SC

Google Docs
Google Drive
Download [pdf]

File Info : application/pdf, 40 Pages, 1.42MB

STARTING & CHARGING SYSTEM
K ELECTRICAL

SC A

SECTION

STARTING & CHARGING SYSTEM C

CONTENTS

PRECAUTIONS ......................................................... 2 Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" ................................................................. 2 Wiring Diagrams and Trouble Diagnosis ................. 2
PREPARATION .......................................................... 3 Special Service Tools .............................................. 3 Commercial Service Tools ....................................... 3
BATTERY ................................................................... 4 How to Handle Battery ............................................ 4 METHODS OF PREVENTING OVER-DISCHARGE .............................................................. 4 CHECKING ELECTROLYTE LEVEL ................... 5 SPECIFIC GRAVITY CHECK .............................. 5 CHARGING THE BATTERY ................................ 6 Trouble Diagnosis with Battery/Starting/Charging System Tester ......................................................... 6 DIAGNOSTIC RESULT ITEM CHART ................. 8 Removal and Installation ......................................... 9 REMOVAL ............................................................ 9 INSTALLATION .................................................... 9
STARTING SYSTEM ............................................... 10 System Description ............................................... 10 Wiring Diagram -- START -- .................................11 VK45DE ENGINE MODELS ...............................11 VQ35DE ENGINE MODELS .............................. 12 Trouble Diagnosis with Battery/Starting/Charging System Tester ....................................................... 13 DIAGNOSTIC RESULT ITEM CHART ............... 13 WORK FLOW ..................................................... 14 DIAGNOSTIC PROCEDURE 1 .......................... 15 DIAGNOSTIC PROCEDURE 2 .......................... 16 MINIMUM SPECIFICATION OF CRANKING

VOLTAGE REFERENCING COOLANT TEM-

PERATURE ........................................................ 16

Removal and Installation ....................................... 17

VK45DE ENGINE MODELS ............................... 17 G VQ35DE ENGINE MODELS (2WD) ................... 18

VQ35DE ENGINE MODELS (AWD) ................... 19

Disassembly and Assembly ................................... 20 Inspection After Disassembly ................................ 22

PINION/CLUTCH CHECK .................................. 22

CHARGING SYSTEM .............................................. 23 System Description ................................................ 23 I

Wiring Diagram -- CHARGE -- ............................ 24

VK45DE ENGINE MODELS ............................... 24

VQ35DE ENGINE MODELS .............................. 25 J

Trouble Diagnosis with Battery/Starting/Charging

System Tester ........................................................ 26

DIAGNOSTIC RESULT ITEM CHART ............... 27 SC WORK FLOW ..................................................... 28

DIAGNOSTIC PROCEDURE 1 .......................... 29

DIAGNOSTIC PROCEDURE 2 .......................... 30 DIAGNOSTIC PROCEDURE 3 .......................... 31 L

DIAGNOSTIC PROCEDURE 4 .......................... 32

DIAGNOSTIC PROCEDURE 5 .......................... 33

MALFUNCTION INDICATOR ............................. 33 M

Removal and Installation ....................................... 34

VK45DE ENGINE MODELS ............................... 34

VQ35DE ENGINE MODELS .............................. 35

Disassembly and Assembly ................................... 37

SERVICE DATA AND SPECIFICATIONS (SDS) ..... 39

Battery ................................................................... 39

Starter .................................................................... 39

Alternator ............................................................... 39

Revision: 2004 November

SC-1

2004.5 FX35/FX45

PRECAUTIONS

PFP:00001

Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT

BELT PRE-TENSIONER"

AKS00794

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 SRS and SB section of this Service Manual.
WARNING: q To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
q Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section.
q Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors.

Wiring Diagrams and Trouble Diagnosis

AKS00796

When you read wiring diagrams, refer to the following: q Refer to GI-15, "How to Read Wiring Diagrams" in GI section. q Refer to PG-3, "POWER SUPPLY ROUTING CIRCUIT" for power distribution circuit in PG section. When you perform trouble diagnosis, refer to the following: q Refer to GI-11, "HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES" in GI section. q Refer to GI-27, "How to Perform Efficient Diagnosis for an Electrical Incident" in GI section.

Revision: 2004 November

SC-2

2004.5 FX35/FX45

PREPARATION Special Service Tools
Tool number Tool name J-44373 Model 620 Battery/Starting/Charging system tester
Commercial Service Tools
Tool number Tool name Power tool

PREPARATION
Description
SEL403X
Description Loosening bolts and nuts
PBIC0190E

PFP:00002
A
AKS00797
B
C
D
E
F
AKS00798
G H
I
J
SC
L
M

Revision: 2004 November

SC-3

2004.5 FX35/FX45

BATTERY

PFP:AYBGL

How to Handle Battery

AKS00799

CAUTION: q If it becomes necessary to start the engine with a booster battery and jumper cables, use a 12-volt
booster battery.
q After connecting battery cables, ensure that they are tightly clamped to battery terminals for good contact.

METHODS OF PREVENTING OVER-DISCHARGE
The following precautions must be taken to prevent over-discharging a battery.
q The battery surface (particularly its top) should always be kept clean and dry.
q The terminal connections should be clean and tight.
q At every routine maintenance, check the electrolyte level. This also applies to batteries designated as "low maintenance" and "maintenance-free".

q When the vehicle is not going to be used over a long period of time, disconnect the negative battery cable.

MEL040F

q Check the charge condition of the battery. Periodically check the specific gravity of the electrolyte. Keep a close check on charge condition to prevent over-discharge.

MEL041F MEL042F

Revision: 2004 November

SC-4

2004.5 FX35/FX45

BATTERY

CHECKING ELECTROLYTE LEVEL

WARNING:

Do not allow battery fluid to come in contact with skin, eyes, fabrics, or painted surfaces. After touch-

ing a battery, do not touch or rub your eyes until you have thoroughly washed your hands. If acid con-

tacts eyes, skin or clothing, immediately flush with water for 15 minutes and seek medical attention. B

q Remove the cell plug using a suitable tool.

q Add distilled water up to the MAX level.

Sulphation A battery will be completely discharged if it is left unattended for a long time and the specific gravity will become less than 1.100. This may result in sulphation on the cell plates. To determine if a battery has been "sulphated", note its voltage and current when charging it. As shown in the figure, less current and higher voltage are observed in the initial stage of charging sulphated batteries. A sulphated battery may sometimes be brought back into service by means of a long, slow charge, 12 hours or more, followed by a battery capacity test.
SPECIFIC GRAVITY CHECK 1. Read hydrometer and thermometer indications at eye level. 2. Use the chart below to correct your hydrometer reading accord-
ing to electrolyte temperature.

E
MEL043F
F
G
H
I
PKIA2353E
J
SC

Hydrometer Temperature Correction
Battery electrolyte temperature °C (°F) 71 (160) 66 (150) 60 (140) 54 (130) 49 (120) 43 (110) 38 (100) 32 (90) 27 (80) 21 (70)
Revision: 2004 November

SC-5

MEL042FA

Add to specific gravity reading 0.032 0.028 0.024 0.020 0.016 0.012 0.008 0.004 0 -0.004
2004.5 FX35/FX45

BATTERY

Battery electrolyte temperature °C (°F) 16 (60) 10 (50) 4 (40) -1 (30) -7 (20) -12 (10) -18 (0)

Add to specific gravity reading -0.008 -0.012 -0.016 -0.020 -0.024 -0.028 -0.032

Corrected specific gravity 1.260 - 1.280 1.230 - 1.250 1.200 - 1.220 1.170 - 1.190 1.140 - 1.160 1.110 - 1.130

Approximate charge condition Fully charged 3/4 charged 1/2 charged 1/4 charged
Almost discharged Completely discharged

CHARGING THE BATTERY
CAUTION: q Do not "quick charge" a fully discharged battery.
q Keep the battery away from open flame while it is being charged.
q 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.
q If battery electrolyte temperature rises above 55°C (131°F), stop charging. Always charge battery at a temperature below 55°C (131°F).

Charging Rates

Amp 50 25 10 5

Time 1 hour 2 hours 5 hours 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.
q If, after charging, the specific gravity of any two cells varies more than 0.050, the battery should be replaced.

Trouble Diagnosis with Battery/Starting/Charging System Tester

AKS0079A

CAUTION: When working with batteries, always wear appropriate eye protection.
NOTE: q To ensure a complete and thorough diagnosis, the battery, starter and alternator test segments must be
done as a set from start to finish.
q If battery surface charge is detected while testing, the tester will prompt you to turn on the headlamps to remove the surface charge.
q If necessary, the tester will prompt you to determine if the battery temperature is above or below 0°C (32°F). Choose the appropriate selection by pressing the up or down arrow button, then press "ENTER" to make the selection.

Revision: 2004 November

SC-6

2004.5 FX35/FX45

BATTERY
1. Turn off all loads on the vehicle electrical system. Clean or repair as necessary.
2. Visually inspect the battery, battery terminals and cable ends with ignition switch in "OFF" position. NOTE: 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 appear during the test procedures. If this occurs, clean the battery post and terminals, reconnect them and restart the test.
3. Connect the red tester lead clamp to the positive battery terminal, and the black to the negative terminal.
4. The tester will turn on automatically. Using the arrow keys, select "IN-VEHICLE" on the tester and then press the "ENTER" key.
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. 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 battery 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 displayed on the tester. Refer to SC-8, "DIAGNOSTIC RESULT ITEM CHART" .

C
SEL404X
D

G
SEL405X
H

I J

SEL406X

SC L

Revision: 2004 November

SC-7

SEL407X
2004.5 FX35/FX45

BATTERY

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: q If necessary, the tester will ask the user to determine if the
battery has just been charged. Choose the appropriate selection by pressing the up or down arrow button and then press the "ENTER" button to make the selection.

q When testing a battery installed in a vehicle that has recently

been driven, select "BEFORE CHARGE".

q If the battery has just been slow charged due to a "CHARGE

SEL576X

& RETEST" decision by the tester, and the tester asks the user "BEFORE CHARGE/AFTER

CHARGE", select "AFTER CHARGE".

DIAGNOSTIC RESULT ITEM CHART

Diagnostic item

Service procedure

GOOD BATTERY

Battery is OK, go to "Trouble Diagnosis","STARTING SYSTEM". Refer to SC-13, "Trouble Diagnosis with Battery/Starting/Charging System Tester" .

REPLACE BATTERY

Replace battery. Before replacing battery, clean the battery cable clamps and battery posts. Perform battery test again with Battery/Starting/Charging system tester. If second test result is "Replace Battery", then do so. Perform battery test again to confirm repair.

BAD CELL-REPLACE

Replace the battery. Perform battery test again with Battery/Starting/Charging system tester to confirm repair.

GOOD-RECHARGE

Perform the slow battery charging procedure. (Initial rate of charge is 10A for 12 hours.)

CHARGE & RETEST

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.
NOTE: If the tester asks the user "BEFORE CHARGE/AFTER CHARGE", select "AFTER CHARGE".

Revision: 2004 November

SC-8

2004.5 FX35/FX45

Removal and Installation
REMOVAL
1. Remove hoodledge cover (right).

BATTERY

2. Disconnect negative battery cable and positive battery cable. CAUTION: When disconnecting, disconnect negative battery cable first.
3. Remove battery fix frame mounting nuts and battery fix frame. 4. Remove relay box from bracket. 5. Remove battery.
INSTALLATION Install in the reverse order of removal. CAUTION: When connecting, connect positive battery cable first.
Battery fix frame mounting nut
: 3.9 N·m (0.4 kg-m, 35 in-lb) Battery terminal nut
: 5.4 N·m (0.55 kg-m, 48 in-lb)

AKS0079B
A

D
PKIA2805E
E

PKIA2806E

I J

Revision: 2004 November

SC-9

2004.5 FX35/FX45

STARTING SYSTEM

PFP:23300

System Description

AKS0079C

Power is supplied at all times: q through 40A fusible link (letter F, located in the fuse and fusible link block) q to ignition switch terminal 1 q through 15A fuse (No. 78, located in the IPDM E/R) q to CPU of IPDM E/R q through 10A fuse (No. 71, located in the IPDM E/R) q to CPU of IPDM E/R. When the selector lever in the P or N position, power is supplied: q from TCM, and through A/T assembly terminal 9

q to IPDM E/R terminal 53.

Ground is supplied:

q to IPDM E/R terminals 38, 50 and 60

q from body grounds E21, E50 and E51.

With the ignition switch in the START position, and provided that the IPDM E/R receives a starter relay ON signal from the CAN lines, the IPDM E/R is energized and power is supplied:
q from ignition switch terminal 5
q to IPDM E/R terminal 4 and
q through IPDM E/R terminal 3
q to starter motor terminal 1.
The starter motor plunger closes and provides a closed circuit between the battery and starter motor. The starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the engine starts.

Revision: 2004 November

SC-10

2004.5 FX35/FX45

STARTING SYSTEM
Wiring Diagram -- START --
VK45DE ENGINE MODELS

AKS0079D
A B C D E F G H I J SC L M

Revision: 2004 November

SC-11

TKWM0548E
2004.5 FX35/FX45

VQ35DE ENGINE MODELS

STARTING SYSTEM

Revision: 2004 November

SC-12

TKWM0549E
2004.5 FX35/FX45

STARTING SYSTEM

Trouble Diagnosis with Battery/Starting/Charging System Tester

AKS0079E

NOTE:

To ensure a complete and thorough diagnosis, the battery, starter and alternator 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 SC-6, "Trouble Diagnosis with Battery/Starting/

Charging System Tester" .

3. Press "ENTER" to begin the starting system test.

4. Start the engine.

E
SEL408X
F

5. Diagnosis result is displayed on the tester. Refer to SC-13, "DIAGNOSTIC RESULT ITEM CHART" .
NOTE: q If the starter performs normally but the engine does not start,
perform engine diagnosis.
q For intermittent "NO CRANK" or "NO STARTER OPERATION" incidents, refer to SC-16, "DIAGNOSTIC PROCEDURE 2" .

SEL409X
I
J
SC

SEL410X

DIAGNOSTIC RESULT ITEM CHART

Diagnostic item

Service procedure

CRANKING VOLTAGE NORMAL

Go to "WORK FLOW", SC-14, "WORK FLOW" .

CRANKING VOLTAGE LOW

Go to "WORK FLOW", SC-14, "WORK FLOW" .

CHARGE BATTERY

Perform the slow battery charging procedure. (Initial rate of charge is 10A for 12 hours.) Perform battery test again with Battery/Starting/Charging system tester. Refer toSC-6, "Trouble Diagnosis with Battery/Starting/Charging System Tester" .

REPLACE BATTERY

Before replacing battery, clean the battery cable clamps and battery posts. Perform battery test again with Battery/Starting/Charging system tester. Refer to SC-6, "Trouble Diagnosis with Battery/Starting/Charging System Tester" . If second test result is "REPLACE BATTERY", then do so. Perform battery test again to confirm repair.

Revision: 2004 November

SC-13

2004.5 FX35/FX45

WORK FLOW

STARTING SYSTEM

SKIB0227E

*1 SC-13, "Trouble Diagnosis with Bat- *2 SC-16, "MINIMUM SPECIFICATION *3 SC-15, "DIAGNOSTIC PROCE-

tery/Starting/Charging System

OF CRANKING VOLTAGE REFER-

DURE 1".

Tester".

ENCING COOLANT TEMPERA-

TURE".

*4 SC-16, "DIAGNOSTIC PROCEDURE 2".

Revision: 2004 November

SC-14

2004.5 FX35/FX45

STARTING SYSTEM

DIAGNOSTIC PROCEDURE 1

Check "B" Terminal Circuit

1. CHECK POWER SUPPLY FOR STARTER MOTOR "B" TERMINAL

1. Remove fuel pump fuse.

2. Crank or start the engine (where possible) until the fuel pressure is released.

3. Turn ignition switch OFF. C
4. Make sure that the starter motor B terminal E313 terminal 2 (B) (VK45DE) or (B/R) (VQ35DE) connection is clean and tight.

5. Check voltage between starter motor B terminal E313 terminal 2 (B) (VK45DE) or (B/R) (VQ35DE) and ground using a digital cir-

cuit tester.

Battery voltage should exist.

OK or NG

OK >> GO TO 2.

NG >> Check harness between the battery and the starter

motor for open circuit.

2. CHECK BATTERY HARNESS CONNECTION (VOLTAGE DROP TEST)
Check voltage between starter motor B terminal E313 terminal 2 (B) (VK45DE) or (B/R) (VQ35DE) and battery positive terminal using a digital circuit tester.
When the ignition switch is in START position, Voltage: Less than 0.5V
OK or NG OK >> GO TO 3. NG >> Check harness between the battery and the starter motor for poor continuity.
3. CHECK STARTER MOTOR GROUND CIRCUIT (VOLTAGE DROP TEST)
1. Turn ignition switch OFF. 2. Check voltage between starter motor case and battery negative
terminal using a digital circuit tester.
When the ignition switch is in START position, Voltage: Less than 0.2V
OK or NG OK >> Starter motor "B" terminal circuit is OK. Further inspection necessary. Refer to SC-14, "WORK FLOW" . NG >> Check the starter motor case and ground for poor continuity.

PKIA2842E

PKIA2370E

PKIA2943E

Revision: 2004 November

SC-15

2004.5 FX35/FX45

STARTING SYSTEM

DIAGNOSTIC PROCEDURE 2 Check "S" Connector Circuit

1. CHECK POWER SUPPLY FOR STARTER MOTOR "S" CONNECTOR

1. Remove fuel pump fuse.
2. Crank or start the engine (where possible) until the fuel pressure is released.
3. Turn ignition switch OFF. 4. Disconnect starter motor S connector.
5. Check voltage between starter motor harness connector E312 (VK45DE) or F33 (VQ35DE) terminal 1 (B) and ground using a digital circuit tester.

When the ignition switch is in START position, Battery voltage should exist.

OK or NG

OK >> GO TO 2. NG >> Check the following.

q 40A fusible link (letter F , located in fuse and fusible link box)

PKIA2807E

q Ignition switch

q Starter relay [within the IPDM E/R (intelligent power distribution module engine room)].

q Harness for open or short

2. CHECK "S" TERMINAL CONNECTION (VOLTAGE DROP TEST)

1. Turn ignition switch OFF.
2. Connect starter motor S connector.
3. Check voltage between starter motor harness connector E312 (VK45DE) or F33 (VQ35DE) terminal 1 (B) and battery positive terminal using a digital circuit tester.

When the ignition switch is in START position, Voltage: Less than 1V

OK or NG
OK >> Starter motor "S" connector circuit is OK. Further inspection necessary. Refer to SC-14, "WORK FLOW" .
NG >> Check harness between the battery and the starter motor "S" connector for poor continuity.

PKIA2808E

MINIMUM SPECIFICATION OF CRANKING VOLTAGE REFERENCING COOLANT TEMPERATURE

Engine coolant temperature -30°C to -20°C (-22°F to -4°F) -19°C to -10°C (-2°F to 14°F)
-9°C to 0°C (16°F to 32°F) More than 1°C (More than 34°F)

Voltage V 8.4 8.9 9.3 9.7

Revision: 2004 November

SC-16

2004.5 FX35/FX45

Removal and Installation
VK45DE ENGINE MODELS

STARTING SYSTEM

AKS00BRA
A

1. Starter motor 4. B terminal nut

2. Starter motor mounting bolt 5. S connector

Removal 1. Disconnect negative battery cable. 2. Remove engine front and rear undercover, using power tools. 3. Disconnect S connector. 4. Remove B terminal nut. 5. Remove starter motor mounting bolts. 6. Loosen A/T fluid cooler tube clip bolts. Refer to AT-271,
"TRANSMISSION ASSEMBLY" in "AUTOMATIC TRANSMISSION (A/T)" section. 7. Remove starter motor to the direction of under side the vehicle.

3. B terminal harness 6. Cylinder block

Installation Install in the reverse order of removal.
CAUTION: Be sure to tighten B terminal nut carefully.

PKIA2809E

PKIA2810E

Revision: 2004 November

SC-17

2004.5 FX35/FX45

STARTING SYSTEM
VQ35DE ENGINE MODELS (2WD)

1. Starter motor mounting bolt 4. B terminal nut 7. Oil pan

2. Harness clip bracket 5. B terminal harness

Removal 1. Disconnect negative battery cable. 2. Remove engine rear undercover, using power tools. 3. Disconnect S connector. 4. Remove B terminal nut. 5. Remove starter motor mounting bolts and harness clip bracket,
using power tools. 6. Remove starter motor to the direction of under side the vehicle.

3. S connector 6. Starter motor

Installation Install in the reverse order of removal.
CAUTION: Be sure to tighten B terminal nut carefully.

PKIA3127E PKIA2812E

Revision: 2004 November

SC-18

2004.5 FX35/FX45

STARTING SYSTEM
VQ35DE ENGINE MODELS (AWD)

1. Starter motor mounting bolt 4. B terminal harness

2. Oil pan 5. B terminal nut

3. Starter motor 6. S connector

Installation
Install in the reverse order of removal. CAUTION: Be sure to tighten B terminal nut carefully.

A B C D E F
PKIA2843E
G H I J SC
PKIA2844E
L M

Revision: 2004 November

SC-19

2004.5 FX35/FX45

STARTING SYSTEM Disassembly and Assembly

AKS0079R

1. Nut 4. Packing 7. Front bracket assembly 10. Washer 13. Rear bracket assembly 16. Packing 19. Clutch gear assembly

2. Magnetic switch assembly 5. Plate 8. Yoke assembly 11. Rear bearing 14. Through bolt 17. Ball 20. Pinion stopper

3. Adjusting plate 6. Shift lever 9. Armature assembly 12. Brush holder assembly 15. Cover 18. Shaft gear assembly 21. Stopper clip

PKIA3126E

Revision: 2004 November

SC-20

2004.5 FX35/FX45

1. Magnetic switch assembly 4. Center bracket (A) 7. Brush holder assembly 10. Through bolt 13. Pinion shaft 16. Center bracket (P) 19. Ball bearing

STARTING SYSTEM

2. Dust cover kit 5. Yoke assembly 8. Thrust washer 11. Internal gear 14. Packing 17. E-ring 20. Caul

3. Shift lever set

PKIA2814E
I

6. Armature assembly

9. Rear cover assembly
J
12. Planetary gear

15. Thrust washer

18. Pinion assembly
SC
21. Gear case assembly

Revision: 2004 November

SC-21

2004.5 FX35/FX45

STARTING SYSTEM

1. Magnetic switch assembly 4. Center bracket (A) 7. Brush holder assembly 10. Through bolt 13. Pinion shaft 16. Center bracket (P) 19. Ball bearing

2. Dust cover kit 5. Yoke assembly 8. Thrust washer 11. Internal gear 14. Packing 17. E-ring 20. Caul

3. Shift lever set 6. Armature assembly 9. Rear cover assembly 12. Planetary gear 15. Thrust washer 18. Pinion assembly 21. Gear case assembly

PKIA2845E

Inspection After Disassembly
PINION/CLUTCH CHECK

AKS0079H

1. Inspect pinion teeth.

q Replace pinion if teeth are worn or damaged. (Also check condition of ring gear teeth.)

2. Inspect reduction gear teeth.

q Replace reduction gear if teeth are worn or damaged. (Also check condition of armature shaft gear teeth.)

3. Check to see if pinion locks in one direction and rotates smoothly in the opposite direction.

q If it locks or rotates in both directions, or unusual resistance is evident, replace.

Revision: 2004 November

SC-22

2004.5 FX35/FX45

CHARGING SYSTEM

CHARGING SYSTEM System Description

PFP:23100
A
AKS0079I

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:

q through 10A fuse (No. 33, located in the fuse and fusible link block)

q to alternator terminal 4 (S).

Terminal B supplies power to charge the battery and operate the vehicle's electrical system. Output voltage is

controlled by the IC regulator at terminal 4 (S) detecting the input voltage.

The charging circuit is protected by the 120A fusible link (VK45DE and VQ35DE AWD).

The alternator is grounded to the engine block.

With the ignition switch in the ON or START position, power is supplied:

q through 10A fuse [No. 14, located in the fuse block (J/B)]

q to combination meter terminal 7 for the charge warning lamp.

Ground is supplied:

q to combination meter terminal 2

q through alternator terminal 3 (L)

q to alternator terminal E (VK45DE) or through body ground (VQ35DE)

q through body ground E304 (VK45DE).

With power and ground supplied, the charge warning lamp will illuminate. When the alternator is providing suf-

ficient voltage with the engine running, the ground is opened and the charge warning lamp will go off.

If the charge warning lamp illuminates with the engine running, a malfunction is indicated.

Revision: 2004 November

SC-23

2004.5 FX35/FX45

CHARGING SYSTEM
Wiring Diagram -- CHARGE --
VK45DE ENGINE MODELS

AKS0079J

Revision: 2004 November

SC-24

TKWM0550E
2004.5 FX35/FX45

CHARGING SYSTEM
VQ35DE ENGINE MODELS
A B C D E F G H I J SC L M

Revision: 2004 November

SC-25

TKWM0551E
2004.5 FX35/FX45

CHARGING SYSTEM

Trouble Diagnosis with Battery/Starting/Charging System Tester

AKS0079K

NOTE: To ensure a complete and thorough diagnosis, the battery, starter and alternator 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 and starting system test with Battery/Starting/ Charging system tester.

3. Press "ENTER" to begin the charging system test.

4. Start engine.

5. Press "ENTER" until "LOADS OFF REV ENGINE 5 SEC" is displayed.
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" to continue.
NOTE: q If after 30 seconds an increase in engine idle speed is not
detected, "RPM NOT DETECTED" will display.
q Some engines may have a higher idle initially after starting, 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.
7. The tester now checks the engine at idle and performs the DIODE/RIPPLE check.
8. When complete, the tester will prompt you to turn on the following electrical loads.
q Heater fan set to highest speed. Do not run the A/C or windshield defroster.
q Headlamp high beam
q Rear window defogger
NOTE: Do not run the windshield wipers or any other cyclical loads.
9. Press "ENTER" to continue.

SEL417X SEL418X SEL419X

Revision: 2004 November

SC-26

SEL420X
2004.5 FX35/FX45

CHARGING SYSTEM
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 continue. 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.
11. Diagnostic result is displayed on the tester. Refer to SC-27, "DIAGNOSTIC RESULT ITEM CHART" .

A
B
C
SEL421X
D
E

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.

G
SEL422X
H
I

DIAGNOSTIC RESULT ITEM CHART

SEL577X

Diagnostic item

Service procedure

CHARGING SYSTEM NORMAL

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

NO CHARGING VOLTAGE

Go to SC-28, "WORK FLOW" .

LOW CHARGING VOLTAGE

Go to SC-28, "WORK FLOW" .

HIGH CHARGING VOLTAGE

Go to SC-28, "WORK FLOW" .

DIODE RIPPLE NORMAL

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

EXCESS RIPPLE DETECTED

Replace the alternator. Perform "DIODE RIPPLE" test again using Battery/Starting/Charging system tester to confirm repair.

DIODE RIPPLE NOT DETECTED

Go to SC-28, "WORK FLOW" .

Revision: 2004 November

SC-27

2004.5 FX35/FX45

WORK FLOW

CHARGING SYSTEM

Revision: 2004 November

SC-28

PKIA2226E
2004.5 FX35/FX45

CHARGING SYSTEM

DIAGNOSTIC PROCEDURE 1

Check "L" Terminal Circuit

1. CHECK "L" TERMINAL CONNECTION

1. Turn ignition switch OFF.

2. Check to see if "L" terminal is clean and tight.

OK or NG C
OK >> GO TO 2. NG >> Repair "L" terminal connection. Confirm repair by performing complete Battery/Starting/Charging
system test. D
2. CHECK "L" TERMINAL CIRCUIT

1. Disconnect alternator connector. 2. Apply ground to alternator harness connector E311 (VK45DE) or
F26 (VQ35DE) terminal 3 (OR) with the ignition switch in the ON position.
CHARGE lamp should light up.
OK or NG OK >> Go to SC-28, "WORK FLOW" . NG >> Check the following. q 10A fuse [No. 14, located in fuse block (J/B)] q CHARGE lamp q Harness for open or short between combination meter and fuse q Harness for open or short between combination meter and alternator

PKIA2815E

Revision: 2004 November

SC-29

2004.5 FX35/FX45

CHARGING SYSTEM

DIAGNOSTIC PROCEDURE 2 Check "B" Terminal Circuit
1. CHECK "B" TERMINAL CONNECTION

1. Turn ignition switch OFF. 2. Check to see if "B" terminal is clean and tight. OK or NG
OK >> GO TO 2. Confirm repair by performing complete Battery/Starting/Charging system test. NG >> Repair "B" terminal connection.
2. CHECK ALTERNATOR "B" TERMINAL CIRCUIT

Check voltage between alternator B terminal E307 terminal 1 (B/R) and ground using a digital circuit tester.
Battery voltage should exist.
OK or NG OK >> GO TO 3. NG >> Check the following. q 120A fusible link [fusible link holder (VK45DE and VQ35DE AWD)] q Harness for open or short between alternator and fusible link (VK45DE and VQ35DE AWD) q Harness for open or short between alternator and battery (VQ35DE 2WD)
3. CHECK "B" TERMINAL CONNECTION (VOLTAGE DROP TEST)

PKIA2944E

1. Start the engine. 2. When the engine running at idle and warm, check voltage
between alternator B terminal E307 terminal 1 (B/R) and battery positive terminal using a digital circuit tester.
Voltage: Less than 0.2V
OK or NG OK >> Replace the alternator. Confirm repair by performing complete Battery/Starting/Charging system test. NG >> Check harness between the battery and the alternator for poor continuity.

PKIA2366E

Revision: 2004 November

SC-30

2004.5 FX35/FX45

CHARGING SYSTEM

DIAGNOSTIC PROCEDURE 3

Check "L" Terminal Circuit

1. CHECK "L" TERMINAL CONNECTION

1. Turn ignition switch OFF.

2. Check to see if "L" terminal is clean and tight.

OK or NG C
OK >> GO TO 2. NG >> Repair "L" terminal connection. Confirm repair by performing complete Battery/Starting/Charging
system test. D
2. CHECK "L" TERMINAL CIRCUIT

1. Disconnect alternator connector. 2. Apply ground to alternator harness connector E311 (VK45DE) or
F26 (VQ35DE) terminal 3 (OR) with the ignition switch in the ON position.
CHARGE lamp should light up.
OK or NG OK >> Replace the alternator. Confirm repair by performing complete Battery/Starting/Charging system test. NG >> Check the following. q 10A fuse [No. 14, located in fuse block (J/B)] q CHARGE lamp q Harness for open or short between combination meter and fuse q Harness for open or short between combination meter and alternator

PKIA2815E

Revision: 2004 November

SC-31

2004.5 FX35/FX45

CHARGING SYSTEM

DIAGNOSTIC PROCEDURE 4 Check "B" Terminal Circuit
1. CHECK "B" TERMINAL CONNECTION

PKIA2944E

1. Start the engine. 2. When the engine running at idle and warm, check voltage
between alternator B terminal E307 terminal 1 (B/R) and battery positive terminal using a digital circuit tester.
Voltage: Less than 0.2V
OK or NG OK >> GO TO 4. NG >> Check harness between the battery and the alternator for poor continuity.
4. CHECK ALTERNATOR DRIVE BELT TENSION

PKIA2366E

1. Turn ignition switch OFF.
2. Check alternator drive belt tension. Refer to EM-170, "Checking Drive Belts" (VK45DE) or EM-15, "Checking Drive Belts" (VQ35DE) in "ENGINE MECHANICAL (EM)" section.

Does drive belt tension normal?

YES or NO

YES NO

>> Replace the alternator. Confirm repair by performing complete Battery/Starting/Charging system test.
>> Readjust drive belt tension. Refer to EM-170, "Tension Adjustment" (VK45DE) or EM-15, "Tension Adjustment" (VQ35DE) in "ENGINE MECHANICAL (EM)" section.

Revision: 2004 November

SC-32

2004.5 FX35/FX45

CHARGING SYSTEM

DIAGNOSTIC PROCEDURE 5

Check "S" Terminal Circuit

1. CHECK "S" TERMINAL CONNECTION

1. Turn ignition switch OFF.

2. Check to see if "S" terminal is clean and tight.

OK or NG C
OK >> GO TO 2. NG >> Repair "S" terminal connection. Confirm repair by performing complete Battery/Starting/Charging
system test. D
2. CHECK ALTERNATOR "S" TERMINAL CIRCUIT

Check voltage between alternator harness connector E311 (VK45DE) or F26 (VQ35DE) terminal 4 (LG) and ground using a digital circuit tester.
Battery voltage should exist.
OK or NG OK >> GO TO 3. NG >> Check the following. q 10A fuse (No. 33, located in fuse and fusible link box) q Harness for open or short between alternator and fuse
3. CHECK "S" TERMINAL CONNECTION (VOLTAGE DROP TEST)

PKIA2816E

1. Start the engine.

2. When the engine running at idle and warm, check voltage

between alternator connector E311 (VK45DE) or F26 (VQ35DE)

terminal 4 (LG) and battery positive terminal using a digital cir-

cuit tester.

Voltage: Less than 0.2V
OK or NG
OK >> Replace the alternator. Confirm repair by performing complete Battery/Starting/Charging system test.
NG >> Check harness between the battery and the alternator for poor continuity.

SC
L
PKIA2817E

MALFUNCTION INDICATOR

The IC regulator warning function activates to illuminate "CHARGE" warning lamp, if any of the following symptoms occur while alternator is operating:

q Excessive voltage is produced.

q No voltage is produced.

Revision: 2004 November

SC-33

2004.5 FX35/FX45

Removal and Installation
VK45DE ENGINE MODELS

CHARGING SYSTEM

AKS00AV7

1. Alternator ground harness mounting bolt 4. Alternator Nut 7. Alternator 10. Alternator mounting bolt

2. B terminal nut 5. Alternator bracket 8. Alternator mounting bolt 11. Alternator stay mounting bolt

PKIA2818E
3. Alternator B terminal harness 6. Alternator connector 9. Alternator stay 12. Alternator ground harness

Removal 1. Disconnect negative battery cable.
2. Remove engine front undercover, using power tools.
3. Remove cooling fan lower shroud. Refer to CO-39, "RADIATOR" in "ENGINE COOLING SYSTEM (CO)" section.
4. Remove alternator, water pump and A/C compressor belt. Refer to EM-170, "Removal and Installation" in "ENGINE MECHANICAL (EM)" section.
5. Remove alternator mounting bolts, using power tools.

6. Disconnect alternator connector. 7. Remove B terminal nut. 8. Remove alternator ground harness mounting bolt. 9. Remove alternator assembly to the direction of under side the
vehicle.

Revision: 2004 November

SC-34

PKIA2954E
PKIA2820E
2004.5 FX35/FX45

CHARGING SYSTEM

Installation

Install in the reverse order of removal, taking care of the following point.

q Install alternator, and check tension of belt. Refer to EM-170, "Checking Drive Belts" in "ENGINE

MECHANICAL (EM)" section.

CAUTION:

Be sure to tighten B terminal nut carefully.

VQ35DE ENGINE MODELS
C

1. B terminal nut

2. Alternator B terminal harness

PKIA2821E

3. Alternator connector

4. Alternator mounting bolt

5. Alternator stay mounting bolt

6. Alternator stay

7. Alternator
J
Removal

1. Disconnect negative battery cable.

2. Remove engine front undercover, using power tools.

3. Remove alternator and power steering belt. Refer to EM-16, "Removal and Installation" in "ENGINE MECHANICAL (EM)" section.

4. Disconnect alternator connector.

5. Remove B terminal nut.

6. Remove harness clip and water hose bracket from alternator. M

PKIA2358E

Revision: 2004 November

SC-35

2004.5 FX35/FX45

CHARGING SYSTEM
7. Remove oil pressure switch harness clip from alternator stay. (2WD)
8. Disconnect oil pressure switch connector. (2WD) 9. Remove alternator stay mounting bolts and alternator stay, using
power tools. 10. Remove alternator mounting bolt, using power tools.

PKIA1923E

11. Remove alternator assembly to the direction of under side the vehicle.
Installation Install in the reverse order of removal, taking care of the following point. q Install alternator, and check tension of belt. Refer to EM-15, "Checking Drive Belts"
MECHANICAL (EM)" section. CAUTION: Be sure to tighten B terminal nut carefully.

in "ENGINE

Revision: 2004 November

SC-36

2004.5 FX35/FX45

CHARGING SYSTEM Disassembly and Assembly

AKS007AI
A

1. Stator assembly 4. Retainer 7. Pulley 10. Double labyrinth seal 13. Rear bracket assembly

I
PKIA2822E

2. Slip ring

3. Rotor assembly

5. Front bearing 8. Pulley nut

6. Front bracket assembly

9. Fun guide

11. IC voltage regulator assembly

12. Diode assembly

14. B terminal nut

15. Through bolt and nut

Revision: 2004 November

SC-37

2004.5 FX35/FX45

CHARGING SYSTEM

1. Rear bearing 4. Front bearing 7. Pulley 10. IC voltage regulator assembly 13. B terminal nut

2. Rotor assembly 5. Through bolt 8. Pulley nut 11. Diode assembly

PKIA2823E
3. Retainer 6. Front bracket assembly 9. Stator assembly 12. Rear bracket assembly

Revision: 2004 November

SC-38

2004.5 FX35/FX45

SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) Battery

PFP:00030
A
AKS0079N

Applied model Type

VK45DE 80D23L

VQ35DE

110D26L

Capacity

V - AH

12 - 52

12 - 64

Cold cranking current (For reference value) A

582

730

Starter
Applied model

VK45DE

VQ35DE (2WD)

AKS0079O
D
VQ35DE (AWD)

M2T85075

S114-880

S114-881

Type

MITSUBISHI make

HITACHI make

Reduction gear type

System voltage

Terminal voltage

No-load

Current

A Less than 145

Less than 90

Revolution

rpm More than 3,300

More than 2,880

Minimum diameter of commutator

mm (in)

31.4 (1.236)

28.0 (1.102)

Minimum length of brush Brush spring tension

mm (in) N (kg, lb)

11.0 (0.433)
26.7 - 36.1 (2.72 - 3.68, 6.80 - 8.12)

10.5 (0.413)
H
16.2 (1.65, 3.6)

Clearance between bearing metal and armature shaft

mm (in)

Less than 0.2 (0.008)

Clearance between pinion front edge and pinion stopper mm (in)

0.5 - 2.0 (0.020 - 0.079)

0.3 - 2.5 (0.012 - 0.098)

Alternator

J
AKS0079P

Applied model

VK45DE

VQ35DE

Type

LR1110 - 716 HITACHI make

A3TG0191

MITSUBISHI make

Nominal rating - A

12 - 110

Ground polarity

Negative

Minimum revolution under no-load (When 13.5V is applied) rpm

Less than 1,100

Less than 1,000

Hot output current (When 13.5V is applied) rpm

More than 70/1,800 More than 91/2,500

More than 110/5,000

More than 37/1,300 More than 92/2,500 More than 103/5,000

Regulated output voltage V

14.1 - 14.7

Minimum length of brush (in)

More than 6.00 (0.236)

More than 5.00 (0.197)

Brush spring pressure (g, oz)

1.00 - 3.43

(102 - 350, 3.60 - 12.34)

4.9 - 6.1 (499 - 622, 17.62 - 21.94)

Slip ring minimum outer diameter (in)

More than 26.0 (1.024)

More than 22.1 (0.870)

Rotor (Field coil) resistance

2.31

1.7 - 2.1

Revision: 2004 November

SC-39

2004.5 FX35/FX45

SERVICE DATA AND SPECIFICATIONS (SDS)

Revision: 2004 November

SC-40

2004.5 FX35/FX45

Acrobat Distiller 4.05 for Windows FrameMaker SGML 5.5.6p145J