ELECTRICAL & POWER CONTROL

CHG
A

B
SECTION
CHARGING SYSTEM C

E
CONTENTS
BASIC INSPECTION .................................... 2 S TERMINAL CIRCUIT ..................................... 17 F
Description ...............................................................17
DIAGNOSIS AND REPAIR WORKFLOW .......... 2 Diagnosis Procedure ...............................................17
Work Flow (With EXP-800 NI or GR8-1200 NI) ........ 2 G
Work Flow (Without EXP-800 NI or GR8-1200 NI)...... 5 WIRING DIAGRAM ...................................... 18
SYSTEM DESCRIPTION .............................. 8 CHARGING SYSTEM ....................................... 18
Wiring Diagram ........................................................18 H
CHARGING SYSTEM .......................................... 8
System Diagram ........................................................ 8 SYMPTOM DIAGNOSIS .............................. 25
System Description ................................................... 8 I
Component Description ............................................ 8 CHARGING SYSTEM ....................................... 25
Symptom Table .......................................................25
POWER GENERATION VOLTAGE VARI-
ABLE CONTROL SYSTEM ................................. 9 PRECAUTION .............................................. 26 J
System Diagram ........................................................ 9
PRECAUTIONS ................................................. 26
System Description ................................................... 9
Precaution for Supplemental Restraint System
Component Description ............................................. 9 K
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
DTC/CIRCUIT DIAGNOSIS ......................... 10 SIONER" .................................................................26
Precaution for Power Generation Variable Voltage
CHARGING SYSTEM PRELIMINARY IN- Control System ........................................................26 L
SPECTION ..........................................................10
Diagnosis Procedure ............................................... 10 PREPARATION ........................................... 27

POWER GENERATION VOLTAGE VARI- PREPARATION ................................................. 27 CHG

ABLE CONTROL SYSTEM OPERATION IN- Special Service Tool ................................................27
Commercial Service Tool ........................................27
SPECTION ..........................................................11
N
Diagnosis Procedure ............................................... 11 REMOVAL AND INSTALLATION ............... 28
B TERMINAL CIRCUIT ......................................13 GENERATOR .................................................... 28
Description .............................................................. 13 Removal and Installation - QR25DE Models ...........28 O
Diagnosis Procedure ............................................... 13 Removal and Installation - VQ40DE Models ...........29
L TERMINAL CIRCUIT (OPEN) .........................14 SERVICE DATA AND SPECIFICATIONS
Description .............................................................. 14 P
Diagnosis Procedure ............................................... 14
(SDS) ............................................................ 30

L TERMINAL CIRCUIT (SHORT) .......................16 SERVICE DATA AND SPECIFICATIONS

Description .............................................................. 16 (SDS) ................................................................. 30
Diagnosis Procedure ............................................... 16 Generator ................................................................30

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 DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION >
BASIC INSPECTION
DIAGNOSIS AND REPAIR WORKFLOW
Work Flow (With EXP-800 NI or GR8-1200 NI) INFOID:0000000010713439

CHARGING SYSTEM DIAGNOSIS WITH EXP-800 NI OR GR8-1200 NI

To test the charging system, use the following special service tools:
• EXP-800 NI Battery and electrical diagnostic analyzer
• GR8-1200 NI Multitasking battery and electrical diagnostic station
NOTE:
Refer to the applicable Instruction Manual for proper charging system diagnosis procedures.

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 DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION >
OVERALL SEQUENCE
A

CHG

AWMIA1283GB
P
DETAILED FLOW
NOTE:
To ensure a complete and thorough diagnosis, the battery, stater and generator test segments must be done
as a set from start to finish.
1.PRELIMINARY INSPECTION
Perform the preliminary inspection. Refer to CHG-10, "Diagnosis Procedure".

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 DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION >

>> GO TO 2.
2.STOP POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM
Stop the operation of the power generation voltage variable control in either of the following procedures.
• After selecting “ENGINE” using CONSULT, set the DUTY value of “ALTERNATOR DUTY” to 0 % by select-
ing “ALTERNATOR DUTY” of “Active Test”. Continue “Active Test” until the end of inspection. (When the
DUTY value is 0 or 100 %, the normal power generation is performed according to the characteristic of the
IC regulator of the generator.)
• Turn the ignition switch OFF, and disconnect the battery current sensor connector. [However, DTC (P1550–
P1554) of the engine might remain. After finishing the inspection, connect the battery current sensor connec-
tor and erase the self diagnosis results history of the engine using CONSULT.]

>> GO TO 3.
3.DIAGNOSIS WITH EXP-800 NI OR GR8-1200 NI
Perform the charging system test using Multitasking battery and electrical diagnostic station GR8-1200 NI or
Battery and electrical diagnostic analyzer EXP-800 NI. Refer to the applicable Instruction Manual for proper
testing procedures.
Test result
NO PROBLEMS>>Charging system is normal and will also show “DIODE RIPPLE” test result.
NO VOLTAGE>>GO TO 4.
LOW VOLTAGE>>GO TO 12.
HIGH VOLTAGE>>GO TO 14.
EXCESSIVE RIPPLE, OPEN PHASE, OPEN DIODE or SHORTED DIODE>>Replace the generator. Refer
to CHG-28, "Removal and Installation - QR25DE Models" or CHG-29, "Removal and Installation -
VQ40DE Models". Perform “DIODE RIPPLE” test again using Multitasking battery and electrical
diagnostic station GR8-1200 NI or Battery and electrical diagnostic analyzer EXP-800 NI to con-
firm repair.
4.INSPECTION WITH CHARGE WARNING LAMP (IGNITION SWITCH IS ON)
Turn the ignition switch ON.
Does the charge warning lamp illuminate?
YES >> GO TO 6.
NO >> GO TO 5.
5.“L” TERMINAL CIRCUIT (OPEN) INSPECTION
Check “L” terminal circuit (open). Refer to CHG-14, "Diagnosis Procedure".
Is the “L” terminal circuit normal?
YES >> Replace generator. Refer to CHG-28, "Removal and Installation - QR25DE Models" or CHG-29,
"Removal and Installation - VQ40DE Models".
NO >> Repair as needed.
6.INSPECTION WITH CHARGE WARNING LAMP (IDLING)
Start the engine and run it at idle.
Does the charge warning lamp turn OFF?
YES >> GO TO 9.
NO >> GO TO 7.
7.“L” TERMINAL CIRCUIT (SHORT) INSPECTION
Check “L” terminal circuit (short). Refer to CHG-16, "Diagnosis Procedure".
Is the “L” terminal circuit normal?
YES >> GO TO 8.
NO >> Repair as needed.
8.“S” TERMINAL CIRCUIT INSPECTION
Check “S” terminal circuit. Refer to CHG-17, "Diagnosis Procedure".
Is the “S” terminal circuit normal?
Revision: August 2014 CHG-4 2015 Frontier NAM
 DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION >
YES >> GO TO 10.
NO >> Repair as needed. A
9.INSPECTION WITH CHARGE WARNING LAMP (ENGINE AT 3,000 RPM)
Increase and maintain the engine speed at 3,000 rpm.
B
Does the charge warning lamp remain off?
YES >> GO TO 11.
NO >> GO TO 10.
C
10.INSPECTION OF GENERATOR PULLEY
Check generator pulley. Refer to CHG-28, "Removal and Installation - QR25DE Models" or CHG-29,
"Removal and Installation - VQ40DE Models". D
Is generator pulley normal?
YES >> Replace generator. Refer to CHG-28, "Removal and Installation - QR25DE Models" or CHG-29,
"Removal and Installation - VQ40DE Models". E
NO >> Repair as needed.
11.“B” TERMINAL CIRCUIT INSPECTION
F
Check “B” terminal circuit. Refer to CHG-13, "Diagnosis Procedure".
Is “B” terminal circuit normal?
YES >> Replace generator. Refer to CHG-28, "Removal and Installation - QR25DE Models" or CHG-29, G
"Removal and Installation - VQ40DE Models".
NO >> Repair as needed.
12.“B” TERMINAL CIRCUIT INSPECTION H
Check “B” terminal circuit. Refer to CHG-13, "Diagnosis Procedure".
Is “B” terminal circuit normal?
YES >> GO TO 13. I
NO >> Repair as needed.
13.INSPECTION OF GENERATOR PULLEY J
Check generator pulley. Refer to CHG-28, "Removal and Installation - QR25DE Models" or CHG-29,
"Removal and Installation - VQ40DE Models".
Is generator pulley normal? K
YES >> Replace generator. Refer to CHG-28, "Removal and Installation - QR25DE Models" or CHG-29,
"Removal and Installation - VQ40DE Models".
NO >> Repair as needed.
L
14.“S” TERMINAL CIRCUIT INSPECTION
Check “S” terminal circuit. Refer to CHG-17, "Diagnosis Procedure".
Is the “S” terminal circuit normal? CHG
YES >> Replace generator. Refer to CHG-28, "Removal and Installation - QR25DE Models" or CHG-29,
"Removal and Installation - VQ40DE Models".
NO >> Repair as needed. N

Work Flow (Without EXP-800 NI or GR8-1200 NI) INFOID:0000000010713440

O
OVERALL SEQUENCE
Before performing a generator test, make sure that the battery is fully charged. A 30-volt voltmeter and suit-
able test probes are necessary for the test.
• Before starting, inspect the fusible link. P

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 DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION >
• Use fully charged battery.

ALMIA0577GB

DETAILED FLOW
1.PRELIMINARY INSPECTION
Perform the preliminary inspection. Refer to CHG-10, "Diagnosis Procedure".

>> GO TO 2.
2.STOP POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM
Stop the operation of the power generation voltage variable control in either of the following procedures:
• After selecting “ENGINE” using CONSULT, set the DUTY value of “ALTERNATOR DUTY” to 0 % by select-
ing “ALTERNATOR DUTY” with “Active Test”. Continue “Active Test” until the end of inspection. (When the
DUTY value is 0 or 100 %, the normal power generation is performed according to the characteristic of the
IC regulator of the generator.)
• Turn the ignition switch OFF, and disconnect the battery current sensor connector. [However, DTC (P1550 -
P1554) of the engine might remain. After finishing the inspection, connect the battery current sensor connec-
tor and erase the self-diagnostic results history of the engine using CONSULT.]

>> GO TO 3.
3.INSPECTION WITH CHARGE WARNING LAMP (IGNITION SWITCH IS TURNED ON)
When ignition switch is turned ON.
Does the charge warning lamp illuminate?

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 DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION >
YES >> GO TO 4.
NO >> GO TO 10. A
4.INSPECTION WITH CHARGE WARNING LAMP (IDLING)
Start the engine and run it at idle
B
Does the charge warning lamp turn OFF?
YES >> GO TO 5.
NO >> GO TO 6.
C
5.INSPECTION WITH CHARGE WARNING LAMP (ENGINE AT 2,500 RPM)
Increase and maintain the engine speed at 2,500 rpm.
Does the charge warning lamp illuminate? D
YES >> GO TO 8.
NO >> Inspection End.
6.“L” TERMINAL CIRCUIT (SHORT) INSPECTION E

Check terminal “L” circuit for (short). Refer to CHG-16, "Diagnosis Procedure".
Is the inspection result normal? F
YES >> GO TO 7.
NO >> Repair as needed.
7. “S” TERMINAL CIRCUIT INSPECTION G
Check terminal “S” circuit. Refer to CHG-17, "Diagnosis Procedure".
Is the inspection result normal? H
YES >> GO TO 8.
NO >> Repair as needed.
8.MEASURE “B” TERMINAL VOLTAGE I
Start engine. With engine running at 2,500 rpm, measure “B” terminal voltage.
What voltage does the measurement result show?
Less than 13.0 V>>GO TO 9. J
More than 16.0 V>>Replace generator. Refer to CHG-28, "Removal and Installation - QR25DE Models" or
CHG-29, "Removal and Installation - VQ40DE Models".
9.“B” TERMINAL CIRCUIT INSPECTION K

Check “B” terminal circuit. Refer to CHG-13, "Diagnosis Procedure".

Is the inspection result normal? L
YES >> Replace generator. Refer to CHG-28, "Removal and Installation - QR25DE Models" or CHG-29,
"Removal and Installation - VQ40DE Models".
NO >> Repair as needed. CHG
10. INSPECTION WITH CHARGE WARNING LAMP (IGNITION SWITCH IS ON)
1. Disconnect generator connector and apply ground to “L” terminal.
2. Turn the ignition switch ON. N
Does the charge warning lamp illuminate?
YES >> Replace generator. Refer to CHG-28, "Removal and Installation - QR25DE Models" or CHG-29,
"Removal and Installation - VQ40DE Models". O
NO >> GO TO 11.
11.CHECK “L” TERMINAL CIRCUIT (OPEN)
P
Check “L” terminal circuit (OPEN). Refer to CHG-14, "Diagnosis Procedure".

>> Repair as needed.

Revision: August 2014 CHG-7 2015 Frontier NAM

 CHARGING SYSTEM
< SYSTEM DESCRIPTION >
SYSTEM DESCRIPTION
CHARGING SYSTEM
System Diagram INFOID:0000000010713441

ALMIA0207GB

System Description INFOID:0000000010713442

The generator 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.
Component Description INFOID:0000000010713443

Component part Description

Terminal “1” Refer to CHG-13, "Description".
Terminal “2” Refer to CHG-14, "Description".
Generator Terminal “3” Refer to CHG-17, "Description".
Used for the power generation voltage variable control system.
Terminal “4”
Refer to CHG-9, "System Description".
The IC regulator warning function activates to illuminate the
charge warning lamp if any of the following symptoms occur while
Combination meter (Charge warning lamp) generator is operating:
• Excessive voltage is produced.
• No voltage is produced.
Used for the power generation voltage variable control system.
IPDM E/R
Refer to CHG-9, "System Description".

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 POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM
< SYSTEM DESCRIPTION >
POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM
A
System Diagram INFOID:0000000010713444

ALMIA0057GB

G
System Description INFOID:0000000010713445

Power generation variable voltage control system has been adopted. By varying the voltage to the generator, H
engine load due to power generation of the generator is reduced and fuel consumption is decreased.
NOTE:
When any malfunction is detected in the power generation variable voltage control system, power generation
is performed according to the characteristic of the IC regulator in the generator. I

Component Description INFOID:0000000010713446

J
Component part Description
The battery current sensor is installed on the battery cable at the
K
negative terminal. The battery current sensor detects the charg-
Battery current sensor
ing/discharging current of the battery and sends a voltage signal
to the ECM according to the current value detected.
The battery current sensor detects the charging/discharging cur- L
rent of the battery. The ECM judges the battery condition based on
this signal.
The ECM judges whether to request more output via the power
generation voltage variable control according to the battery condi-
CHG
ECM
tion.
When performing the power generation voltage variable control,
the ECM calculates the target power generation voltage according N
to the battery condition and sends the calculated value as the pow-
er generation command value to the IPDM E/R.
The IPDM E/R converts the received power generation command
IPDM E/R value into a pulse width modulated (PWM) command signal and O
sends it to the IC regulator.
The IC regulator controls the power generation voltage by the tar-
get power generation voltage based on the received PWM com- P
mand signal.
Generator (IC regulator)
When there is no PWM command signal, the generator performs
the normal power generation according to the characteristic of the
IC regulator.

Revision: August 2014 CHG-9 2015 Frontier NAM

 CHARGING SYSTEM PRELIMINARY INSPECTION
< DTC/CIRCUIT DIAGNOSIS >
DTC/CIRCUIT DIAGNOSIS
CHARGING SYSTEM PRELIMINARY INSPECTION
Diagnosis Procedure INFOID:0000000010713447

1.CHECK BATTERY TERMINALS CONNECTION

Check if battery terminals are clean and tight.
Is the inspection result normal?
YES >> GO TO 2.
NO >> Repair battery terminal connection. Confirm repair by performing complete Charging system test
using EXP-800 NI or GR8-1200 NI (if available). Refer to the applicable Instruction Manual for
proper testing procedures.
2.CHECK FUSE
Check for blown fuse and fusible link.

Unit Power source (Power supply terminals) Fuse or Fusible Link

Battery (terminal 3) Fuse 30
Generator
Battery (terminal 1) Fusible Link A
Combination meter Ignition switch ON (terminal 2) Fuse 14
Is the inspection result normal?
YES >> GO TO 3.
NO >> Replace the blown fuse or fusible link after repairing the affected circuit.
3.CHECK GENERATOR GROUND TERMINAL CONNECTION
Check if connector E209 terminal 5 is clean.
Is the inspection result normal?
YES >> GO TO 4.
NO >> Repair connection.
4.CHECK DRIVE BELT TENSION
Check drive belt tension. Refer to CHG-28, "Removal and Installation - QR25DE Models" or CHG-29,
"Removal and Installation - VQ40DE Models".
Is the inspection result normal?
YES >> Inspection End.
NO >> Repair as needed.

Revision: August 2014 CHG-10 2015 Frontier NAM

 POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM OPERATION
INSPECTION
< DTC/CIRCUIT DIAGNOSIS >
POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM OPER-
A
ATION INSPECTION
Diagnosis Procedure INFOID:0000000010713448
B

Regarding Wiring Diagram information. Refer to CHG-18, "Wiring Diagram".

C

CAUTION:
When performing this inspection, always use a charged battery that has completed the battery inspec-
D
tion. (When the charging rate of the battery is low, the response speed of the voltage change will
become slow. This can cause an incorrect inspection.)
1.CHECK ECM (CONSULT) E
Perform ECM self-diagnosis with CONSULT. Refer to EC-58, "CONSULT Function" (QR25DE) or EC-518,
"CONSULT Function" (VQ40DE).
Self-diagnostic results content F
No malfunction detected>> GO TO 2.
Malfunction detected>> Check applicable parts, and repair or replace corresponding parts.
2.CHECK OPERATION OF POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM G
1. Connect CONSULT and start the engine.
2. The selector lever is in “P” or “N” position and all of the electric loads and A/C, etc. are turned OFF.
3. Select “ALTERNATOR DUTY” in “Active Test” of “ENGINE”, and then check the value of “BATTERY H
VOLT” monitor when DUTY value of “DUTY” is set to 40.0 %.

“BATTERY VOLT” I
2 seconds after setting the : 12 - 13.6 V
DUTY value of “ALTERNA-
TOR DUTY” to 40.0 % J

4. Check the value of “BATTERY VOLT” monitor when DUTY value of “DUTY” is set to 80.0%.
K
“BATTERY VOLT”
20 seconds after setting : +0.5 V or more against
the DUTY value of “ALTER- the value of “BATTERY L
NATOR DUTY” to 80.0 % VOLT” monitor when
DUTY value is 40.0 %
Is the inspection result normal? CHG
YES >> Inspection End.
NO >> GO TO 3.
3.CHECK IPDM E/R (CONSULT) N

Perform IPDM E/R self-diagnosis with CONSULT. Refer to PCS-11, "CONSULT Function (IPDM E/R)".
Is the inspection result normal? O
No malfunction detected>> GO TO 4.
Malfunction detected>> Check applicable parts, and repair or replace corresponding parts.
4.CHECK HARNESS BETWEEN GENERATOR AND IPDM E/R P
1. Turn ignition switch OFF.
2. Disconnect generator connector and IPDM E/R connector.
3. Check continuity between generator harness connector and IPDM E/R harness connector.

Revision: August 2014 CHG-11 2015 Frontier NAM

 POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM OPERATION
INSPECTION
< DTC/CIRCUIT DIAGNOSIS >

Generator IPDM E/R

Continuity
Connector Terminal Connector Terminal
E205 4 E122 37 Yes
4. Check continuity between generator harness connector and ground.

Generator
— Continuity
Connector Terminal
E205 4 Ground No
Is the inspection result normal?
YES >> Replace IPDM E/R. Refer to PCS-28, "Removal and Installation of IPDM E/R" .
NO >> Repair harness or connectors between IPDM E/R and generator.

Revision: August 2014 CHG-12 2015 Frontier NAM

 B TERMINAL CIRCUIT
< DTC/CIRCUIT DIAGNOSIS >
B TERMINAL CIRCUIT
A
Description INFOID:0000000010713449

“B” terminal circuit supplies power to charge the battery and to operate the vehicles electrical system. B
Diagnosis Procedure INFOID:0000000010713450

C
Regarding Wiring Diagram information. Refer to CHG-18, "Wiring Diagram".

D
1.CHECK “B” TERMINAL CONNECTION
1. Turn ignition switch OFF.
2. Check if “B” terminal is clean and tight. E
Is the inspection result normal?
YES >> GO TO 2.
NO >> Repair terminal “B” connection. Confirm repair by performing complete Charging system test F
using the EXP-800 NI or GR8-1200 NI (if available). Refer to applicable Instruction Manual for
proper testing procedures.
2.CHECK “B” TERMINAL CIRCUIT G
Check voltage between generator “B” terminal and ground.

(+)
H
Voltage
Generator (-)
(Approx.)
Connector Terminal
I
E206 1 Ground Battery voltage
Is the inspection result normal?
YES >> GO TO 3. J
NO >> Check harness for open between generator and fusible link.
3.CHECK “B” TERMINAL CONNECTION (VOLTAGE DROP TEST)
K
1. Start engine, then engine running at idle and warm.
2. Check voltage between battery positive terminal and generator connector “B” terminal.
L
(+)
Voltage
Generator (-)
(Approx.)
Connector Terminal CHG
E206 1 Battery positive terminal Less than 0.2V
Is the inspection result normal?
YES >> “B” terminal circuit is normal. Refer to CHG-2, "Work Flow (With EXP-800 NI or GR8-1200 NI)" or N
CHG-5, "Work Flow (Without EXP-800 NI or GR8-1200 NI)".
NO >> Check harness between battery and generator for continuity.
O

Revision: August 2014 CHG-13 2015 Frontier NAM

 L TERMINAL CIRCUIT (OPEN)
< DTC/CIRCUIT DIAGNOSIS >
L TERMINAL CIRCUIT (OPEN)
Description INFOID:0000000010713451

The “L” terminal circuit controls the charge warning lamp. The charge warning lamp turns ON when the igni-
tion switch is set to ON or START. When the generator is providing sufficient voltage with the engine running,
the charge warning lamp turns OFF. If the charge warning lamp illuminates with the engine running, a malfunc-
tion is indicated.
Diagnosis Procedure INFOID:0000000010713452

Regarding Wiring Diagram information. Refer to CHG-18, "Wiring Diagram".

1.CHECK “L” TERMINAL CONNECTION

1. Turn ignition switch OFF.
2. Check if “L” terminal is clean and tight.

Is the inspection result normal?

YES >> GO TO 2.
NO >> Repair “L” terminal connection. Confirm repair by performing complete Charging system test
using EXP-800 NI or GR8-1200 NI (if available). Refer to applicable Instruction Manual for proper
testing procedures.
2.CHECK “L” TERMINAL CIRCUIT (OPEN)
1. Disconnect the generator connector.
2. Apply ground to generator harness connector terminal.
3. Check condition of the charge warning lamp with the ignition switch in the ON position.

Generator Condition
Connector Terminal Ground Ignition switch position Charge warning lamp
E205 2 ON Illuminate
Does it illuminate?
YES >> “L” terminal circuit is normal. Refer to CHG-2, "Work Flow (With EXP-800 NI or GR8-1200 NI)" or
CHG-5, "Work Flow (Without EXP-800 NI or GR8-1200 NI)".
NO >> GO TO 3.
3.CHECK HARNESS CONTINUITY (OPEN CIRCUIT)
1. Disconnect the battery cable from the negative terminal.
2. Disconnect the combination meter connector.
3. Check continuity between generator harness connector and combination meter harness connector.

Generator Combination meter

Continuity
Connector Terminal Connector Terminal
E205 2 M24 2 Yes
is the inspection result normal?
YES >> GO TO 4.
NO >> Repair or replace the harness or connectors.
4.CHECK HARNESS CONTINUITY (OPEN CIRCUIT)
Check continuity between combination meter harness connector and the fuse block (J/B).

Combination meter Fuse box (J/B)

Continuity
Connector Terminal Connector Terminal
M24 16 M4 5P Yes

Revision: August 2014 CHG-14 2015 Frontier NAM

 L TERMINAL CIRCUIT (OPEN)
< DTC/CIRCUIT DIAGNOSIS >
Is the inspection result normal?
YES >> GO TO 5. A
NO >> Repair or replace the harness or connectors.
5.CHECK POWER SUPPLY CIRCUIT
B
1. Connect the battery cable to the negative terminal.
2. Check voltage between combination meter harness connector and ground.
C
(+)
Voltage
Combination meter (-) Condition
(Approx.)
Connector Terminal D
When the ignition
M24 16 Ground Battery voltage
switch is in ON position
Is the inspection result normal? E
YES >> Replace the combination meter. Refer to MWI-91, "Removal and Installation" .
NO >> Repair or replace the harness or connectors.
F

CHG

Revision: August 2014 CHG-15 2015 Frontier NAM

 L TERMINAL CIRCUIT (SHORT)
< DTC/CIRCUIT DIAGNOSIS >
L TERMINAL CIRCUIT (SHORT)
Description INFOID:0000000010713453

The terminal “L” circuit controls the charge warning lamp. The charge warning lamp turns ON when the igni-
tion switch is set to ON or START. When the generator is providing sufficient voltage with the engine running,
the charge warning lamp turns off. If the charge warning lamp illuminates with the engine running, a malfunc-
tion is indicated.
Diagnosis Procedure INFOID:0000000010713454

Regarding Wiring Diagram information, refer to CHG-18, "Wiring Diagram".

1.CHECK “L” TERMINAL CIRCUIT (SHORT)

1. Turn ignition switch OFF.
2. Disconnect generator connector.
3. Turn ignition switch ON.
Does charge warning lamp illuminate?
YES >> GO TO 2.
NO >> Refer to CHG-2, "Work Flow (With EXP-800 NI or GR8-1200 NI)" or CHG-5, "Work Flow (Without
EXP-800 NI or GR8-1200 NI)".
2.CHECK HARNESS CONTINUITY (SHORT CIRCUIT)
1. Turn ignition switch OFF.
2. Disconnect the battery cable from the negative terminal.
3. Disconnect combination meter connector.
4. Check continuity between the combination meter harness connector and ground.

Combination meter
Continuity
Connector Terminal Ground
M24 2 No
Is the inspection result normal?
YES >> Replace the combination meter. Refer to MWI-91, "Removal and Installation".
NO >> Repair or replace the harness or connectors.

Revision: August 2014 CHG-16 2015 Frontier NAM

 S TERMINAL CIRCUIT
< DTC/CIRCUIT DIAGNOSIS >
S TERMINAL CIRCUIT
A
Description INFOID:0000000010713455

The output voltage of the generator is controlled by the IC regulator at terminal “S” detecting the input voltage B
from battery.
The “S” terminal circuit detects the battery voltage to adjust the generator output voltage with the IC voltage
regulator.
C
Diagnosis Procedure INFOID:0000000010713456

D
Regarding Wiring Diagram information. Refer to CHG-18, "Wiring Diagram".

1.CHECK “S” TERMINAL CONNECTION E

1. Turn ignition switch OFF.

2. Check if “S” terminal is clean and tight. F
Is the inspection result normal?
YES >> GO TO 2.
NO >> Repair “S” terminal connection. Confirm repair by performing complete Charging system test G
using EXP-800 NI or GR8-1200 NI (if available). Refer to the applicable Instruction Manual for
proper testing procedures.
2.CHECK “S” TERMINAL CIRCUIT H
Check voltage between generator harness connector and ground.

(+) I
Voltage
Generator (-) (Approx.)
Connector Terminal
J
E205 3 Ground Battery voltage
Is the inspection result normal?
YES >> Refer to CHG-2, "Work Flow (With EXP-800 NI or GR8-1200 NI)" or CHG-5, "Work Flow (Without K
EXP-800 NI or GR8-1200 NI)".
NO >> Check harness for open between generator and fuse.
L

CHG

Revision: August 2014 CHG-17 2015 Frontier NAM

 CHARGING SYSTEM
< WIRING DIAGRAM >
WIRING DIAGRAM
CHARGING SYSTEM
Wiring Diagram INFOID:0000000010713457

ABMWA2797GB

Revision: August 2014 CHG-18 2015 Frontier NAM

 CHARGING SYSTEM
< WIRING DIAGRAM >

CHG

ABMIA5518GB

Revision: August 2014 CHG-19 2015 Frontier NAM

 CHARGING SYSTEM
< WIRING DIAGRAM >

ABMIA5519GB

Revision: August 2014 CHG-20 2015 Frontier NAM

 CHARGING SYSTEM
< WIRING DIAGRAM >

CHG

ABMIA4357GB

Revision: August 2014 CHG-21 2015 Frontier NAM

 CHARGING SYSTEM
< WIRING DIAGRAM >

ABMIA5520GB

Revision: August 2014 CHG-22 2015 Frontier NAM

 CHARGING SYSTEM
< WIRING DIAGRAM >

CHG

ABMIA4359GB

Revision: August 2014 CHG-23 2015 Frontier NAM

 CHARGING SYSTEM
< WIRING DIAGRAM >

ABMIA5522GB

Revision: August 2014 CHG-24 2015 Frontier NAM

 CHARGING SYSTEM
< SYMPTOM DIAGNOSIS >
SYMPTOM DIAGNOSIS A
CHARGING SYSTEM
Symptom Table INFOID:0000000010713458
B

Symptom Reference
C
Battery discharged
The charge warning lamp does not illuminate when the ignition
switch is set to ON.
Refer to CHG-2, "Work Flow (With EXP-800 NI or GR8-1200 NI)" D
The charge warning lamp does not turn OFF after the engine or CHG-5, "Work Flow (Without EXP-800 NI or GR8-1200 NI)".
starts.
The charging warning lamp turns ON when increasing the engine E
speed.

CHG

Revision: August 2014 CHG-25 2015 Frontier NAM

 PRECAUTIONS
< PRECAUTION >
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000010713459

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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SR and SB section of this Service Man-
ual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the SR section.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni-
tion ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with a
hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
• When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the
battery and wait at least three minutes before performing any service.
Precaution for Power Generation Variable Voltage Control System INFOID:0000000010713460

CAUTION:
For this model, the battery current sensor that is installed to the negative battery cable measures the
charging/discharging current of the battery and performs various engine controls. If an electrical com-
ponent is connected directly to the negative battery terminal, the current flowing through that compo-
nent will not be measured by the battery current sensor. This condition may cause a malfunction of
the engine control system and battery discharge may occur. Do not connect an electrical component
or ground wire directly to the battery terminal.

Revision: August 2014 CHG-26 2015 Frontier NAM

 PREPARATION
< PREPARATION >
PREPARATION A
PREPARATION
Special Service Tool INFOID:0000000010713461
B

The actual shape of the tools may differ from those illustrated here.
Tool number Description
(TechMate No.) C
Tool name
— Tests batteries, starting and charging
( — ) Model GR8-1200 NI systems and charges batteries. D
Multitasking battery and electrical diag- For operating instructions, refer to diag-
nostic station nostic station instruction manual.

AWIIA1239ZZ

F
— Tests batteries and charging systems.
( — ) Model EXP-800 NI For operating instructions, refer to diag-
Battery and electrical diagnostic analyzer nostic analyzer instruction manual.
G

H
JSMIA0806ZZ

Commercial Service Tool INFOID:0000000010713462

Tool name Description

Power tool Loosening nuts, screws and bolts J

PIIB1407E L

CHG

Revision: August 2014 CHG-27 2015 Frontier NAM

 GENERATOR
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION
GENERATOR
Removal and Installation - QR25DE Models INFOID:0000000010713463

AWMIA1172GB

1. Generator 2. Starter motor assembly 3. Terminal "1"

4. Generator lower stud

REMOVAL
1. Disconnect the negative battery terminal. Refer to PG-89, "Removal and Installation".
2. Remove front fender protector (RH). Refer to EXT-27, "Removal and Installation of Front Fender Protec-
tor".
3. Remove the drive belt. Refer to EM-14, "Removal and Installation".
4. Disconnect the harness connectors from the generator.
5. Remove generator nut, using power tools.
6. Remove the generator upper bolt, using power tools.
7. Remove the generator.
INSTALLATION
Installation is in the reverse order of removal.
• Be sure the generator spacer is in place on the lower stud.
• Install the generator and check tension of drive belt. Refer to EM-14, "Checking Drive Belts".

Terminal "1" nut : 10.8 N·m (1.1 kg-m, 8 ft-lb)

CAUTION:
Be sure to tighten terminal "1" nut carefully.
• For this model, the power generation voltage variable control system that controls the power generation volt-
age of the generator has been adopted. Therefore, the power generation voltage variable control system
operation inspection should be performed after replacing the generator, and then make sure that the system
operates normally. Refer to CHG-10, "Diagnosis Procedure".

Revision: August 2014 CHG-28 2015 Frontier NAM

 GENERATOR
< REMOVAL AND INSTALLATION >
Removal and Installation - VQ40DE Models INFOID:0000000010713464

AWMIA1170GB
I
1. Generator 2. Engine block 3. Generator stay

NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill- J
ing.
REMOVAL
K
1. Disconnect the negative battery terminal.Refer to PG-89, "Removal and Installation".
2. Remove engine cooling fan (Motor driven type). Refer to CO-48, "Removal and Installation (Motor driven
type)". L
3. Remove the drive belt. Refer to EM-129, "Removal and Installation".
4. Remove generator stay, using power tools.
5. Remove the generator upper bolt, using power tools. CHG
6. Disconnect the harness connectors from the generator.
7. Remove the generator.
N
INSTALLATION
Installation is in the reverse order of removal.
• Install the generator and check tension of drive belt. Refer to EM-129, "Adjustment".
O
Terminal "1" nut : 10.8 N·m (1.1 kg-m, 8 ft-lb)
CAUTION:
P
Be sure to tighten terminal "1" nut carefully.
• For this model, the power generation voltage variable control system that controls the power generation volt-
age of the generator has been adopted. Therefore, the power generation voltage variable control system
operation inspection should be performed after replacing the generator, and then make sure that the system
operates normally. Refer to CHG-10, "Diagnosis Procedure".

Revision: August 2014 CHG-29 2015 Frontier NAM

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Generator INFOID:0000000010713465

Engine QR25DE VQ40DE

LR1110-724C TG15S192
Type*
Hitachi Valeo
Nominal rating 12V-110A 14V-130A
Ground polarity Negative
Minimum revolution under no-load 1,100 rpm 1,200 rpm
More than 35A/1,300 rpm More than 52A/1,500 rpm
Hot output current (When 13.5 volts is ap- More than 70A/1,800 rpm More than 82A/1,800 rpm
plied) More than 91A/2,500 rpm More than 115A/2,500 rpm
More than 110A/5,000 rpm More than 130A/5,000 rpm
Regulated output voltage 13.5 - 14.0V @ 20°C (68°F) 13.5 - 14.0 @ 20°C (68°F)
Adjustment range of power generation vari-
11.7 - 15.3V 11.7 - 15.3V
able voltage control
*: Always check with the Parts Department for the latest parts information.

Revision: August 2014 CHG-30 2015 Frontier NAM