
I to park/neutral position relay terminal 5.
Models with Theft Warning System NJSC0004S0201 ST
With the ignition switch ON or START position, power is supplied
I through 10A fuse [No. 20, located in the fuse block (J/B)]
I to theft warning relay terminals 1 and 3. RS
If the theft warning system is triggered, ground is supplied
I through smart entrance control unit terminal 19 BT
I to theft warning relay terminal 2.
Then power to the starter motor is interrupted.
If the theft warning system is not triggered, power is supplied HA
I through theft warning relay terminal 4
I to park/neutral position (PNP) relay terminal 1.
Models without Theft Warning System NJSC0004S0202
With the ignition switch ON or START position, power is supplied
EL
I through 10A fuse [No. 20, located in the fuse block (J/B)]
I to park/neutral position (PNP) relay terminal 1.
With the selector lever in the P or N position, ground is supplied IDX
I to park/neutral position relay terminal 2 through the park/neutral position switch
I from body grounds, F9 and F10.
Then park/neutral position relay is energized and power is supplied
I from park/neutral position relay terminal 3
SC-13
 STARTING SYSTEM
System Description (Cont’d)
I 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-14
 STARTING SYSTEM
Wiring Diagram — START —/Sedan

Wiring Diagram — START —/Sedan NJSC0005

M/T MODELS NJSC0005S03
GI

MA

EM

LC

EC

FE

CL

MT

AT

AX

SU

BR

ST

RS

BT

HA

EL

IDX

HSC018

SC-15
 STARTING SYSTEM
Wiring Diagram — START —/Sedan (Cont’d)
A/T MODELS EXCEPT FOR EUROPE NJSC0005S04

HSC019

SC-16
 STARTING SYSTEM
Wiring Diagram — START —/Sedan (Cont’d)
A/T MODELS FOR EUROPE NJSC0005S05

GI

MA

EM

LC

EC

FE

CL

MT

AT

AX

SU

BR

ST

RS

BT

HA

EL

IDX

HSC013

SC-17
 STARTING SYSTEM
Wiring Diagram — START —/Hatchback

Wiring Diagram — START —/Hatchback NJSC0028

MEL936L

SC-18
 STARTING SYSTEM
Trouble Diagnoses

Trouble Diagnoses NJSC0018

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

MA

EM

LC

EC

FE

CL

MT

AT

AX

SU

BR

ST

RS

BT

HA

EL
SEL761W
IDX

SC-19
 STARTING SYSTEM
Construction

Construction NJSC0006

MEL674E

SEL027UC

SC-20
STARTING SYSTEM
Construction (Cont’d)

GI

MA

EM

LC

EC

FE

CL

MT

AT
MEL673E
AX

SU

BR

ST

RS

BT

HA

EL

IDX

MEL136LA

SC-21
 STARTING SYSTEM
Construction (Cont’d)

MEL613LB

MEL232M

SC-22
 STARTING SYSTEM
Removal and Installation

Removal and Installation NJSC0007

REMOVAL
1. Remove intake air duct and air cleaner assembly.
NJSC0007S01
GI
2. Disconnect starter harness.
3. Remove starter bolts (two). MA
4. Remove starter.

EM

SEL909TA LC
INSTALLATION NJSC0007S02
To install, reverse the removal procedure. EC

FE

CL

MEL137L
MT
Inspection NJSC0019
MAGNETIC SWITCH CHECK AT
NJSC0019S01
I Before starting to check, disconnect battery ground cable.
I Disconnect “M” terminal of starter motor. AX
1. Continuity test (between “S” terminal and switch body).
I No continuity ... Replace.
2. Continuity test (between “S” terminal and “M” terminal). SU
I No continuity ... Replace.
BR

ST

RS

BT

HA
MEL138L

PINION/CLUTCH CHECK NJSC0019S02

1. Inspect pinion teeth.
I Replace pinion if teeth are worn or damaged. (Also check
condition of ring gear teeth.) EL
2. Inspect reduction gear teeth (If equipped).
I Replace reduction gear if teeth are worn or damaged. (Also IDX
check condition of armature shaft gear teeth.)
3. Check to see if pinion locks in one direction and rotates
smoothly in the opposite direction.
I If it locks or rotates in both directions, or unusual resistance is
MEL139L evident. ... Replace.
SC-23
 STARTING SYSTEM
Inspection (Cont’d)
BRUSH CHECK NJSC0019S03
Brush NJSC0019S0301
Check wear of brush.
Wear limit length:
Refer to SDS (SC-41).
I Excessive wear ... Replace.

SEL014Z

Brush Spring Check NJSC0019S0302

Check brush spring pressure with brush spring detached from
brush.
Spring pressure (with new brush):
Refer to SDS (SC-41).
I Not within the specified values ... Replace.

SEL015Z

Brush Holder NJSC0019S0303

1. Perform insulation test between brush holder (positive side)
and its base (negative side).
I Continuity exists. ... Replace.
2. Check brush to see if it moves smoothly.
I If brush holder is bent, replace it; if sliding surface is dirty,
clean.

SEL016Z

SC-24
 STARTING SYSTEM
Inspection (Cont’d)
YOKE CHECK NJSC0019S04
Magnet is secured to yoke by bonding agent. Check magnet to see
that it is secured to yoke and for any cracks. Replace malfunction- GI
ing parts as an assembly.
CAUTION:
Do not clamp yoke in a vice or strike it with a hammer. MA

EM

LC

EC

FE

CL

SEL018Z
MT
ARMATURE CHECK NJSC0019S05
1. Continuity test (between two segments side by side). AT
I No continuity ... Replace.
2. Insulation test (between each commutator bar and shaft).
AX
I Continuity exists. ... Replace.

SU

BR
SEL019Z

3. Check commutator surface.

I Rough ... Sand lightly with No. 500 - 600 emery paper.
ST

RS

BT

HA
SEL020Z

4. Check diameter of commutator.

Commutator minimum diameter:
Refer to SDS (SC-41).
I Less than specified value ... Replace. EL

IDX

SEL021Z

SC-25
 STARTING SYSTEM
Inspection (Cont’d)
5. Check depth of insulating mold from commutator surface.
I Less than 0.2 mm (0.008 in) ... Undercut to 0.5 to 0.8 mm
(0.020 to 0.031 in)

SEL022Z

Assembly NJSC0020
Apply high-temperature grease to lubricate the bearing, gears and
frictional surface when assembling the starter.
Carefully observe the following instructions.

PINION PROTRUSION LENGTH ADJUSTMENT NJSC0020S01

Clearance (QG engine models) NJSC0020S0101
With pinion driven out by magnetic switch, push pinion back to
remove slack and measure clearance “” between the front edge
of the pinion and the pinion stopper.
Clearance “”:
Refer to SDS (SC-41).

SEL026Z

Movement (YD engine models) NJSC0020S0102

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-41).

MEL140L

SC-26
 STARTING SYSTEM
Assembly (Cont’d)
I Not in the specified value ... Adjust by adjusting plate.

GI

MA

EM

SEL633BA LC

EC

FE

CL

MT

AT

AX

SU

BR

ST

RS

BT

HA

EL

IDX

SC-27
 CHARGING SYSTEM
System Description

System Description NJSC0009

SEDAN NJSC0009S01
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:
I 10A fuse (No. 33, 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 80A (A/T models with QG13DE engine and M/T models with gasoline engine) or 100A (A/T models
except QG13DE engine and diesel engine models) fusible link.
The alternator is grounded to the engine block.
With the ignition switch in the ON or START position, power is supplied
I through 10A fuse [No. 30, located in the fuse block (J/B)]
I to combination meter terminal 17 (Models with tachometer) or 22 (Models without tachometer) for the
charge warning lamp.
Ground is supplied to terminal 62 (Models with tachometer) or 61 (Models without tachometer) of the combi-
nation meter through terminal 3 (L) of the alternator. With power and ground supplied, the charge warning lamp
will illuminate. When the alternator is providing sufficient voltage with the engine running, the ground is opened
and the charge warning lamp will go off.
If the charge warning lamp illuminates with the engine running, a fault is indicated.
HATCHBACK NJSC0009S02
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:
I 10A fuse (No. 33, 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 80A (Gasoline engine models without daytime light system) or 100A (A/T models, diesel engine mod-
els and gasoline engine models with daytime light system) fusible link.
The alternator is grounded to the engine block.
With the ignition switch in the ON or START position, power is supplied
I through 10A fuse [No. 30, located in the fuse block (J/B)]
I to combination meter terminal 40
Ground is supplied to terminal 1 of the combination meter through terminal 3 (L) of the alternator. With power
and ground supplied, the charge warning lamp will illuminate. When the alternator is providing sufficient volt-
age 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-28
 CHARGING SYSTEM
Wiring Diagram — CHARGE —/Sedan

Wiring Diagram — CHARGE —/Sedan NJSC0010

GASOLINE ENGINE MODELS EXCEPT FOR EUROPE NJSC0010S01
GI

MA

EM

LC

EC

FE

CL

MT

AT

AX

SU

BR

ST

RS

BT

HA

EL

IDX

GSC012A

SC-29
 CHARGING SYSTEM
Wiring Diagram — CHARGE —/Sedan (Cont’d)
GASOLINE ENGINE MODELS FOR EUROPE NJSC0010S02

HSC014

SC-30
 CHARGING SYSTEM
Wiring Diagram — CHARGE —/Sedan (Cont’d)
DIESEL ENGINE MODELS NJSC0010S03

GI

MA

EM

LC

EC

FE

CL

MT

AT

AX

SU

BR

ST

RS

BT

HA

EL

IDX

GSC013A

SC-31
 CHARGING SYSTEM
Wiring Diagram — CHARGE —/Hatchback

Wiring Diagram — CHARGE —/Hatchback NJSC0029

MEL937L

SC-32
 CHARGING SYSTEM
Trouble Diagnoses

Trouble Diagnoses NJSC0011

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 Inspec- GI
tion Table.
I Before starting, inspect the fusible link.
MA
I Use fully charged battery.
WITH IC REGULATOR NJSC0011S01
EM

LC

EC

FE

CL

MT

AT

AX

SU

BR
SEL338V
ST
NOTE:
I If the inspection result is OK even though the charging system is malfunctioning, check the B terminal
connection. (Check the tightening torque.) RS
I When field circuit is open, check condition of rotor coil, rotor slip ring and brush. If necessary, replace faulty
parts with new ones.
BT
MALFUNCTION INDICATOR NJSC0011S02
The IC regulator warning function activates to illuminate “CHARGE” warning lamp, if any of the following
symptoms occur while alternator is operating: HA
I Excessive voltage is produced.
I No voltage is produced.

EL

IDX

SC-33
 CHARGING SYSTEM
Construction

Construction NJSC0012

MEL480HB

MEL141LD

SC-34
CHARGING SYSTEM
Construction (Cont’d)

GI

MA

EM

LC

EC

FE

CL

MT

AT
MEL141LA
AX

SU

BR

ST

RS

BT

HA

EL

IDX

MEL142LA

SC-35
 CHARGING SYSTEM
Construction (Cont’d)

MEL143L

MEL144L

SC-36
 CHARGING SYSTEM
Construction (Cont’d)

GI

MA

EM

LC

EC

FE

CL

MT

AT
MEL497L
AX

SU

BR

Removal and Installation NJSC0013 ST

REMOVAL (QG ENGINE) NJSC0013S01
1. Loosen drive belt idler pulley.
2. Remove drive belt idler pulley (include tightening screw). RS
3. Remove alternator harness.
4. Remove alternator upper bolt and lower bolt. BT
5. Remove alternator.

HA
MEL145L

REMOVAL (YD ENGINE) NJSC0013S03

1. Remove alternator harness.
2. Loosen alternator upper nut and lower bolt.
3. Loosen drive belt.
EL
4. Remove alternator bracket bolts (two).
5. Remove alternator upper nut and lower bolt. IDX
6. Remove alternator.

MEL146L

SC-37
 CHARGING SYSTEM
Removal and Installation (Cont’d)
INSTALLATION NJSC0013S02
To install, reverse the removal procedure.

Disassembly NJSC0021
REAR COVER NJSC0021S01
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.

SEL032Z

REAR BEARING NJSC0021S02

CAUTION:
I Do not reuse rear bearing after removal. Replace with a
new one.
I Do not lubricate rear bearing outer race.

Inspection NJSC0022
ROTOR CHECK NJSC0022S01
1. Resistance test
Resistance: Refer to SDS (SC-42).
I Not within the specified values ... Replace rotor.
2. Insulator test
I Continuity exists ... Replace rotor.
3. Check slip ring for wear.
Slip ring minimum outer diameter:
SEL033Z Refer to SDS (SC-42).
I Not within the specified values ... Replace rotor.

SC-38
 CHARGING SYSTEM
Inspection (Cont’d)
BRUSH CHECK NJSC0022S02
1. Check smooth movement of brush.
I Not smooth ... Check brush holder and clean. GI
2. Check brush for wear.
I Replace brush if it is worn down to the limit line. MA

EM

LC

EC

FE

CL

SEL034Z
MT
STATOR CHECK NJSC0022S03
1. Continuity test AT
I No continuity ... Replace stator.
2. Ground test
AX
I Continuity exists ... Replace stator.

SU

BR

ST

RS

BT

HA
SEL037Z

Assembly NJSC0023
RING FITTING IN REAR BEARING NJSC0023S01
I Fix ring into groove in rear bearing so that it is as close to the EL
adjacent area as possible.
CAUTION:
Do not reuse rear bearing after removal. IDX

SEL044Z

SC-39
 CHARGING SYSTEM
Assembly (Cont’d)
REAR COVER INSTALLATION NJSC0023S02
1. Fit brush assembly, diode assembly, regulator assembly and
stator.
2. Push brushes up with fingers and install them to rotor.
Take care not to damage slip ring sliding surface.

SEL048Z

SEL049Z

SC-40
 SERVICE DATA AND SPECIFICATIONS (SDS)
Battery

Battery NJSC0014

Applied
QG engine YD22 engine GI
model

YUASA type code (Hatch- YUASA type code (Hatch-

Type 34B19L 46B24L 55D23L 65D26L
back) back)
110D26L
MA
025 027 067 096

Capacity
12-27 12-36 12-48 12-52 12-60 12-64 12-70
EM
V-AH

Starter NJSC0015
LC
0 001 116 006 S114-570B S114-800B M2T48681 M0T83581 M8T71371

Type BOSCH HITACHI make MITSUBISHI make

EC
Non-reduction Non-reduction Reduction Non-reduction Reduction Reduction

Applied model QG engine YD22 engine

FE
System voltage V 12

Terminal voltage V 11.5 11.5 11.0 11.5 11.0 11.0

CL
Current A Less than 48 Less than 60 Less than 90 Less than 53 Less than 90 Less than 145
No-load
More than More than More than More than More than More than
MT
Revolution rpm
5,800 6,000 2,700 6,000 2,750 3,300

Minimum diameter of commutator mm

33.5 (1.319) 28.0 (1.102) 31.4 (1.236) 28.8 (1.134) 31.4 (1.236) AT
(in)

Minimum length of brush mm (in) 3.5 (0.138) 9.0 (0.354) 10.5 (0.413) 11.5 (0.453) 7.0 (0.276) 11.0 (0.433)
AX
5.2 (0.53, 1.17)
9.8 - 13.7 12.7 - 17.7 13.7 - 25.5 18.6 - 24.5 26.5 - 36.3
at 7.5 mm
Brush spring tension N (kg, lb) (1.0 - 1.4, (1.3 - 1.8, (1.4 - 2.6, (1.9 - 2.5, (2.7 - 3.7,
(0.295 in) brush
length
2.2 - 3.1) 2.9 - 4.0) 3.1 - 5.7) 4.2 - 5.5) 6.0 - 8.2) SU
Clearance between bearing metal and
— Less than 0.2 (0.008) —
armature shaft mm (in)
BR
Clearance “” between pinion front 0.0 - 3.9 0.5 - 2.0
0.3 - 2.5 (0.012 - 0.098) —
edge and pinion stopper mm (in) (0 - 0.154) (0.020 - 0.079)

Movement “” in height of pinion 0.5 - 2.0

ST
— —
assembly mm (in) (0.020 - 0.079)

RS

BT

HA

EL

IDX

SC-41
 SERVICE DATA AND SPECIFICATIONS (SDS)
Alternator

Alternator NJSC0016

LR165-719 LR180-762 LR190-753 LR1100-724 A2TB3191A A2TB4291 A3TB0771

Type
HITACHI make MITSUBISHI make

Applied model QG engine YD engine QG engine YD22 engine

Nominal rating V-A 12-70 12-80 12-90 12-100 12-80 12-90

Ground polarity Negative

Minimum revolutions under

Less than Less than Less than Less than
no-load (When 13.5V is Less than 1,300
1,000 1,000 1,000 1,000
applied) rpm

More than More than More than More than More than More than More than
17/1,300 23/1,300 23/1,300 34/1,300 15/1,300 25/1,300 29/1,300
Hot output current (When More than More than More than Morethan More than More than More than
13.5V is applied) A/rpm 49/2,500 65/2,500 65/2,500 83/2,500 69/2,500 67/2,500 76/2,500
More than More than More than More than More than More than More than
63.5/5,000 77/5,000 87/5,000 91/5,000 83/5,000 88/5,000 88/5,000

Regulated output voltage V 14.1 - 14.7

Minimum length of brush mm

More than 6.0 (0.236) More than 5.0 (0.197)
(in)

Brush spring pressure N (g,

1.0 - 3.43 (102 - 350, 3.60 - 12.34) 4.8 - 6.0 (490 - 610, 17.28 - 21.51)
oz)

Slip ring minimum diameter

More than 26.0 (1.024) More than 22.1 (0.870)
mm (in)

Rotor coil resistance at 20°

2.58 2.67 2.31 2.3 - 2.7 1.8 - 2.1 1.6 - 1.9
(68°F) Ω

SC-42