Precautions
Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
The Supplemental Restraint System (SRS), including "AIR BAG" and "SEAT BELT PRE-TENSIONER", works with seat belts to reduce the risk or severity of injury during certain types of collisions. It comprises driver and front passenger air bag modules, seat belt pre-tensioners, a diagnosis sensor unit, a warning lamp, wiring harness, and a spiral cable. Detailed service information is available in the RS section of this Service Manual.
WARNING: ⚠️ To prevent SRS malfunction, which could increase injury risk in a collision, all maintenance must be performed by an authorized NISSAN dealer. Improper maintenance, including incorrect removal/installation, can cause personal injury due to unintentional activation. Refer to the RS section for Air Bag Module and Spiral Cable removal. Do not use electrical test equipment on SRS circuits unless specified. Components with yellow insulation are typically related to the SRS.
Wiring Diagrams and Trouble Diagnosis
For wiring diagrams, refer to GI-10 "HOW TO READ WIRING DIAGRAMS" and EL-11 "POWER SUPPLY ROUTING". For trouble diagnosis, consult GI-33 "How To Follow Test Group In Trouble Diagnoses" and GI-22 "HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT".
Preparation
Special Service Tool
A specialized tool is required for battery, starting, and charging system testing: J-44373 Model 620 Battery/Starting/Charging system tester.
Battery
How to Handle Battery
CAUTION: Use a 12-volt booster battery for jump-starting. Ensure battery cables are tightly clamped for good contact. Never add distilled water through the specific gravity check hole.
Methods of Preventing Over-Discharge
- Keep the battery surface and terminals clean and dry.
- Ensure terminal connections are clean and tight.
- Check electrolyte level during routine maintenance, even for low-maintenance or maintenance-free batteries.
- For long periods of non-use, disconnect the negative battery terminal (or turn off the storage switch if equipped).
- Monitor battery charge condition and periodically check electrolyte specific gravity to prevent over-discharge.
Checking Electrolyte Level
WARNING: Avoid contact of battery fluid with skin, eyes, or fabrics. If contact occurs, flush affected areas with water for 15 minutes and seek medical attention.
Sulphation
A battery left unattended for extended periods may discharge, leading to sulphation on cell plates. If the specific gravity drops below 1.100, sulphation may occur. Charging a sulphated battery typically shows lower current and higher voltage initially. A long, slow charge (12+ hours) may restore serviceability, followed by a capacity test.
Specific Gravity Check
- Read hydrometer and thermometer indications at eye level.
- Correct hydrometer readings based on electrolyte temperature using the following chart:
| Battery electrolyte temperature °C (°F) | Add to specific gravity reading |
|---|---|
| 71 (160) | 0.032 |
| 66 (150) | 0.028 |
| 60 (140) | 0.024 |
| 54 (129) | 0.020 |
| 49 (120) | 0.016 |
| 43 (110) | 0.012 |
| 38 (100) | 0.008 |
| 32 (90) | 0.004 |
| 27 (80) | 0 |
| 21 (70) | -0.004 |
| 16 (60) | -0.008 |
| 10 (50) | -0.012 |
Charging the Battery
CAUTION: Do not "quick charge" a fully discharged battery. Keep the battery away from open flames during charging. Connect charger leads before turning on the charger to prevent sparks. Stop charging if electrolyte temperature exceeds 60°C (140°F).
Charging Rates
| Amps | Time |
|---|---|
| 50 | 1 hour |
| 25 | 2 hours |
| 10 | 5 hours |
| 5 | 10 hours |
Do not exceed a 50 ampere charging rate. The ammeter on the charger will decrease as the battery charges, indicating normal voltage increase. If specific gravity varies by more than .050 between any two cells after charging, replace the battery.
Starting System
System Description
This section details the starting system operation for KA24DE, VG33E M/T, and VG33E A/T models, outlining power supply paths, relay operations, and starter motor engagement.
Wiring Diagrams - START
Wiring diagrams are provided for KA24DE, VG33E M/T, and VG33E A/T models, illustrating the electrical connections for the starting system.
Trouble Diagnoses with Battery/Starting/Charging System Tester
This guide outlines the procedure for using a Battery/Starting/Charging System Tester for diagnosis. It includes steps for connecting the tester, selecting test parameters (CCA, JIS), and interpreting results like "GOOD BATTERY", "REPLACE BATTERY", "BAD CELL-REPLACE", "GOOD-RECHARGE", and "CHARGE & RETEST".
Diagnostic Result Item Chart
This chart lists diagnostic items and their corresponding service procedures, such as "CRANKING VOLTAGE NORMAL/LOW", "CHARGE BATTERY", and "REPLACE BATTERY".
Work Flow
A troubleshooting flowchart guides technicians through diagnosing starting system issues based on cranking voltage (normal or low) and engine cranking behavior. It directs users to specific diagnostic procedures or component checks.
Diagnostic Procedures
Detailed diagnostic procedures (1, 2, and 3) are provided to check specific circuits and connections related to the starter motor, including "B" terminal, "S" terminal, and ground circuits, often involving voltage drop tests.
Minimum Specification of Cranking Voltage Referencing Coolant Temperature
This table provides minimum acceptable cranking voltage values based on engine coolant temperature for KA24DE and VG33E engines.
| Engine coolant temperature | Voltage V (KA24DE) | Voltage V (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 |
Construction
Exploded views and parts lists are provided for the starter motor construction for KA24DE and VG33E models, detailing components like the gear case, pinion assembly, armature, and brush holder assembly.
Removal and Installation
Instructions for removing and installing the starter motor for both KA24DE and VG33E models are included, requiring removal of the engine undercover and specific bolts.
Pinion/Clutch Check
Procedures for inspecting pinion teeth, reduction gear teeth, and checking pinion lock/rotation are described to identify worn or damaged components.
Charging System
System Description
The generator produces DC voltage for the vehicle's electrical system and battery charging, regulated by an IC regulator. Power is supplied via fusible links and fuses. The charging circuit is protected by fusible links. The charge warning lamp illuminates when the ignition is ON and turns off when the generator is operating correctly. If the lamp stays on while the engine is running, a fault is indicated.
Wiring Diagrams - CHARGE
Wiring diagrams for the charging system are presented for KA24DE and VG33E models, illustrating connections to the ignition switch, battery, combination meter, and generator.
Trouble Diagnoses with Battery/Starting/Charging System Tester
This section details the process for diagnosing charging system issues using the specialized tester. It covers steps for performing tests like "LOADS OFF REV ENGINE 5 SEC" and "DIODE/RIPPLE" checks, and interpreting results such as "CHARGING SYSTEM NORMAL", "NO CHARGING VOLTAGE", "LOW CHARGING VOLTAGE", "HIGH CHARGING VOLTAGE", "DIODE RIPPLE NORMAL", "EXCESS RIPPLE DETECTED", and "DIODE RIPPLE NOT DETECTED".
Work Flow
Troubleshooting flowcharts are provided for various charging system faults, guiding technicians through checks like charging lamp status, drive belt tension, and specific terminal circuit diagnostics.
Diagnostic Procedures 1, 2, 3
These procedures detail checks for the "L" terminal, "B" terminal, and "S" terminal circuits of the generator, including voltage checks and voltage drop tests to identify faults in wiring or components.
Malfunction Indicator
The IC regulator activates the "CHARGE" warning lamp if excessive or no voltage is produced by the generator while it is operating.
Construction
Exploded views and parts lists detail the construction of the generator for KA24DE and VG33E models, identifying components such as the pulley assembly, rotor, stator, IC regulator assembly, and diode assembly.
Removal and Installation
Instructions are provided for the removal and installation of the generator for both KA24DE and VG33E models, including steps like removing the engine undercover, splash shield, disconnecting connectors, loosening the adjustment bolt, and removing generator bolts.
Service Data and Specifications (SDS)
This section provides technical specifications for key components.
Battery Specifications
| Attribute | USA | Canada |
|---|---|---|
| Applied area | 55D23R | 65D26R |
| Type | 12-60 V-AH | 12-65 V-AH |
| Cold cranking current A (For reference value) | 356 | 413 |
Starter Specifications
| Attribute | KA24DE | VG33E |
|---|---|---|
| Engine Type | MITSUBISHI make | MITSUBISHI make |
| Model Number | M000T60082ZC | M000T60187ZC |
| System voltage | 12 V | 12 V |
| Terminal voltage | 11.0 V | 11.0 V |
| No-load Current | Less than 90 A | Less than 90 A |
| Revolution | More than 2,500 rpm | More than 2,500 rpm |
| Minimum diameter of commutator | 29.3 mm (1.154 in) | 29.3 mm (1.154 in) |
| Minimum length of brush | 7.0 mm (0.276 in) | 7.0 mm (0.276 in) |
| Brush spring tension | 5.8 - 21.6 N (0.59 - 2.20 kg, 1.30 - 4.86 lb) | 5.8 - 21.6 N (0.59 - 2.20 kg, 1.30 - 4.86 lb) |
| Clearance of bearing metal and armature shaft mm (in) | 0.1 (0.004) | 0.1 (0.004) |
| Clearance between pinion front edge and pinion stopper mm (in) | 0.2 - 2.0 (0.008 - 0.079) | 0.2 - 2.0 (0.008 - 0.079) |
Generator Specifications
| Attribute | KA24DE | VG33E |
|---|---|---|
| Engine Type | LR170-757B | LR180-756B |
| Manufacturer | HITACHI make | HITACHI make |
| Nominal rating | 12 V-70 A | 12 V-80 A |
| Ground polarity | Negative | Negative |
| Minimum revolution under no-load (When 13.5 volts are applied) | Less than 1,000 rpm | Less than 1,000 rpm |
| Hot output current (When 13.5 volts are applied) | More than 17 A/1,300 rpm More than 54 A/2,500 rpm More than 72 A/5,000 rpm | More than 23 A/1,300 rpm More than 65 A/2,500 rpm More than 77 A/5,000 rpm |
| Regulated output voltage | 14.1 - 14.7 V | 14.1 - 14.7 V |
| Minimum length of brush | 6.0 mm (0.236 in) | 6.0 mm (0.236 in) |
| Brush spring pressure | 1.000 - 2.452 N (102 - 250 g, 3.60 - 8.82 oz) | 1.000 - 2.452 N (102 - 250 g, 3.60 - 8.82 oz) |
| Slip ring minimum outer diameter | 26.0 mm (1.024 in) | 26.0 mm (1.024 in) |
| Rotor (Field coil) resistance | 2.6 Ω | 2.7 Ω |
