STARTING & CHARGING SYSTEM GI

SECTION SC MA

EM

LC

EC

CONTENTS FE

PRECAUTIONS ...............................................................2 Construction...............................................................23

CL
Supplemental Restraint System (SRS) ″AIR KA24DE MODELS ...................................................23
BAG″ and ″SEAT BELT PRE-TENSIONER″...............2 VG33E MODELS .....................................................24 MT
Wiring Diagrams and Trouble Diagnosis.....................2 Removal and Installation ...........................................25
PREPARATION ...............................................................3 KA24DE MODELS ...................................................25
Special Service Tool ....................................................3 VG33E MODELS .....................................................25 AT
BATTERY.........................................................................4 Pinion/Clutch Check ..................................................25
How to Handle Battery ................................................4 CHARGING SYSTEM ....................................................26
METHODS OF PREVENTING OVER-DISCHARGE ......4 System Description....................................................26 TF
CHECKING ELECTROLYTE LEVEL ............................4 Wiring Diagram - CHARGE -.....................................27
SPECIFIC GRAVITY CHECK ......................................5 KA24DE MODELS ...................................................27
CHARGING THE BATTERY ........................................6 VG33E MODELS .....................................................28 PD
Trouble Diagnoses with Battery/Starting/Charging Trouble Diagnoses with Battery/Starting/Charging
System Tester ..............................................................7 System Tester ............................................................29
DIAGNOSTIC RESULT ITEM CHART ........................31
AX
DIAGNOSTIC RESULT ITEM CHART ..........................9
STARTING SYSTEM .....................................................10 WORK FLOW ..........................................................32
DIAGNOSTIC PROCEDURE 1 ..................................33
System Description....................................................10 SU
KA24DE MODELS ...................................................10 DIAGNOSTIC PROCEDURE 2 ..................................34
VG33E M/T MODELS ...............................................11 DIAGNOSTIC PROCEDURE 3 ..................................35
MALFUNCTION INDICATOR ....................................36
VG33E A/T MODELS................................................12 BR
Wiring Diagram - START -.........................................13 Construction...............................................................37
KA24DE MODELS ...................................................13 KA24DE MODELS ...................................................37
VG33E M/T MODELS ...............................................14 VG33E MODELS .....................................................38 ST
VG33E A/T MODELS................................................15 Removal and Installation ...........................................38
Trouble Diagnoses with Battery/Starting/Charging KA24DE MODELS ...................................................38
System Tester ............................................................16 VG33E MODELS .....................................................39 RS
DIAGNOSTIC RESULT ITEM CHART ........................17
SERVICE DATA AND SPECIFICATIONS (SDS) .........40
WORK FLOW ..........................................................18 Battery........................................................................40
DIAGNOSTIC PROCEDURE 1 ..................................19 Starter ........................................................................40 BT
DIAGNOSTIC PROCEDURE 2 ..................................21 Generator...................................................................40
MINIMUM SPECIFICATION OF CRANKING
VOLTAGE REFERENCING COOLANT
HA
TEMPERATURE ......................................................22

EL

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

Supplemental Restraint System (SRS) “AIR

BAG” and “SEAT BELT PRE-TENSIONER” NGSC0001
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 Supplemental Restraint System consists of driver air bag module (located in the center of the
steering wheel), front passenger air bag module (located on the instrument panel on passenger side), seat
belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
쐌 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.
쐌 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.
쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral cable and wiring harnesses (except “SEAT BELT PRE-TENSIONER”) cov-
ered with yellow insulation either just before the harness connectors or for the complete harness
are related to the SRS.
Wiring Diagrams and Trouble Diagnosis NGSC0002
When you read wiring diagrams, refer to the following:
쐌 GI-10, “HOW TO READ WIRING DIAGRAMS”
쐌 EL-11, “POWER SUPPLY ROUTING” for power distribution circuit
When you perform trouble diagnosis, refer to the following:
쐌 GI-33, “How To Follow Test Group In Trouble Diagnoses”
쐌 GI-22, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”

SC-2
 PREPARATION
Special Service Tool

Special Service Tool NGSC0018

Tool number
Description GI
Tool name

J-44373 Model 620

Battery/Starting/Charging MA
system tester

EM

LC

EC

FE

CL

SEL403X MT

AT

TF

PD

AX

SU

BR

ST

RS

BT

HA

EL

IDX
SC-3
 BATTERY
How to Handle Battery

How to Handle Battery NGSC0003

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

METHODS OF PREVENTING OVER-DISCHARGE NGSC0003S01

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

MEL040F

쐌 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

쐌 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 NGSC0003S02

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-4
 BATTERY
How to Handle Battery (Cont’d)
쐌 Remove the cell plug using a suitable tool.
쐌 Add distilled water up to the MAX level.
GI

MA

EM

MEL043F LC
Sulphation NGSC0003S0201
A battery will be completely discharged if it is left unattended EC
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- FE
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. CL
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. MT
SEL709E

SPECIFIC GRAVITY CHECK NGSC0003S03

1. Read hydrometer and thermometer indications at eye level. AT

TF

PD

AX
MEL042FA

2. Use the chart below to correct your hydrometer reading

according to electrolyte temperature. SU
Hydrometer Temperature Correction NGSC0003S0301
BR
Battery electrolyte temperature °C (°F) Add to specific gravity reading

71 (160) 0.032
ST
66 (150) 0.028

60 (140) 0.024
RS
54 (129) 0.020

49 (120) 0.016 BT
43 (110) 0.012

38 (100) 0.008 HA
32 (90) 0.004

27 (80) 0

21 (70) −0.004

16 (60) −0.008 EL
10 (50) −0.012
IDX
SC-5
 BATTERY
How to Handle Battery (Cont’d)

Battery electrolyte temperature °C (°F) Add to specific gravity reading

4 (39) −0.016

−1 (30) −0.020

−7 (20) −0.024

−12 (10) −0.028

−18 (0) −0.032

Corrected specific gravity Approximate charge condition

1.260 - 1.280 Fully charged

1.230 - 1.250 3/4 charged

1.200 - 1.220 1/2 charged

1.170 - 1.190 1/4 charged

1.140 - 1.160 Almost discharged

1.110 - 1.130 Completely discharged

CHARGING THE BATTERY NGSC0003S04

CAUTION:
쐌 Do not “quick charge” a fully discharged battery.
쐌 Keep the battery away from open flame while it is being
charged.
쐌 When connecting the charger, connect the leads first, then
turn on the charger. Do not turn on the charger first, as
this may cause a spark.
쐌 If battery electrolyte temperature rises above 60°C (140°F),
stop charging. Always charge battery at a temperature
below 60°C (140°F).
Charging Rates NGSC0003S0401

Amps Time

50 1 hour

25 2 hours

10 5 hours

5 10 hours

Do not charge at more than 50 ampere rate.

NOTE:
The ammeter reading on your battery charger will automatically
decrease as the battery charges. This indicates that the voltage of
the battery is increasing normally as the state of charge improves.
The charging amps indicated above refer to initial charge rate.
쐌 If, after charging, the specific gravity of any two cells varies
more than .050, the battery should be replaced.

SC-6
 BATTERY
Trouble Diagnoses with Battery/Starting/Charging System Tester

Trouble Diagnoses with

Battery/Starting/Charging System Tester
CAUTION:
NGSC0019
GI
When working with batteries, always wear appropriate eye
protection. MA
NOTE:
쐌 To ensure a complete and thorough diagnosis, the battery,
starter and generator test segments must be done as a set EM
from start to finish.
쐌 If battery surface charge is detected while testing, the tester
will prompt you to turn on the headlights to remove the surface LC
charge.
쐌 If necessary, the tester will prompt you to determine if the bat-
tery temperature is above or below 0°C (32°F). Choose the EC
appropriate selection by pressing the up or down arrow button,
then press “ENTER” to make the selection.
FE

CL

MT
1. Turn off all loads on the vehicle electrical system. Clean or
repair as necessary. AT
2. Visually inspect the battery, battery terminals and cable ends
with ignition switch in “OFF” position.
NOTE: TF
The contact surface between the battery terminals, cable ends and
tester leads must be clean for a valid test. A poor connection will
prevent testing and a “CHECK CONNECTION” message will PD
appear during the test procedures. If this occurs, clean the battery
post and terminals, reconnect them and restart the test.
AX
SEL404X 3. Connect the red tester lead clamp to the positive battery
terminal, and the black to the negative terminal.
SU

BR

ST

RS

4. The tester will turn on automatically. Using the arrow keys, BT

select “IN-VEHICLE” on the tester and then press the “ENTER”
key.
HA

EL
SEL405X
IDX
SC-7
 BATTERY
Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)
5. Locate the battery type and rating stamped or written on the
top case of the battery to be tested.
NOTE:
The battery type and rating will have either of the following.
CCA: Cold Cranking Amps (490 CCA, 550 CCA, etc.)
JIS: Japanese Industrial Standard.
Battery is stamped with a number such as:
80D26L: 80 (rank of output), D (physical size-depth), 26 (width
in cm). The last character L (post configuration) is not input into
the tester.
SEL406X
The tester requires the rating for the battery be entered exactly
as it is written or stamped on the battery. Do not attempt a CCA
conversion for JIS stamped batteries. JIS must be input
directly.
6. Using the arrow and “ENTER” keys alternately, select the bat-
tery type and rating.
NOTE:
The tester lists five choices; CCA, JIS, IEC, DIN, and EN. Only use
CCA or JIS.

7. Press “ENTER” to begin the test. Diagnosis results are dis-

played on the tester. Refer to “DIAGNOSTIC RESULT ITEM
CHART”, SC-9.

SEL407X

8. Press “ENTER”, then test output code is displayed. Record the

test output code on the repair order.
9. Toggle back to the “DIAGNOSTIC SCREEN” for test results.
NOTE:
쐌 If necessary, the tester will ask the user to determine if the
battery has just been charged. Choose the appropriate selec-
tion by pressing the up or down arrow button and then press
the “ENTER” button to make the selection.
쐌 When testing a battery installed in a vehicle that has recently
been driven, select “BEFORE CHARGE”.
SEL576X 쐌 If the battery has just been slow charged due to a “CHARGE
& RETEST” decision by the tester, and the tester asks the user
“BEFORE CHARGE/AFTER CHARGE”, select “AFTER
CHARGE”.

SC-8
 BATTERY
Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

DIAGNOSTIC RESULT ITEM CHART NGSC0019S01

Diagnostic item Service procedure GI

Battery is OK. Refer to “Trouble Diagnoses with Battery/Starting/Charging System Tester”,
GOOD BATTERY
SC-16.
MA
Replace battery.
Before replacing battery, clean the battery cable clamps and battery posts. Perform bat-
REPLACE BATTERY
tery test again with Battery/Starting/Charging system tester. If second test result is EM
“Replace Battery”, then do so. Perform battery test again to confirm repair.

Replace the battery. Perform battery test again with Battery/Starting/Charging system
BAD CELL-REPLACE LC
tester to confirm repair.

Perform the slow battery charging procedure. (Initial rate of charge is 10A for 12 hours.)
GOOD-RECHARGE
Perform battery test again with Battery/Starting/Charging system tester.
EC
Perform the slow battery charging. (Initial rate of charge is 10A for 12 hours.)
Perform battery test again with Battery/Starting/Charging system tester to confirm repair.
CHARGE & RETEST NOTE: FE
If the tester asks the user “BEFORE CHARGE/AFTER CHARGE”, select “AFTER
CHARGE”.
CL

MT

AT

TF

PD

AX

SU

BR

ST

RS

BT

HA

EL

IDX
SC-9
 STARTING SYSTEM
System Description

System Description NGSC0004

KA24DE MODELS NGSC0004S01
Power is supplied at all times
쐌 through 40A fusible link (letter e, located in the fuse and fusible link box)
쐌 to ignition switch terminal B.
With the ignition switch in the START position, power is supplied
쐌 through ignition switch terminal ST
쐌 to clutch interlock relay terminal 5.
With the ignition switch in the ON or START position, power is supplied
쐌 through 10A fuse [No. 11, located in the fuse block (J/B)]
쐌 to clutch interlock relay terminal 2.
With the clutch pedal depressed, ground is supplied
쐌 to clutch interlock relay terminal 1
쐌 through clutch interlock switch terminal 1
쐌 through clutch interlock switch terminal 2
쐌 through body grounds M14 and M68.
The clutch interlock relay is energized and power is supplied
쐌 through clutch interlock relay terminal 3
쐌 to starter motor windings terminal S.
The starter motor plunger closes and provides a closed circuit between the battery and the starter motor. The
starter motor is grounded to the cylinder block. With power and ground supplied, the starter motor operates.

SC-10
 STARTING SYSTEM
System Description (Cont’d)

VG33E M/T MODELS =NGSC0004S02

Power is supplied at all times
쐌 through 40A fusible link (letter e, located in the fuse and fusible link box) GI
쐌 to ignition switch terminal B.
With the ignition switch in the START position, power is supplied MA
쐌 through ignition switch terminal ST
쐌 to clutch interlock relay terminal 5.
With the ignition switch in the ON or START position, power is supplied EM
쐌 through 10A fuse [No. 11, located in the fuse block (J/B)]
쐌 to clutch interlock relay terminal 2 and LC
쐌 through 10A fuse [No. 5, located in the fuse block (J/B)]
쐌 to vehicle security relay terminal 2 (models with power door locks).
If the vehicle security system is not triggered (models with power door locks) and clutch pedal is depressed,
EC
ground is supplied
쐌 to clutch interlock relay terminal 1 FE
쐌 through vehicle security relay terminals 3, 4 (models with power door locks) and
쐌 through clutch interlock switch terminal 1
쐌 through clutch interlock switch terminal 2 CL
쐌 through body grounds M14 and M68.
The clutch interlock relay is energized and power is supplied MT
쐌 through clutch interlock relay terminal 3
쐌 to starter motor windings terminal S.
The starter motor plunger closes and provides a closed circuit between the battery and the starter motor. The
AT
starter motor is grounded to the cylinder block. With power and ground supplied, the starter motor operates.
If the vehicle security system is triggered (models with power door locks), ground is supplied to vehicle secu- TF
rity relay terminal 1 through smart entrance control unit terminal 40, disengaging the clutch interlock relay and
preventing starter motor operation.
PD

AX

SU

BR

ST

RS

BT

HA

EL

IDX
SC-11
 STARTING SYSTEM
System Description (Cont’d)

VG33E A/T MODELS =NGSC0004S03

Power is supplied at all times
쐌 through 40A fusible link (letter e, located in the fuse and fusible link box)
쐌 to ignition switch terminal B.
With the ignition switch in the START position, power is supplied
쐌 through ignition switch terminal ST
쐌 to park/neutral position (PNP) relay terminal 5.
With the ignition switch in the ON or START position, power is supplied
쐌 through 10A fuse [No. 12, located in the fuse block (J/B)]
쐌 to PNP switch terminal 1 and
쐌 through 10A fuse [No. 5, located in the fuse block (J/B)]
쐌 to vehicle security relay terminal 2 (models with power door locks).
With the selector lever in the P or N position, power is supplied
쐌 through PNP switch terminal 2
쐌 to PNP relay terminal 2.
If the vehicle security system is not triggered (models with power door locks), ground is supplied
쐌 to PNP relay terminal 1
쐌 through body grounds E12 and E54 (models without power door locks) or
쐌 through vehicle security relay terminals 3, 4 (models with power door locks) and
쐌 through body grounds M14 and M68.
The PNP relay is energized and power is supplied
쐌 through PNP relay terminal 3
쐌 to starter motor windings terminal S.
The starter motor plunger closes and provides a closed circuit between the battery and the starter motor. The
starter motor is grounded to the cylinder block. With power and ground supplied, the starter motor operates.
If the vehicle security system is triggered (models with power door locks), ground is supplied to vehicle secu-
rity relay terminal 1 through smart entrance control unit terminal 40, disengaging the PNP relay and prevent-
ing starter motor operation.

SC-12
 STARTING SYSTEM
Wiring Diagram — START —

Wiring Diagram — START — NGSC0005

KA24DE MODELS NGSC0005S01
GI

MA

EM

LC

EC

FE

CL

MT

AT

TF

PD

AX

SU

BR

ST

RS

BT

HA

EL
LSC026

IDX
SC-13
 STARTING SYSTEM
Wiring Diagram — START — (Cont’d)

VG33E M/T MODELS NGSC0005S02

WSC065

SC-14
 STARTING SYSTEM
Wiring Diagram — START — (Cont’d)

VG33E A/T MODELS NGSC0005S03

GI

MA

EM

LC

EC

FE

CL

MT

AT

TF

PD

AX

SU

BR

ST

RS

BT

HA

WSC066 EL

IDX
SC-15
 STARTING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester

Trouble Diagnoses with

Battery/Starting/Charging System Tester NGSC0020
NOTE:
To ensure a complete and thorough diagnosis, the battery, starter
and generator test segments must be done as a set from start to
finish.

1. Turn off all loads on the vehicle electrical system.

2. Perform battery test with Battery/Starting/Charging system
tester. Refer to “Trouble Diagnoses with Battery/Starting/
Charging System Tester”, SC-7.
3. Press “ENTER” to begin the starting system test.

SEL408X

4. Start the engine.

SEL409X

5. Diagnosis result is displayed on the tester. Refer to “DIAG-

NOSTIC RESULT ITEM CHART”, SC-17.
NOTE:
쐌 If the starter performs normally but the engine does not start,
perform engine diagnosis.
쐌 For intermittent “NO CRANK” or “NO STARTER OPERATION”
incidents, refer to “DIAGNOSTIC PROCEDURE 2”, SC-21.

SEL410X

SC-16
 STARTING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

DIAGNOSTIC RESULT ITEM CHART NGSC0020S01

Diagnostic item Service procedure GI

CRANKING VOLTAGE NORMAL Go to “WORK FLOW”, SC-18.

CRANKING VOLTAGE LOW Go to “WORK FLOW”, SC-18. MA

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

FE

CL

MT

AT

TF

PD

AX

SU

BR

ST

RS

BT

HA

EL

IDX
SC-17
 STARTING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

WORK FLOW NGSC0020S02

SEL411X

*1 SC-7 *3 SC-19 *4 SC-21

*2 SC-22

SC-18
 STARTING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

DIAGNOSTIC PROCEDURE 1 NGSC0020S03

Check “B” Terminal Circuit NGSC0020S0301
GI
1 CHECK POWER SUPPLY FOR STARTER MOTOR “B” TERMINAL
1. Remove the fuel pump fuse.
2. Crank or start the engine (where possible) until the fuel pressure is released. MA
3. Turn the ignition switch OFF.
4. Check that the starter motor terminal “B” [E210, (B/R) for KA24DE models or E203, (B/L) for VG33E models] connec-
tion is clean and tight. EM
5. Check voltage between starter motor terminal “B” [E210, (B/R) for KA24DE models or E203, (B/L) for VG33E models]
and ground using a digital circuit tester.
LC

EC

FE

CL
LSC037

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

2 CHECK BATTERY CABLE CONNECTION QUALITY (VOLTAGE DROP TEST) TF

1. Check voltage between starter motor terminal “B” [E210, (B/R) for KA24DE models or E203, (B/L) for VG33E models]
and battery positive terminal using a digital circuit tester.
PD

AX

SU

BR
LSC038

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

BT

HA

EL

IDX
SC-19
 STARTING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

3 CHECK STARTER MOTOR GROUND CIRCUIT (VOLTAGE DROP TEST)

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

LSC039

OK or NG
OK 䊳 Starter motor “B” terminal circuit is OK. Further inspection necessary. Refer to “WORK
FLOW”, SC-18.
NG 䊳 Check the starter motor case and ground for poor continuity.

SC-20
 STARTING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

DIAGNOSTIC PROCEDURE 2 =NGSC0020S04

Check “S” Terminal Circuit NGSC0020S0401
GI
1 CHECK POWER SUPPLY FOR STARTER MOTOR “S” TERMINAL
1. Remove the fuel pump fuse.
2. Crank or start the engine (where possible) until the fuel pressure is released. MA
3. Turn the ignition OFF.
4. Disconnect starter motor terminal “S” [E209 (B/R) for KA24DE models or E202 (B/R) for VG33E models] connector.
5. Check voltage between starter motor terminal “S” [E209, (B/R) for KA24DE models or E202, (B/R) for VG33E models] EM
and ground using a digital circuit tester.

LC

EC

FE

LSC040
CL
OK or NG
OK 䊳 GO TO 2.
MT
NG 䊳 Check the following.
쐌 40A fusible link (letter e, located in fuse and fusible link box) AT
쐌 Clutch interlock relay
쐌 Park/neutral position relay
쐌 Harness for open or short TF

2 CHECK “S” TERMINAL CONNECTION QUALITY (VOLTAGE DROP TEST)

PD
1. Connect starter motor terminal “S” [E209, (B/R) for KA24DE models or E202, (B/R) for VG33E models] connector.
2. Check voltage between starter motor terminal “S” [E209, (B/R) for KA24DE models or E202, (B/R) for VG33E models]
and battery positive terminal using a digital tester. AX

SU

BR

ST
LSC041
RS
OK or NG
OK 䊳 Starter motor “S” terminal circuit is OK. Further inspection necessary. Refer to “WORK
FLOW”, SC-18. BT
NG 䊳 Check harness between the battery and the starter motor “S” terminal for poor continuity.
HA

EL

IDX
SC-21
 STARTING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

MINIMUM SPECIFICATION OF CRANKING VOLTAGE

REFERENCING COOLANT TEMPERATURE =NGSC0020S05

Voltage V
Engine coolant temperature
KA24DE VG33E

−30°C to −20°C (−22°F to −4°F) 8.0 8.6

−19°C to −10°C (−2°F to 14°F) 9.0 9.3

−9°C to 0°C (16°F to 32°F) 9.9 9.5

More than 1°C (More than 34°F) 10.2 10.2

SC-22
 STARTING SYSTEM
Construction

Construction =NGSC0006
KA24DE MODELS NGSC0006S01
GI

MA

EM

LC

EC

FE

CL

MT

AT

TF

PD

AX

SU

BR

ST

RS
LSC053

1. Gear case 7. Pinion stopper set 12. Packing BT

2. Shift lever 8. Pinion assembly 13. Yoke
3. Plate 9. Internal gear 14. Armature
4. Packing 10. Pinion shaft 15. Brush holder assembly HA
5. Adjusting plate 11. Planetary gear 16. Rear cover
6. Magnetic switch assembly

EL

IDX
SC-23
 STARTING SYSTEM
Construction (Cont’d)

VG33E MODELS NGSC0006S02

LSC052

1. Sleeve bearing 7. Packing 13. Washer

2. Gear case 8. Adjusting plate 14. Brush (–)
3. Pinion stopper set 9. Magnetic switch assembly 15. Brush holder
4. Pinion assembly 10. Yoke 16. Sleeve bearing
5. Shift lever 11. Brush (+) 17. Rear cover
6. Plate 12. Armature

SC-24
 STARTING SYSTEM
Removal and Installation

Removal and Installation NGSC0007

KA24DE MODELS
Removal
NGSC0007S01
GI
NGSC0007S0101
1. Remove engine under cover.
2. Remove two bolts and starter. MA
Installation NGSC0007S0102
To install, reverse the removal procedure. EM

MEL271H LC
VG33E MODELS NGSC0007S02
Removal NGSC0007S0201 EC
1. Remove engine under cover.
2. Remove two bolts and starter.
FE
Installation NGSC0007S0202
To install, reverse the removal procedure.
CL

ASC020
MT
Pinion/Clutch Check NGSC0008
1. Inspect pinion teeth. AT
쐌 Replace pinion if teeth are worn or damaged. (Also check
condition of ring gear teeth.)
TF
2. Inspect reduction gear teeth.
쐌 Replace reduction gear if teeth are worn or damaged. (Also
check condition of armature shaft gear teeth.) PD
3. Check to see if pinion locks in one direction and rotates
smoothly in the opposite direction.
쐌 If it locks or rotates in both directions, or unusual resistance is AX
evident, replace.
SU

BR

ST

RS

BT

HA

EL

IDX
SC-25
 CHARGING SYSTEM
System Description

System Description NGSC0009

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.
Power is supplied at all times to generator terminal S through:
쐌 80A fusible link [letter a, located in the fuse and fusible link box (with KA24DE engine)] or
쐌 100A fusible link [letter a, located in the fuse and fusible link box (with VG33E engine)] and
쐌 7.5A fuse (No. 36, located in the fuse and fusible link box).
Generator terminal B supplies power to charge the battery and operate the vehicle’s electrical system. Out-
put voltage is controlled by the IC regulator at generator terminal S detecting the input voltage. The charging
circuit is protected by the 80A fusible link (with KA24DE engine) or the 100A fusible link (with VG33E engine).
Ground is supplied to generator terminal E through body ground E203 (with KA24DE engine) or body ground
A1 (with VG33E engine).
With the ignition switch in the ON or START position, power is supplied
쐌 through 10A fuse [No. 11, located in the fuse block (J/B)]
쐌 to combination meter terminal 17 for the charge warning lamp.
Ground is supplied to combination meter terminal 43 through generator terminal L. With power and ground
supplied, the charge warning lamp will illuminate. When the generator 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-26
 CHARGING SYSTEM
Wiring Diagram — CHARGE —

Wiring Diagram — CHARGE — NGSC0010

KA24DE MODELS NGSC0010S01
GI

MA

EM

LC

EC

FE

CL

MT

AT

TF

PD

AX

SU

BR

ST

RS

BT

HA

EL
WSC072

IDX
SC-27
 CHARGING SYSTEM
Wiring Diagram — CHARGE — (Cont’d)

VG33E MODELS NGSC0010S02

WSC073

SC-28
 CHARGING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester

Trouble Diagnoses with

Battery/Starting/Charging System Tester
NOTE:
NGSC0021
GI
To ensure a complete and thorough diagnosis, the battery, starter
and generator test segments must be done as a set from start to MA
finish.

EM

LC
1. Turn off all loads on the vehicle electrical system.
2. Perform battery and starting system test with Battery/Starting/
Charging system tester.
EC
3. Press “ENTER” to begin the charging system test.
4. Start engine. FE

CL

SEL417X
MT
5. Press “ENTER” until “LOADS OFF REV ENGINE 5 SEC” is
displayed. AT
6. Raise and hold the engine speed at 1,500 to 2,000 rpm for
about 5 seconds, then return the engine to idle.
Once the increase in engine rpm is detected, press “ENTER” TF
to continue.
NOTE:
쐌 If after 30 seconds an increase in engine idle speed is not PD
detected, “RPM NOT DETECTED” will display.
쐌 Some engines may have a higher idle initially after starting, AX
SEL418X particularly when the engine is cold. The tester may detect this
without any other action being taken. If this occurs, continue on
with the testing process. The final results will not be affected. SU

BR

ST

RS

7. The tester now checks the engine at idle and performs the BT
DIODE/RIPPLE check.
8. When complete, the tester will prompt you to turn on the fol-
lowing electrical loads. HA
쐌 Heater fan set to highest speed. Do not run the A/C or wind-
shield defroster.
쐌 Headlamp high beam
쐌 Rear window defogger
NOTE: EL
Do not run the windshield wipers or any other cyclical loads.
SEL419X
IDX
SC-29
 CHARGING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)
9. Press “ENTER” to continue.

SEL420X

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

SEL421X

11. Diagnostic result is displayed on the tester. Refer to “DIAG-

NOSTIC RESULT ITEM CHART”, SC-31.

SEL422X

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

SEL577X

SC-30
 CHARGING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

DIAGNOSTIC RESULT ITEM CHART NGSC0021S01

Diagnostic item Service procedure GI

CHARGING SYSTEM NORMAL Charging system is normal and will also show DIODE RIPPLE test result.

NO CHARGING VOLTAGE Go to “WORK FLOW”, SC-32. MA

LOW CHARGING VOLTAGE Go to “WORK FLOW”, SC-32.

HIGH CHARGING VOLTAGE Go to “WORK FLOW”, SC-32. EM

DIODE RIPPLE NORMAL Diode ripple is OK and will also show CHARGING VOLTAGE test result.

Replace the generator. Perform “DIODE RIPPLE” test again using Battery/Starting/ LC
EXCESS RIPPLE DETECTED
Charging system tester to confirm repair.

DIODE RIPPLE NOT DETECTED Go to “WORK FLOW”, SC-32. EC

FE

CL

MT

AT

TF

PD

AX

SU

BR

ST

RS

BT

HA

EL

IDX
SC-31
 CHARGING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

WORK FLOW NGSC0021S02

LSC047

SC-32
 CHARGING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

DIAGNOSTIC PROCEDURE 1 NGSC0021S03

Check “L” Terminal Circuit NGSC0021S0301
GI
1 CHECK “L” TERMINAL CONNECTION
Check to see if “L” terminal is clean and tight.
MA
OK or NG
OK 䊳 GO TO 2.
EM
NG 䊳 Repair “L” terminal connection. Confirm repair by performing complete Battery/Starting/
Charging system test.
LC
2 CHECK “L” TERMINAL CIRCUIT
1. Disconnect E207 for KA24DE models or A8 for VG33E models connector from generator. EC
2. Apply ground to terminal “L” [E207, (Y/B) for KA24DE models or A8, (Y/B) for VG33E models] with the ignition switch in
the ON position.
FE

CL

MT

AT
LSC042

OK or NG
TF
OK 䊳 Replace the generator. Confirm repair by performing complete Battery/Starting/Charging
system test.
NG 䊳 Check the following. PD
쐌 10A fuse [No. 11, located in fuse block (J/B)]
쐌 CHARGE lamp
쐌 Harness for open or short between combination meter and fuse AX
쐌 Harness for open or short between combination meter and generator

SU

BR

ST

RS

BT

HA

EL

IDX
SC-33
 CHARGING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

DIAGNOSTIC PROCEDURE 2 =NGSC0021S04

Check “B” Terminal Circuit NGSC0021S0401

1 CHECK “B” TERMINAL CONNECTION

Check to see if “B” terminal is clean and tight.
OK or NG
OK 䊳 GO TO 2. Confirm repair by performing complete Battery/Starting/Charging system test.
NG 䊳 Repair “B” terminal connection.

2 CHECK GENERATOR “B” TERMINAL CIRCUIT

Check voltage between generator terminal “B” [E208, (W) for KA24DE models or A6, (W) for VG33E models] and ground
using a digital circuit tester.

LSC043

OK or NG
OK 䊳 GO TO 3.
NG 䊳 Check the following.
쐌 80A fusible link (letter a, located in fuse and fusible link box) for KA24DE models
쐌 100A fusible link (letter a, located in fuse and fusible link box) for VG33E models
쐌 Harness for open or short between generator and fusible link

3 CHECK “B” TERMINAL CONNECTION QUALITY (VOLTAGE DROP TEST)

Check voltage between generator terminal “B” [E208, (W) for KA24DE models or A6, (W) for VG33E models] and battery
positive terminal using a digital tester.

LSC044

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

SC-34
 CHARGING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

DIAGNOSTIC PROCEDURE 3 =NGSC0021S05

Check “S” Terminal Circuit NGSC0021S0501
GI
1 CHECK “S” TERMINAL CONNECTION
Check to see if “S” terminal is clean and tight.
MA
OK or NG
OK 䊳 GO TO 2.
EM
NG 䊳 Repair “S” terminal connection. Confirm repair by performing complete Battery/Starting/
Charging system test.
LC
2 CHECK GENERATOR “S” TERMINAL CIRCUIT
Check voltage between generator terminal “S” [E207, (G/B) for KA24DE models or A8, (G/B) for VG33E models] and EC
ground using a digital circuit tester.

FE

CL

MT

LSC045 AT
OK or NG
OK 䊳 GO TO 3. TF
NG 䊳 Check the following.
쐌 7.5A fuse (No. 36, located in fuse and fusible link box)
쐌 Harness for open or short between generator and fuse PD

3 CHECK “S” TERMINAL CONNECTION QUALITY (VOLTAGE DROP TEST) AX

Check voltage between generator terminal “S” [E207, (G/B) for KA24DE models or A8, (G/B) for VG33E models] and bat-
tery positive terminal using a digital tester.
SU

BR

ST

RS
LSC046

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

EL

IDX
SC-35
 CHARGING SYSTEM
Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

MALFUNCTION INDICATOR =NGSC0021S06

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

SC-36
 CHARGING SYSTEM
Construction

Construction =NGSC0012
KA24DE MODELS NGSC0012S01
GI

MA

EM

LC

EC

FE

CL

MT

AT

TF
ASC013
PD
1. Pulley assembly 5. Rotor 9. IC regulator assembly
2. Front cover 6. Slip ring 10. Diode assembly
3. Front bearing 7. Stator 11. Packing AX
4. Retainer 8. Fan guide 12. Rear cover

SU

BR

ST

RS

BT

HA

EL

IDX
SC-37
 CHARGING SYSTEM
Construction (Cont’d)

VG33E MODELS NGSC0012S02

LSC054

1. Pulley assembly 5. Rotor 9. IC regulator assembly

2. Front cover 6. Slip ring 10. Diode assembly
3. Front bearing 7. Stator 11. Packing
4. Retainer 8. Fan guide 12. Rear cover

Removal and Installation NGSC0013

KA24DE MODELS NGSC0013S01
Removal NGSC0013S0101
1. Remove engine undercover.
2. Remove RH side splash shield.
3. Disconnect harness connectors.
4. Loosen adjustment bolt, remove belt.
5. Remove two generator bolts and generator.
Installation NGSC0013S0102
AEL676B
To install, reverse the removal procedure.

SC-38
 CHARGING SYSTEM
Removal and Installation (Cont’d)
VG33E MODELS NGSC0013S02
Removal
1. Disconnect harness connectors.
NGSC0013S0201
GI
2. Remove engine undercover.
3. Loosen adjustment bolt, remove belt. MA
4. Remove 3 generator bolts and generator.
Installation NGSC0013S0202 EM
To install, reverse the removal procedure.

ASC012 LC

EC

FE

CL

MT

AT

TF

PD

AX

SU

BR

ST

RS

BT

HA

EL

IDX
SC-39
 SERVICE DATA AND SPECIFICATIONS (SDS)
Battery

Battery NGSC0014

Applied area USA Canada

Type 55D23R 65D26R

Capacity V-AH 12-60 12-65

Cold cranking current A

356 413
(For reference value)

Starter NGSC0015

Engine KA24DE VG33E

M000T60082ZC M000T60187ZC

Type MITSUBISHI make

Reduction gear type

System voltage 12 V

Terminal voltage 11.0 V

No-load Current Less than 90 A

Revolution More than 2,500 rpm

Minimum diameter of commutator 29.3 mm (1.154 in)

Minimum length of brush 7.0 mm (0.276 in)

Brush spring tension 5.8 - 21.6 N (0.59 - 2.20 kg, 1.30 - 4.86 lb)

Clearance of bearing metal and armature shaft mm

0.1 (0.004)
(in)

Clearance between pinion front edge and pinion stop-

0.2 - 2.0 (0.008 - 0.079)
per mm (in)

Generator NGSC0016

Engine KA24DE VG33E

LR170-757B LR180-756B
Type
HITACHI make

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

Ground polarity Negative

Minimum revolution under no-load (When 13.5

Less than 1,000 rpm
volts are applied)

More than 17 A/1,300 rpm More than 23 A/1,300 rpm

Hot output current (When 13.5 volts are
More than 54 A/2,500 rpm More than 65 A/2,500 rpm
applied)
More than 72 A/5,000 rpm More than 77 A/5,000 rpm

Regulated output voltage 14.1 - 14.7 V

Minimum length of brush 6.0 mm (0.236 in)

Brush spring pressure 1.000 - 2.452 N (102 - 250 g, 3.60 - 8.82 oz)

Slip ring minimum outer diameter 26.0 mm (1.024 in)

Rotor (Field coil) resistance 2.6 Ω 2.7 Ω

SC-40