ELECTRICAL & POWER CONTROL

SECTION CHG
CHARGING SYSTEM
B

E
CONTENTS
HOW TO USE THIS MANUAL ...................... 3 POWER GENERATION VOLTAGE VARIABLE F
CONTROL SYSTEM ................................................... 8
APPLICATION NOTICE ...................................... 3 POWER GENERATION VOLTAGE VARIABLE
Information ................................................................ 3 CONTROL SYSTEM : Component Parts Location..... 8 G
POWER GENERATION VOLTAGE VARIABLE
PRECAUTION ............................................... 4 CONTROL SYSTEM : Component Description ........ 9
PRECAUTIONS ................................................... 4 SYSTEM ............................................................ 10 H

FOR EUROPE ............................................................. 4 CHARGING SYSTEM ................................................10

FOR EUROPE : Precaution for Supplemental Re- CHARGING SYSTEM : System Diagram ................10
straint System (SRS) "AIR BAG" and "SEAT BELT I
CHARGING SYSTEM : System Description ...........11
PRE-TENSIONER" ................................................... 4
FOR EUROPE : Precautions Necessary for Steer- POWER GENERATION VOLTAGE VARIABLE
ing Wheel Rotation After Battery Disconnection ...... 4 CONTROL SYSTEM ..................................................11 J
FOR EUROPE : Precaution for Power Generation POWER GENERATION VOLTAGE VARIABLE
Voltage Variable Control System .............................. 5 CONTROL SYSTEM : System Diagram ..................11
POWER GENERATION VOLTAGE VARIABLE K
EXCEPT FOR EUROPE .............................................. 5 CONTROL SYSTEM : System Description .............11
EXCEPT FOR EUROPE : Precaution for Supple-
mental Restraint System (SRS) "AIR BAG" and WIRING DIAGRAM ...................................... 12
"SEAT BELT PRE-TENSIONER" .............................. 5 L
EXCEPT FOR EUROPE : Precautions Necessary CHARGING SYSTEM ....................................... 12
for Steering Wheel Rotation After Battery Discon- Application Notice ....................................................12
nection ....................................................................... 6 CHG
TYPE A .......................................................................12
EXCEPT FOR EUROPE : Precaution for Power
TYPE A : Wiring Diagram ........................................13
Generation Voltage Variable Control System ........... 6
TYPE B .......................................................................16 N
PREPARATION ............................................ 7 TYPE B : Wiring Diagram ........................................17
PREPARATION ................................................... 7 TYPE C .......................................................................21
Commercial Service Tools ........................................ 7 TYPE C : Wiring Diagram ........................................22 O
Special Service Tools ................................................ 7
TYPE D .......................................................................26
SYSTEM DESCRIPTION .............................. 8 TYPE D : Wiring Diagram ........................................27
P
COMPONENT PARTS ........................................ 8 BASIC INSPECTION ................................... 28
CHARGING SYSTEM .................................................. 8 DIAGNOSIS AND REPAIR WORKFLOW ........ 28
CHARGING SYSTEM : Component Parts Loca- Work Flow ................................................................28
tion ............................................................................ 8
CHARGING SYSTEM : Component Description ...... 8 CHARGING SYSTEM PRELIMINARY IN-
SPECTION ........................................................ 30

CHG-1
 Inspection Procedure .............................................. 30 ALTERNATOR .................................................. 39
POWER GENERATION VOLTAGE VARI- HR12DE ..................................................................... 39
ABLE CONTROL SYSTEM OPERATION IN- HR12DE : Exploded View ....................................... 39
SPECTION ......................................................... 31 HR12DE : Removal and Installation ....................... 42
Inspection Procedure .............................................. 31 HR12DE : Disassembly and Assembly ................... 43
HR12DE : Inspection .............................................. 44
DTC/CIRCUIT DIAGNOSIS ......................... 33
HR12DDR .................................................................. 45
B TERMINAL CIRCUIT ...................................... 33 HR12DDR : Exploded View .................................... 45
Description .............................................................. 33 HR12DDR : Removal and Installation ..................... 47
Diagnosis Procedure .............................................. 33 HR12DDR : Disassembly and Assembly ................ 48
HR12DDR : Inspection ............................................ 49
L TERMINAL CIRCUIT (OPEN) ........................ 34
Description .............................................................. 34 HR15DE ..................................................................... 50
Diagnosis Procedure .............................................. 34 HR15DE : Exploded View ....................................... 50
HR15DE : Removal and Installation ....................... 52
L TERMINAL CIRCUIT (SHORT) ...................... 36 HR15DE : Disassembly and Assembly ................... 53
Description .............................................................. 36 HR15DE : Inspection .............................................. 54
Diagnosis Procedure .............................................. 36
K9K ............................................................................ 55
S TERMINAL CIRCUIT ...................................... 37 K9K : Exploded View .............................................. 55
Description .............................................................. 37 K9K : Removal and Installation ............................... 56
Diagnosis Procedure .............................................. 37
SERVICE DATA AND SPECIFICATIONS
SYMPTOM DIAGNOSIS ............................. 38 (SDS) .......................................................... 58
CHARGING SYSTEM ........................................ 38 SERVICE DATA AND SPECIFICATIONS
Symptom Table ...................................................... 38 (SDS) ................................................................. 58
Alternator ................................................................ 58
REMOVAL AND INSTALLATION ............... 39

CHG-2
 APPLICATION NOTICE
< HOW TO USE THIS MANUAL >
HOW TO USE THIS MANUAL A
APPLICATION NOTICE
Information INFOID:0000000006434447
B
In this manual, “Idling Stop System” is referred to as “Stop / Start System”.
C

CHG

CHG-3
 PRECAUTIONS
< PRECAUTION >
PRECAUTION
PRECAUTIONS
FOR EUROPE
FOR EUROPE : Precaution for Supplemental Restraint System (SRS) "AIR BAG" and
"SEAT BELT PRE-TENSIONER" INFOID:0000000006843048

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. Information necessary to service the system safely is included in the “SRS AIR BAG” and
“SEAT BELT” of this Service Manual.

The vehicle may be equipped with a passenger air bag deactivation switch. Because no rear seat exists where
a rear-facing child restraint can be placed, the switch is designed to turn off the passenger air bag so that a
rear-facing child restraint can be used in the front passenger seat. The switch is located in the center of the
instrument panel, near the ashtray. When the switch is turned to the ON position, the passenger air bag is
enabled and could inflate for certain types of collision. When the switch is turned to the OFF position, the pas-
senger air bag is disabled and will not inflate. A passenger air bag OFF indicator on the instrument panel lights
up when the passenger air bag is switched OFF. The driver air bag always remains enabled and is not affected
by the passenger air bag deactivation switch.

WARNING:
Always observe the following items for preventing accidental activation.
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision that 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 “SRS AIR BAG”.
• 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.
• The vehicle may be equipped with a passenger air bag deactivation switch which can be operated by
the customer. When the passenger air bag is switched OFF, the passenger air bag is disabled and
will not inflate. When the passenger air bag is switched ON, the passenger air bag is enabled and
could inflate for certain types of collision. After SRS maintenance or repair, make sure the passenger
air bag deactivation switch is in the same position (ON or OFF) as when the vehicle arrived for ser-
vice.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
Always observe the following items for preventing accidental activation.
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition 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 3 minutes before performing any service.
FOR EUROPE : Precautions Necessary for Steering Wheel Rotation After Battery Dis-
connection INFOID:0000000006843050

CAUTION:
Comply with the following cautions to prevent any error and malfunction.
• Before removing and installing any control units, first turn the ignition switch to the LOCK position,
then disconnect both battery cables.
• After finishing work, confirm that all control unit connectors are connected properly, then re-connect
both battery cables.

CHG-4
 PRECAUTIONS
< PRECAUTION >
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing
work. If a DTC is detected, perform trouble diagnosis according to self-diagnosis results. A
For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock and
cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro-
B
cedure below before starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables. C
NOTE:
Supply power using jumper cables if battery is discharged.
2. Turn the ignition switch to ACC position. D
(At this time, the steering lock will be released.)
3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned. E
4. Perform the necessary repair operation.
5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock F
when the ignition switch is turned to LOCK position.)
6. Perform self-diagnosis check of all control units using CONSULT.
FOR EUROPE : Precaution for Power Generation Voltage Variable Control System G
INFOID:0000000006843051

CAUTION:
For thailand model, the battery current sensor that is installed to the battery cable at the negative ter- H
minal measures the charging/discharging current of the battery, and performs various controls. If the
electrical component or the ground wire is connected directly to the battery terminal, the current other
than that being measured with the battery current sensor is charging to or discharging from the bat- I
tery. This condition causes the malfunction of the control, and then the battery discharge may occur.
Do not connect the electrical component or the ground wire directly to the battery terminal.
EXCEPT FOR EUROPE J
EXCEPT FOR EUROPE : Precaution for Supplemental Restraint System (SRS) "AIR
BAG" and "SEAT BELT PRE-TENSIONER" INFOID:0000000006057597
K
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. Information necessary to service the system safely is included in the “SRS AIR BAG” and L
“SEAT BELT” of this Service Manual.
WARNING:
Always observe the following items for preventing accidental activation. CHG
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision that 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 N
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see “SRS AIR BAG”.
• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser- O
vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS P
WARNING:
Always observe the following items for preventing accidental activation.
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, never 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.

CHG-5
 PRECAUTIONS
< PRECAUTION >
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.
EXCEPT FOR EUROPE : Precautions Necessary for Steering Wheel Rotation After
Battery Disconnection INFOID:0000000006057598

CAUTION:
Comply with the following cautions to prevent any error and malfunction.
• Before removing and installing any control units, first turn the ignition switch to the LOCK position,
then disconnect both battery cables.
• After finishing work, confirm that all control unit connectors are connected properly, then re-connect
both battery cables.
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing
work. If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.
For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock and
cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro-
cedure below before starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Turn the ignition switch to ACC position.
(At this time, the steering lock will be released.)
3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned.
4. Perform the necessary repair operation.
5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock
when the ignition switch is turned to LOCK position.)
6. Perform self-diagnosis check of all control units using CONSULT.
EXCEPT FOR EUROPE : Precaution for Power Generation Voltage Variable Control
System INFOID:0000000006067207

CAUTION:
For thailand model, the battery current sensor that is installed to the battery cable at the negative ter-
minal measures the charging/discharging current of the battery, and performs various controls. If the
electrical component or the ground wire is connected directly to the battery terminal, the current other
than that being measured with the battery current sensor is charging to or discharging from the bat-
tery. This condition causes the malfunction of the control, and then the battery discharge may occur.
Do not connect the electrical component or the ground wire directly to the battery terminal.

CHG-6
 PREPARATION
< PREPARATION >
PREPARATION A
PREPARATION
Commercial Service Tools INFOID:0000000006057227
B

Tool name Description

C
Power tool

D
Loosening bolts, nuts and screws

E
PIIB1407E

Special Service Tools INFOID:0000000007321277

F

Tool number
Description
Tool name G

KV10118200 (included in the adapter H

kit: Mot. 1732) Removing and installing alternator pulley
Alternator pulley adapter
I
PKIA1241E

CHG

CHG-7
 COMPONENT PARTS
< SYSTEM DESCRIPTION >
SYSTEM DESCRIPTION
COMPONENT PARTS
CHARGING SYSTEM
CHARGING SYSTEM : Component Parts Location INFOID:0000000006057230

JMMIA0386ZZ

1. Charge warning lamp (On the combi- 2. Alternator

nation meter)

CHARGING SYSTEM : Component Description INFOID:0000000006057231

Component part Description

“B” terminal Refer to CHG-33, "Description".
Alternator “S” terminal Refer to CHG-37, "Description".
“L” terminal Refer to CHG-34, "Description".
The IC voltage regulator warning function activates to illuminate
the charge warning lamp, if any of the following symptoms occur
Combination meter (Charge warning lamp) while alternator is operating:
• Excessive voltage is produced.
• No voltage is produced.

POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM

POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM : Component
Parts Location INFOID:0000000006067201

NOTE:

CHG-8
 COMPONENT PARTS
< SYSTEM DESCRIPTION >
This system is applied only for models with battery current sensor. The battery current sensor is installed to
the battery cable at the negative terminal. A

JMMIA0387ZZ

F
1. Alternator 2. IPDM E/R 3. ECM
Refer to PCS-8, "Component Parts Refer to EC3-28, "ENGINE CON-
Location" (with Intelligent Key sys- TROL SYSTEM :
tem), PCS-76, "Component Parts Component Parts Location" G
Location"(withou Intelligent Key sys- (HR12DE), EC3-809, "ENGINE
tem). CONTROL SYSTEM :
Component Parts Location"
(HR12DDR), EC4-15, H
"Component Parts Location"
(HR15DE).
4. Battery current sensor I
A. Battely

POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM : Component De-

J
scription INFOID:0000000006067202

NOTE:
This system is applied only for models with battery current sensor. The battery current sensor is installed to K
the battery cable at the negative terminal.

Component part Description L

IC voltage regulator controls the power generation voltage by the
target power generation voltage based on the received power gen-
eration command signal.
Alternator (IC voltage regulator) CHG
When there is no power generation command signal, the alterna-
tor performs the normal power generation according to the char-
acteristic of the IC voltage regulator.
Battery current sensor is installed to the battery cable at the neg- N
ative terminal, and it detects the charging/discharging current of
Battery current sensor
the battery and sends the voltage signal to ECM according to the
current value.
O
Battery current sensor detects the charging/discharging current of
the battery. ECM judges the battery condition based on this signal.
ECM judges whether to perform the power generation voltage
variable control according to the battery condition. P
ECM
When performing the power generation voltage variable control,
ECM calculates the target power generation voltage according to
the battery condition and sends the calculated value as the power
generation command value signal to IPDM E/R.
IPDM E/R converts the received power generation command val-
IPDM E/R ue into the power generation command signal (PWM signal) and
sends it to the IC voltage regulator.

CHG-9
 SYSTEM
< SYSTEM DESCRIPTION >
SYSTEM
CHARGING SYSTEM
CHARGING SYSTEM : System Diagram INFOID:0000000006057228

GASOLINE ENGINE MODELS

JPMIA0426GB

DIESEL ENGINE MODELS

JPMIA0250GB

CHG-10
 SYSTEM
< SYSTEM DESCRIPTION >
CHARGING SYSTEM : System Description INFOID:0000000006057229

A
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 voltage regulator.
POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM B

POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM : System Dia-

gram INFOID:0000000006067199
C
NOTE:
This system is applied only for models with battery current sensor. The battery current sensor is installed to
the battery cable at the negative terminal. D

I
JMMIA0388GB

POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM : System De- J

scription INFOID:0000000006067200

By performing the power generation voltage variable control, the engine load due to the power generation of
the alternator is reduced and fuel consumption is decreased. K
NOTE:
• This system is applied only for models with battery current sensor. The battery current sensor is installed to
the battery cable at the negative terminal. L
• When any malfunction is detected in the power generation voltage variable control system, the power gener-
ation is performed according to the characteristic of the IC voltage regulator of the alternator.
CHG

CHG-11
 CHARGING SYSTEM
< WIRING DIAGRAM >
WIRING DIAGRAM
CHARGING SYSTEM
Application Notice INFOID:0000000007230347

Wiring diagram type Destination

• Models for Thailand
• Models for general area from Thailand plant*
TYPE A
• Models for China
• Models for India (HR12DE engine models): Vehicle production: From May 2010 to April 2011
• Models for Australia
• Models for New Zealand
• Models for Hong Kong
TYPE B
• Models for India (K9K engine models): Vehicle production: From October 2010 to April 2011
• Models for Europe (Without stop/start system): Vehicle production: From July 2010 to June 2011
• Models for general area from India plant*
• Models for Europe (With stop/start system): Vehicle production: From April 2011 to June 2011
TYPE C
• Models for South Africa
• Models for India: Vehicle production: From May 2011
TYPE D • Models for Lebanon and Jordan
• Models for Europe: Vehicle production: From July 2011
*: Refer to GI-26, "Information About Identification or Model Code" to identify a production plant.
TYPE A

CHG-12
 CHARGING SYSTEM
< WIRING DIAGRAM >
TYPE A : Wiring Diagram INFOID:0000000006881514

CHG

JCMWM8586GB
P

CHG-13
 CHARGING SYSTEM
< WIRING DIAGRAM >

JCMWM8587GB

CHG-14
 CHARGING SYSTEM
< WIRING DIAGRAM >

CHG

JCMWM8588GB

CHG-15
 CHARGING SYSTEM
< WIRING DIAGRAM >

JCMWM8589GB

TYPE B

CHG-16
 CHARGING SYSTEM
< WIRING DIAGRAM >
TYPE B : Wiring Diagram INFOID:0000000006057236

CHG

JCMWM9898GB
P

CHG-17
 CHARGING SYSTEM
< WIRING DIAGRAM >

JCMWM9899GB

CHG-18
 CHARGING SYSTEM
< WIRING DIAGRAM >

CHG

JCMWM9900GB

CHG-19
 CHARGING SYSTEM
< WIRING DIAGRAM >

JCMWM9901GB

CHG-20
 CHARGING SYSTEM
< WIRING DIAGRAM >

CHG

JCMWM9902GB

TYPE C P

CHG-21
 CHARGING SYSTEM
< WIRING DIAGRAM >
TYPE C : Wiring Diagram INFOID:0000000007230352

JCMWN0829GB

CHG-22
 CHARGING SYSTEM
< WIRING DIAGRAM >

CHG

JCMWA8219GB

CHG-23
 CHARGING SYSTEM
< WIRING DIAGRAM >

JCMWA8220GB

CHG-24
 CHARGING SYSTEM
< WIRING DIAGRAM >

CHG

JCMWA8221GB

CHG-25
 CHARGING SYSTEM
< WIRING DIAGRAM >

JCMWA8222GB

TYPE D

CHG-26
 CHARGING SYSTEM
< WIRING DIAGRAM >
TYPE D : Wiring Diagram INFOID:0000000007605537

CHG

JRMWC2909GB
P

CHG-27
 DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION >
BASIC INSPECTION
DIAGNOSIS AND REPAIR WORKFLOW
Work Flow INFOID:0000000006057237

1.PRELIMINARY INSPECTION
Perform the preliminary inspection. Refer to CHG-30, "Inspection Procedure".

Models with battery current sensor>>GO TO 2.

Models without battery current sensor>>GO TO 3.
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” of “SELECT SYSTEM” using CONSULT, set the DUTY value of “ALTERNATOR
DUTY” to 0 % by selecting “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 alternator.)
• 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 ON)
Turn the ignition switch ON.
Does the charge warning lamp illuminate?
YES >> GO TO 4.
NO >> GO TO 11.
4.INSPECTION WITH CHARGE WARNING LAMP (IDLING)
Start the engine and run it at idle.
Does the charge warning lamp turn OFF?
YES >> GO TO 5.
NO >> GO TO 6.
5.INSPECTION WITH CHARGE WARNING LAMP
Increase and maintain the engine speed at 2,500 rpm.
Does the charge warning lamp illuminate?
YES >> GO TO 8.
NO >> INSPECTION END
6.“L” TERMINAL CIRCUIT (SHORT) INSPECTION
Check “L” terminal circuit (short). Refer to CHG-36, "Diagnosis Procedure".
Is the inspection result normal?
YES-1 >> GO TO 7. (Gasoline engine models)
YES-2 >> GO TO 8. (Diesel engine models)
NO >> Repair as needed.
7.“S” TERMINAL CIRCUIT INSPECTION
Check “S” terminal circuit. Refer to CHG-37, "Diagnosis Procedure".
Is the inspection result normal?
YES >> GO TO 8.
NO >> Repair as needed.
8.MEASURE “B” TERMINAL VOLTAGE
Start engine. When keeping engine running at 2,500 rpm, measure “B” terminal voltage.
CHG-28
 DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION >
What voltage does the measurement result show?
Less than 13.0 V>>GO TO 9. A
More than 16.0 V>>Replace IC voltage regulator.
9.“B” TERMINAL CIRCUIT INSPECTION
B
Check “B” terminal circuit. Refer to CHG-33, "Diagnosis Procedure".
Is the inspection result normal?
YES >> GO TO 10. C
NO >> Repair as needed.
10.DISASSEMBLE AND CHECK ALTERNATOR
Check the following conditions. D
• Rotor coil
• Rotor slip ring
• Brush E
• Stator coil
Refer to CHG-44, "HR12DE : Inspection" (HR12DE), CHG-49, "HR12DDR : Inspection" (HR12DDR), CHG-
54, "HR15DE : Inspection" (HR15DE).
F
Are these normal?
YES >> Replace IC voltage regulator and/or diode assembly.
NO >> Repair as needed.
G
11.INSPECTION WITH CHARGE WARNING LAMP (IGNITION SWITCH IS ON)
1. Disconnect alternator connector and ground “L” harness side.
2. Turn the ignition switch ON. H
Does the charge warning lamp illuminate?
YES >> GO TO 12.
NO >> GO TO 13. I
12.DISASSEMBLE AND CHECK ALTERNATOR
Check the following conditions. J
• Rotor coil
• Rotor slip ring
• Brush
Refer to CHG-44, "HR12DE : Inspection" (HR12DE), CHG-49, "HR12DDR : Inspection" (HR12DDR), CHG- K
54, "HR15DE : Inspection" (HR15DE).
Are these normal?
YES >> Replace IC voltage regulator. L
NO >> Repair as needed.
13.CHECK “L” TERMINAL CIRCUIT (OPEN) CHG
Check “L” terminal circuit (open). Refer to CHG-34, "Diagnosis Procedure".

>> Repair as needed. N

CHG-29
 CHARGING SYSTEM PRELIMINARY INSPECTION
< BASIC INSPECTION >
CHARGING SYSTEM PRELIMINARY INSPECTION
Inspection Procedure INFOID:0000000006057239

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 terminals connection.
2.CHECK FUSE
Check for blown fuse and fusible link.

Unit Power source (Power supply terminals) Fuse No.

Alternator Battery (“S” terminal) 32 (gasoline engine models)
5 (without stop/start system)
Combination meter Ignition switch ON (“L” terminal)
64 (with stop/start system)
Is the inspection result normal?
YES >> GO TO 3.
NO >> Be sure to eliminate the cause of malfunction before installing new fuse.
3.CHECK “E” TERMINAL CONNECTION (ALTERNATOR GROUND)
Check if “E” terminal (alternator ground) is clean and tight.
Is the inspection result normal?
YES >> GO TO 4.
NO >> Repair “E” terminal (alternator ground) connection.
4.CHECK DRIVE BELT TENSION
Check drive belt tension. Refer to EM-27, "Inspection" (HR12DE), EM-192, "Inspection" (HR12DDR), EM-331,
"Inspection" (HR15DE) or EM-457, "Inspection" (K9K).
Is the inspection result normal?
YES >> INSPECTION END
NO >> Repair as needed.

CHG-30
 POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM OPERATION
INSPECTION
< BASIC INSPECTION >
POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM OPER-
A
ATION INSPECTION
Inspection Procedure INFOID:0000000006069245
B
CAUTION:
When performing this inspection, always use a charged battery that has completed the battery inspec-
tion. (When the charging rate of the battery is low, the response speed of the voltage change will C
become slow. This can cause an incorrect inspection.)
1.CHECK ECM (CONSULT)
D
Perform ECM self-diagnosis with CONSULT. Refer to EC3-89, "CONSULT Function" (HR12DE Type 1*), EC3-
519, "CONSULT Function" (HR12DE Type 2*), EC3-898, "CONSULT Function" (HR12DDR), EC4-50, "CON-
SULT Function" (HR15DE Type 1*), EC4-350, "CONSULT Function" (HR15DE Type 2*) or ECD-30, "CON- E
SULT Function" (K9K).
*: Refer to EC3-21, "How to Check Vehicle Type".
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. Check that the selector lever is in “P” or “N” position and that all of the electric loads and A/C, etc. are
turned OFF. H
3. Select “ALTERNATOR DUTY” at “Active Test” of “ENGINE”, and then check the value of “BATTERY
VOLT” monitor when DUTY value of “ALTERNATOR DUTY” is set to 40.0 %.

“BATTERY VOLT” I

2 seconds after setting the : 12 - 13.6 V

DUTY value of “ALTERNA-
J
TOR DUTY” to 40.0 %

4. Check the value of “BATTERY VOLT” monitor when DUTY value of “ALTERNATOR DUTY” is set to
80.0%. K

“BATTERY VOLT”
20 seconds after setting : +0.5 V or more against L
the DUTY value of “ALTER- the value of “BATTERY
NATOR DUTY” to 80.0 % VOLT” monitor when
DUTY value is 40.0 % CHG
Is the measurement value within the specification?
YES >> INSPECTION END
N
NO >> GO TO 3.
3.CHECK IPDM E/R (CONSULT)
Perform IPDM E/R self-diagnosis with CONSULT. Refer to PCS-17, "CONSULT Function (IPDM E/R)" (with O
Intelligent Key system), PCS-84, "CONSULT Function (IPDM E/R)" (without Intelligent Key system).
Self-diagnostic results content
No malfunction detected>> GO TO 4. P
Malfunction detected>> Check applicable parts, and repair or replace corresponding parts.
4.CHECK HARNESS BETWEEN ALTERNATOR AND IPDM E/R
1. Turn ignition switch OFF.
2. Disconnect alternator connector and IPDM E/R connector.
3. Check continuity between alternator harness connector and IPDM E/R harness connector.

CHG-31
 POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM OPERATION
INSPECTION
< BASIC INSPECTION >

Alternator harness connector IPDM E/R harness connector

Continuity
Connector Terminal Connector Terminal
F15 5 F113 48 Existed
4. Check continuity between alternator harness connector and ground.

Alternator harness connector

Continuity
Connector Terminal Ground
F15 5 Not existed
Is the inspection result normal?
YES >> Replace IPDM E/R.
NO >> Repair harness or connector between IPDM E/R and alternator.

CHG-32
 B TERMINAL CIRCUIT
< DTC/CIRCUIT DIAGNOSIS >
DTC/CIRCUIT DIAGNOSIS A
B TERMINAL CIRCUIT
Description INFOID:0000000006057240
B
“B” terminal circuit supplies power to charge the battery and to operate the vehicle’s electrical system.
Diagnosis Procedure INFOID:0000000006057241 C

1.CHECK “B” TERMINAL CONNECTION

1. Turn ignition switch OFF. D
2. Check if “B” terminal is clean and tight.
Is the inspection result normal?
YES >> GO TO 2. E
NO >> Repair “B” terminal connection.
2.CHECK “B” TERMINAL CIRCUIT
F
Check voltage between alternator “B” terminal and ground.

Terminals
G
(+) Voltage (Approx.)
(–)
Alternator “B” terminal Terminal
F14 1 Ground Battery voltage H
Is the inspection result normal?
YES >> GO TO 3.
NO >> Check harness for open between alternator and fusible link. I
3.CHECK “B” TERMINAL CONNECTION (VOLTAGE DROP TEST)
1. Start engine, then engine running at idle and warm. J
2. Check voltage between battery positive terminal and alternator “B” terminal.

Terminals
K
(–) Voltage (Approx.)
(+)
Alternator “B” terminal Terminal
Battery positive terminal F14 1 Less than 0.2 V L
Is the inspection result normal?
YES >> “B” terminal circuit is normal. Refer to CHG-28, "Work Flow".
NO >> Check harness between battery and alternator for poor continuity. CHG

CHG-33
 L TERMINAL CIRCUIT (OPEN)
< DTC/CIRCUIT DIAGNOSIS >
L TERMINAL CIRCUIT (OPEN)
Description INFOID:0000000006057242

The “L” terminal circuit controls the charge warning lamp. The charge warning lamp illuminates when the igni-
tion switch is set to ON or START. When the alternator is providing sufficient voltage with the engine running,
the charge warning lamp will go off. If the charge warning lamp illuminates with the engine running, a malfunc-
tion is indicated.
Diagnosis Procedure INFOID:0000000006057243

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.
2.CHECK “L” TERMINAL CIRCUIT (OPEN)
1. Disconnect alternator connector.
2. Apply ground to alternator harness connector terminal.
3. Check condition of the charge warning lamp with the ignition switch in the ON position.

Condition
Alternator harness connector Terminal
Ground Ignition switch position Charge warning lamp
F15 3 ON Illuminate
Does it illuminate?
YES >> “L” terminal circuit is normal. Refer to CHG-28, "Work Flow".
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 alternator harness connector and combination meter harness connector.

Alternator harness connector Combination meter harness connector

Continuity
Connector No. Terminal No. Connector No. Terminal No.
F15 3 M34 35 Existed
Is the inspection result normal?
YES >> GO TO 4.
NO >> Repair the harness or connector.
4.CHECK HARNESS CONTINUITY (OPEN CIRCUIT)
Check continuity between combination meter harness connector M34 terminal 3 and 10A fuse [No.5 (without
stop/start system, 64 (with stop/start system) located in the fuse block (J/B)].
Does continuity exist?
YES >> GO TO 5.
NO >> Repair the harness.
5.CHECK POWER SUPPLY CIRCUIT
1. Connect the battery cable to the negative terminal.
2. Check voltage between combination meter harness connector and ground.

CHG-34
 L TERMINAL CIRCUIT (OPEN)
< DTC/CIRCUIT DIAGNOSIS >

Terminals A
(+)
Condition Voltage (Approx.)
Combination meter (–)
Terminal
harness connector B
When the ignition switch is in
M34 3 Ground Battery voltage
ON position
Is the inspection result normal? C
YES >> Replace combination meter.
NO >> Inspect the power supply circuit. Refer to PG-54, "TYPE A : Wiring Diagram - IGNITION POWER
SUPPLY -". D

CHG

CHG-35
 L TERMINAL CIRCUIT (SHORT)
< DTC/CIRCUIT DIAGNOSIS >
L TERMINAL CIRCUIT (SHORT)
Description INFOID:0000000006057244

The “L” terminal circuit controls the charge warning lamp. The charge warning lamp illuminates when the igni-
tion switch is set to ON or START. When the alternator is providing sufficient voltage with the engine running,
the charge warning lamp will go off. If the charge warning lamp illuminates with the engine running, a malfunc-
tion is indicated.
Diagnosis Procedure INFOID:0000000006057245

1.CHECK “L” TERMINAL CIRCUIT (SHORT)

1. Turn ignition switch OFF.
2. Disconnect alternator connector.
3. Turn ignition switch ON.
Does charge warning lamp illuminate?
YES >> GO TO 2.
NO >> Refer to CHG-28, "Work Flow".
2.CHECK HARNESS CONTINUITY (SHORT CIRCUIT)
1. Turn the ignition switch OFF.
2. Disconnect the battery cable from the negative terminal.
3. Disconnect combination meter connector.
4. Check continuity between combination meter harness connector and ground.

Combination meter harness connector

Continuity
Connector No. Terminal No. Ground
M34 35 Not existed
Is the inspection result normal?
YES >> Replace combination meter.
NO >> Repair the harness.

CHG-36
 S TERMINAL CIRCUIT
< DTC/CIRCUIT DIAGNOSIS >
S TERMINAL CIRCUIT
A
Description INFOID:0000000006057246

The output voltage of the alternator is controlled by the IC voltage regulator at the “S” terminal detecting the B
input voltage.
The “S” terminal circuit detects the battery voltage to adjust the alternator output voltage with the IC voltage
regulator.
C
Diagnosis Procedure INFOID:0000000006057247

1.CHECK “S” TERMINAL CONNECTION D

1. Turn ignition switch OFF.
2. Check if “S” terminal is clean and tight.
Is the inspection result normal? E
YES >> GO TO 2.
NO >> Repair “S” terminal connection.
2.CHECK “S” TERMINAL CIRCUIT F
Check voltage between alternator harness connector and ground.

Terminals
G
(+) Voltage (Approx.)
(–)
Alternator harness connector Terminal H
F15 4 Ground Battery voltage
Is the inspection result normal?
YES >> Refer to CHG-28, "Work Flow". I
NO >> Check harness for open between alternator and fuse.

CHG

CHG-37
 CHARGING SYSTEM
< SYMPTOM DIAGNOSIS >
SYMPTOM DIAGNOSIS
CHARGING SYSTEM
Symptom Table INFOID:0000000006057248

Symptom Reference
Discharged battery
The charge warning lamp does not illuminate when the ignition
switch is set to ON.
The charge warning lamp does not turn OFF after the engine Refer to CHG-28, "Work Flow".
starts.
The charging warning lamp turns ON when increasing the engine
speed.

CHG-38
 ALTERNATOR
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION A
ALTERNATOR
HR12DE
B
HR12DE : Exploded View INFOID:0000000006057264

REMOVAL C

JMMIA0372GB
K
1. Alternator bracket 2. Alternator bracket mounting bolt 3. Alternator mounting bolt (upper)
4. Alternator mounting bolt (lower) 5. Alternator 6. “B” terminal harness
7. “B” terminal nut 8. Alternator connector L
Refer to GI-4, "Components" for symbols in the figure.

DISASSEMBLY CHG

CHG-39
 ALTERNATOR
< REMOVAL AND INSTALLATION >
Type: 2607689

JMMIA0406GB

1. Rotor assembly 2. Retainer 3. Front bearing

4. Front bracket assembly 5. Pulley 6. Pulley nut
7. Stator assembly 8. Rear bearing 9. Rear bracket assembly
10. Circuit board assembly 11. Regulator assembly 12. Stud bolt
13. Through bolt 14. Cover
Refer to GI-4, "Components" for symbols in the figure.

CHG-40
 ALTERNATOR
< REMOVAL AND INSTALLATION >
Type: A005TL0191
A

H
JMMIA0389GB

1. Rear bearing 2. Rotor assembly 3. Retainer

4. Front bearing 5. Front bracket assembly 6. Pulley I
7. Pulley nut 8. Stator assembly 9. IC voltage regulator assembly
10. Diode assembly 11. Rear bracket assembly 12. Terminal set
Refer to GI-4, "Components" for symbols in the figure. J

Type: A002TX1191ZT
K

CHG

JMMIA0484GB

CHG-41
 ALTERNATOR
< REMOVAL AND INSTALLATION >

1. Rear bearing 2. Rotor assembly 3. Retainer

4. Front bearing 5. Front bracket assembly 6. Pulley
7. Pulley nut 8. Stator assembly 9. IC voltage regulator assembly
10. Diode assembly 11. Rear bracket assembly 12. Terminal set
Refer to GI-4, "Components" for symbols in the figure.

HR12DE : Removal and Installation INFOID:0000000006057265

REMOVAL
1. Disconnect the battery cable from the negative terminal. Refer to PG-529, "FOR MAINTENANCE
REQUIRED BATTERY MODELS : Removal and Installation" (Maintenance required battery models) or
PG-530, "FOR MAINTENANCE FREE BATTERY MODELS : Removal and Installation" (Maintenance free
battery models).
2. Remove air duct (inlet). Refer to EM-33, "TYPE 1 : Removal and Installation" (For the vehicle type 1) or
EM-34, "TYPE 2 : Removal and Installation" (For the vehicle type 2).
Regarding to the vehicle type, refer to EM-8, "How to Check Vehicle Type".
3. Remove drive belt. Refer to EM-26, "Removal and Installation".
4. Remove condenser side seal. Refer to DLK-194, "HR12DE : Exploded View".
5. Remove A/C compressor mounting bolts, and then temporarily put A/C compressor on radiator core sup-
port lower (for models with A/C). Refer to HA-31, "Exploded View".
6. Disconnect alternator connector.
7. Remove “B” terminal nut and disconnect “B” terminal harness.
8. Remove alternator mounting bolt (upper).
9. Remove alternator mounting bolt (lower).
10. Remove alternator from the lateral side of the vehicle.

: Vehicle front

JMMIA0485ZZ

INSTALLATION
Note the following items, and install in the reverse order of removal.
CAUTION:
• Temporarily tighten the alternator bolts in order from the lower to the upper, and then tighten them in
order from the lower to the upper.
• For the alternator, the front side (pulley side) surface is the reference surface. Fit the reference sur-
face to the alternator mounting part, and then tighten the bolts.
• Be careful to tighten “B” terminal nut to specified torque.
• Install alternator, and check tension of belt. Refer to EM-27, "Inspection".
• For this model (with battery current sensor models), the power generation voltage variable control
system that controls the power generation voltage of the alternator has been adopted. Therefore, the
power generation voltage variable control system operation inspection should be performed after
replacing the alternator, and then make sure that the system operates normally. Refer to CHG-31,
"Inspection Procedure".

CHG-42
 ALTERNATOR
< REMOVAL AND INSTALLATION >
The battery current sensor is installed to the battery cable at
the negative terminal. A

JPBIA3262ZZ

D
NOTE:
Tighten mounting bolts according to the following procedures for installing alternator bracket.
1. Temporarily tighten mounting bolt (1). E
2. Temporarily tighten mounting bolt (2).
3. Tighten mounting bolts in numerical order as shown in the fig-
ure.
F

JMMIA0495ZZ H
HR12DE : Disassembly and Assembly INFOID:0000000006057266

I
DISASSEMBLY (Type: 2607689)
Rear Bracket Assembly
1. Remove rear cover. J
2. Remove IC voltage regulator assembly.
3. Separate front bracket assembly, stator assembly and rear cover.
NOTE: K
• Raise the temperature of the center of the rear cover approxi-
mately between 30°C (86°F) and 50°C (122°F).
• Insert the tip of the suitable tool into the clearance between L
front cover and stator core, and then separate front side (front
bracket assembly, rotor assembly) and rear side (rear cover,
stator assembly, diode assembly).
CAUTION: CHG
Be careful not to damage stator assembly.

N
PKIC1176E

DISASSEMBLY (Type: A005TL0191, A002TX1191ZT)

O
Rear Bracket Assembly
NOTE:
P

CHG-43
 ALTERNATOR
< REMOVAL AND INSTALLATION >
Rear bracket assembly may be hard to remove because a ring is
used to lock outer race of rear bearing. To facilitate removal of rear
bracket assembly, heat only the bearing box section until the temper-
ature increases to approximately 30°C (86°F) with a soldering iron
(200W capacity).
CAUTION:
Never use a heat gun, as if can damage diode assembly.

SEL032Z

ASSEMBLY
Rear Bearing
CAUTION:
• Never reuse rear bearing. Replace with a new one.
• Never lubricate rear bearing outer race.
Rear Bracket Assembly Installation
1. Fit brush assembly, diode assembly, regulator assembly and
stator.

SKIB4529E

2. Push brushes up with fingers and install them to rotor.

NOTE:
Take care not damage slip ring sliding surface.

SKIB4530E

HR12DE : Inspection INFOID:0000000006057267

INSPECTION
Rotor Check
1. Resistance test

Resistance : Refer to SDS CHG-58, "Alternator".

• Replace the rotor if the measurement value is outside of the
specified range.
2. Insulator test
• Replace the rotor if continuity exists.
3. Check slip ring for wear.

SKIB4525E

CHG-44
 ALTERNATOR
< REMOVAL AND INSTALLATION >

Slip ring minimum : Refer to SDS CHG-58, "Alterna- A

outer diameter tor".
• Replace the rotor if the measurement value is outside of the specified range.
B
Brush Check
1. Check smooth movement of brush.
• Check brush holder and clean if it is not smooth.
C
2. Check brush for wear.
• Replace brush if it is worn down to the limit line.
D

SKIB4526E

Stator Check F
1. Continuity test
• Replace the stator if continuity does not exist.
G

I
SKIB4527E

2. Ground test J
• Replace the stator if continuity exists.

CHG
SKIB4528E

HR12DDR
HR12DDR : Exploded View INFOID:0000000007315633
N

REMOVAL
O

CHG-45
 ALTERNATOR
< REMOVAL AND INSTALLATION >

JMMIA0905GB

1. Accessory belt tensioner assembly 2. Accessory belt tensioner assembly 3. Alternator mounting bolt (upper)
mounting bolt
4. Alternator mounting bolt (lower) 5. Alternator 6. “B” terminal harness
7. “B” terminal nut 8. Alternator connector
, : Indicates that the part is connected at points with same symbol in actual vehicle.
Refer to GI-4, "Components" for symbols not described on the above.

DISASSEMBLY

CHG-46
 ALTERNATOR
< REMOVAL AND INSTALLATION >
Type: A002TX1181ZT
A

H
JMMIA0906GB

1. Rear bearing 2. Rotor assembly 3. Retainer

4. Front bearing 5. Front bracket assembly 6. Pulley I
7. Pulley cap 8. Stator assembly 9. IC voltage regulator assembly
10. Diode assembly 11. Rear bracket assembly 12. Terminal set
Refer to GI-4, "Components" for symbols in the figure. J

HR12DDR : Removal and Installation INFOID:0000000007315634

K
REMOVAL
1. Disconnect the battery cable from the negative terminal. Refer to PG-529, "FOR MAINTENANCE
REQUIRED BATTERY MODELS : Removal and Installation" (Maintenance required battery models) or L
PG-530, "FOR MAINTENANCE FREE BATTERY MODELS : Removal and Installation" (Maintenance free
battery models).
2. Remove drive belt. Refer to EM-190, "Removal and Installation (Drive Belt)". CHG
3. Remove radiator core support upper.
• For the vehicle type 3: Refer to DLK-537, "HR12DDR : Removal and Installation".
• For the vehicle type 4: Refer to DLK-745, "HR12DDR : Removal and Installation". N
• For the vehicle type 5: Refer to DLK-892, "HR12DDR : Removal and Installation".
• For the vehicle type 6: Refer to DLK-1022, "HR12DDR : Removal and Installation".
Regarding to the vehicle type, refer to DLK-382, "Information".
4. Remove air inlet hose 1 and air inlet tube 1 as a set. Refer to EM-199, "Removal and Installation". O
5. Disconnect alternator connector.
6. Remove “B” terminal nut and disconnect “B” terminal harness.
P
7. Remove alternator mounting bolt (upper).
8. Remove alternator mounting bolt (lower).

CHG-47
 ALTERNATOR
< REMOVAL AND INSTALLATION >
9. Remove alternator upward from the vehicle.

JMMIA0907ZZ

INSTALLATION
Note the following items, and install in the reverse order of removal.
CAUTION:
• Temporarily tighten the alternator bolts in order from the lower to the upper, and then tighten them in
order from the lower to the upper.
• For the alternator, the front side (pulley side) surface is the reference surface. Fit the reference sur-
face to the alternator mounting part, and then tighten the bolts.
• Be careful to tighten “B” terminal nut to the specified torque.
• Install alternator, and check tension of belt. Refer to EM-192, "Inspection".
• For this model, the power generation voltage variable control system that controls the power gener-
ation voltage of the alternator has been adopted. Therefore, the power generation voltage variable
control system operation inspection should be performed after replacing the alternator, and then
make sure that the system operates normally. Refer to CHG-31, "Inspection Procedure".
NOTE:
Tighten mounting bolts according to the following procedures for installing accessory belt tensioner assembly.
1. Temporarily tighten mounting bolt (1).
2. Temporarily tighten mounting bolt (2).
3. Tighten mounting bolts in numerical order as shown in the fig-
ure.

JMMIA0908ZZ

HR12DDR : Disassembly and Assembly INFOID:0000000007315635

DISASSEMBLY
Rear Bracket Assembly
NOTE:
Rear bracket assembly may be hard to remove because a ring is
used to lock outer race of rear bearing. To facilitate removal of rear
bracket assembly, heat only the bearing box section until the temper-
ature increases to approximately 30°C (86°F) with a soldering iron
(200W capacity).
CAUTION:
Never use a heat gun, as if can damage diode assembly.

SEL032Z

Front Bracket Assembly

CHG-48
 ALTERNATOR
< REMOVAL AND INSTALLATION >
1. Set rotor to the vise.
CAUTION: A
• Be careful not to damage the rotor.
• Use copper plate or thick cloth for rotor in the vise.
2. Remove pulley cap, using suitable tool. B

SKIB0531E

D
3. Remove alternator pulley, using alternator pulley adaptor (a)
[SST: KV10118200].
E

G
JSMIA0063ZZ

ASSEMBLY H
Rear Bearing
CAUTION:
• Never reuse rear bearing. Replace with a new one. I
• Never lubricate rear bearing outer race.
Rear Bracket Assembly Installation
1. Fit brush assembly, diode assembly, regulator assembly and J
stator.

SKIB4529E
CHG

2. Push brushes up with fingers and install them to rotor.

NOTE: N
Take care not damage slip ring sliding surface.

SKIB4530E

HR12DDR : Inspection INFOID:0000000007315636

INSPECTION

CHG-49
 ALTERNATOR
< REMOVAL AND INSTALLATION >
Rotor Check
1. Resistance test

Resistance : Refer to SDS CHG-58, "Alternator".

• Replace the rotor if the measurement value is outside of the
specified range.
2. Insulator test
• Replace the rotor if continuity exists.
3. Check slip ring for wear.

Slip ring minimum : Refer to SDS CHG-58, "Alterna- SKIB4525E

outer diameter tor".

• Replace the rotor if the measurement value is outside of the specified range.
Brush Check
1. Check smooth movement of brush.
• Check brush holder and clean if it is not smooth.
2. Check brush for wear.
• Replace brush if it is worn down to the limit line.

SKIB4526E

Stator Check
1. Continuity test
• Replace the stator if continuity does not exist.

SKIB4527E

2. Ground test
• Replace the stator if continuity exists.

SKIB4528E

HR15DE
HR15DE : Exploded View INFOID:0000000006370544

REMOVAL

CHG-50
 ALTERNATOR
< REMOVAL AND INSTALLATION >

JSMIA0093GB F

1. Alternator bracket mounting bolt 2. Alternator bracket 3. Alternator mounting bolt

4. Alternator 5. “B” terminal harness 6. “B” terminal nut
G
7. Alternator connector
Refer to GI-4, "Components" for symbols in the figure.

DISASSEMBLY H

Type: LR190-772
I

CHG

JMMIA0448GB P

1. Stator assembly 2. Rotor assembly 3. Rotor spacer

4. Retainer 5. Front bearing 6. Front bracket assembly
7. Pulley 8. Pulley nut 9. Fan guide
10. IC voltage regulator assembly 11. Diode assembly 12. Labyrinth seal
13. Bush 14. Rear bracket assembly 15. Insulating bush

CHG-51
 ALTERNATOR
< REMOVAL AND INSTALLATION >
16. Through bolt
Refer to GI-4, "Components" for symbols in the figure.

Type: A002TG0891ZT

PKID1495E

1. Rear bearing 2. Rotor assembly 3. Retainer

4. Front bearing 5. Front bracket assembly 6. Pulley
7. Pulley nut 8. Stator assembly 9. IC voltage regulator assembly
10. Diode assembly 11. Rear bracket assembly 12. “B” terminal set
Refer to GI-4, "Components" for symbols in the figure.

HR15DE : Removal and Installation INFOID:0000000006370545

REMOVAL
1. Disconnect the battery cable from the negative terminal. Refer to PG-529, "FOR MAINTENANCE
REQUIRED BATTERY MODELS : Removal and Installation" (Maintenance required battery models) or
PG-530, "FOR MAINTENANCE FREE BATTERY MODELS : Removal and Installation" (Maintenance free
battery models).
2. Remove air duct (inlet). Refer to EM-337, "Removal and Installation".
3. Remove drive belt. Refer to EM-330, "Removal and Installation".
4. Remove front bumper fascia. Refer to EXT-14, "Removal and Installation".
5. Remove horn. Refer to HRN-15, "Removal and Installation".
6. Disconnect alternator connector.
7. Remove “B” terminal nut and disconnect “B” terminal harness.
8. Remove alternator mounting bolts.

CHG-52
 ALTERNATOR
< REMOVAL AND INSTALLATION >
9. Move alternator toward vehicle front and remove it from the
vehicle. A

: Vehicle front
B

JMMIA0486ZZ

D
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION: E
• Temporarily tighten the alternator bolts in order from the lower to the upper, and then tighten them in
order from the upper to the lower.
• For the alternator, the front side (pulley side) surface is the reference surface. Fit the reference sur-
face to the alternator mounting part, and then tighten the bolts. F
• Be careful to tighten “B” terminal nut to the specified torque.
• Install alternator, and check tension of belt. Refer to EM-331, "Inspection".
NOTE: G
Tighten mounting bolts according to the following procedures for installing alternator bracket.
1. Temporarily tighten mounting bolt (1).
2. Temporarily tighten mounting bolt (2).
3. Tighten mounting bolts in numerical order as shown in the fig- H
ure.

JMMIA0463ZZ

HR15DE : Disassembly and Assembly INFOID:0000000006370546 K

DISASSEMBLY
L
Rear Bracket Assembly
NOTE:
Rear bracket assembly may be hard to remove because a ring is
used to lock outer race of rear bearing. To facilitate removal of rear CHG
bracket assembly, heat only the bearing box section until the temper-
ature increases to approximately 30°C (86°F) with a soldering iron
(200W capacity). N
CAUTION:
Never use a heat gun, as if can damage diode assembly.
O

SEL032Z
P
ASSEMBLY
Rear Bearing
CAUTION:
• Never reuse rear bearing. Replace with a new one.
• Never lubricate rear bearing outer race.
Rear Bracket Assembly Installation

CHG-53
 ALTERNATOR
< REMOVAL AND INSTALLATION >
1. Fit brush assembly, diode assembly, regulator assembly and
stator.

SKIB4529E

2. Push brushed up with fingers and install them to rotor.

NOTE:
Take care not damage slip ring sliding surface.

SKIB4530E

HR15DE : Inspection INFOID:0000000006370547

INSPECTION AFTER DISASSEMBLY

Rotor Check
1. Resistance test

Resistance : Refer to SDS CHG-58, "Alternator".

• Replace the rotor if the measurement value is outside of the
specified range.
2. Insulator test
• Replace the rotor if continuity exists.
3. Check slip ring for wear.

Slip ring minimum : Refer to SDS CHG-58, "Alterna- SKIB4525E

outer diameter tor".

• Replace the rotor if the measurement value is outside of the specified range.
Brush Check
1. Check smooth movement of brush.
• Check brush holder and clean if it is not smooth.
2. Check brush for wear.
• Replace brush if it is worn down to the limit line.

SKIB4526E

Stator Check

CHG-54
 ALTERNATOR
< REMOVAL AND INSTALLATION >
1. Continuity test
• Replace the stator if continuity does not exist. A

SKIB4527E

D
2. Ground test
• Replace the stator if continuity exists.
E

G
SKIB4528E

K9K H
K9K : Exploded View INFOID:0000000006833316

REMOVAL I

CHG

JMMIA0254GB

O
1. Alternator 2. “B” terminal harness 3. Alternator bracket
4. Alternator connector
Refer to GI-4, "Components" for symbols in the figure. P
DISASSEMBLY

CHG-55
 ALTERNATOR
< REMOVAL AND INSTALLATION >
Type: 2543562B

JMMIA0622GB

1. Rotor assembly 2. Retainer 3. Front bearing

4. Front bracket assembly 5. Pulley 6. Stator assembly
7. Rear bearing 8. Rear bracket assembly 9. Circuit board assembly
10. Regulator assembly 11. Stud bolt 12. Through bolt
13. Cover
Refer to GI-4, "Components" for symbols in the figure.

K9K : Removal and Installation INFOID:0000000006833317

REMOVAL
1. Disconnect the battery cable from the negative terminal. Refer to PG-529, "FOR MAINTENANCE
REQUIRED BATTERY MODELS : Removal and Installation" (Maintenance required battery models) or
PG-530, "FOR MAINTENANCE FREE BATTERY MODELS : Removal and Installation" (Maintenance free
battery models).
2. Remove air duct (inlet). Refer to EM-461, "Removal and Installation".
3. Remove drive belt. Refer to EM-456, "Removal and Installation".
4. Remove front bumper fascia. Refer to EXT-14, "Removal and Installation".
5. Remove horn. Refer to HRN-15, "Removal and Installation".
6. Disconnect alternator connector.
7. Remove “B” terminal nut and disconnect “B” terminal harness.
8. Remove upper alternator mounting bolt.
9. Completely loosen lower alternator mounting bolt, and pull it out until the bolt head is in contact with the
side member. And then, remove the alternator by pulling it forward.
NOTE:
The alternator can be removed together with the bolts by pulling it forward and using the alternator bracket
bolt hole cutout.

CHG-56
 ALTERNATOR
< REMOVAL AND INSTALLATION >
10. Move alternator toward vehicle front and remove it from the
vehicle. A

: Vehicle front
B

JMMIA0486ZZ

D
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Be careful to tighten “B” terminal nut to the specified torque. E
• Install alternator, and check tension of belt. Refer to EM-457, "Inspection".

CHG

CHG-57
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 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Alternator INFOID:0000000006057255

HR12DE HR15DE HR15DE

Applied model HR12DE (A/T, M/T) HR12DDR K9K
(CVT) (LHD) (RHD)
A002TX1991 A002TX1981 A002TG0891
A005TL0191 2607689 LR190-722 2543562B
ZT ZT ZT
Type
MITSUBISHI HITACHI MITSUBISHI
VALEO make MITSUBISHI make VALEO make
make male make
Nominal rating
12 -100 12 - 90 12 -150 12 - 90
[V - A]
Ground polarity Negative
Minimum revolu-
tion under no-load
Less than
(When 13.5 V is Less than 1,300 Less than 1,600 Less than 1,300
1,000
applied)
[rpm]
More than 21/ More than 8/ More than 23/ More than 27/ More than 52/
Hot output current 1,300 1,300 1,300 1,300 1,800
(When 13.5 V is More than 79/ More than 74/ More than 126/2,500 More than 65/ More than 76/ More than 92/
applied) 2,500 2,500 More than 152/5,000 2,500 2,500 3,000
[A/rpm] More than 95/ More than 93/ More than 87/ More than 85/ More than
5,000 5,000 5,000 5,000 112/6,000
Regulated output
voltage 14.1 - 14.7*
[V]
Minimum length of
More than 13.85 - 14.55 More than
brush More than 5.00 (0.1969) 6.00 (0.236) —
5.00 (0.1969) (0.54 - 0.57) 5.00 (0.1969)
[mm (in)]
Brush spring pres- 4.1 - 5.3 (439 1.76 - 3.1 1.0 - 3.4 (102 4.8 - 6.0 (490
4.1 - 5.3 (439 - 520, 15.5 -
sure - 520, 15.5 - (179 - 316, - 350, 3.60 - - 612, 17.3 - —
18.4)
[N (g, oz)] 18.4) 6.31 - 11.15) 12.34) 21.6)
Slip ring minimum
More than More than More than More than
outer diameter More than 22.1 (0.870) 26.0 (1.024)
22.1 (0.870) 14.6 (0.563) 22.1 (0.870) 14.0 (0.540)
[mm (in)]
Rotor (Field coil)
resistance 2.0 - 2.3 2.04 - 2.26 1.9 - 2.2 2.52 - 2.82 1.6 - 2.0 2.08 - 2.30
[Ω]
*: Adjustment range of power generation voltage variable control is 11.4 − 15.6 V.

CHG-58