ELECTRICAL & POWER CONTROL

SECTION CHG
CHARGING SYSTEM
B

E
CONTENTS
PRECAUTION ............................................... 2 CHARGING SYSTEM PRELIMINARY IN- F
SPECTION ........................................................ 11
PRECAUTIONS ................................................... 2 Inspection Procedure ...............................................11
Precautions for Removing Battery Terminal ............. 2 G
Precaution for Procedure without Cowl Top Cover...... 2 DTC/CIRCUIT DIAGNOSIS ......................... 12
PREPARATION ............................................ 3 B TERMINAL CIRCUIT ..................................... 12
Diagnosis Procedure ...............................................12 H
PREPARATION ................................................... 3
Commercial Service Tools ........................................ 3 L TERMINAL CIRCUIT (OPEN) ........................ 13
Diagnosis Procedure ...............................................13 I
SYSTEM DESCRIPTION .............................. 4
L TERMINAL CIRCUIT (SHORT) ..................... 14
COMPONENT PARTS ........................................ 4 Diagnosis Procedure ...............................................14
J
CHARGING SYSTEM .................................................. 4 S TERMINAL CIRCUIT ..................................... 15
CHARGING SYSTEM : Component Parts Loca- Diagnosis Procedure ...............................................15
tion ............................................................................ 4
CHARGING SYSTEM : Alternator ............................ 4 SYMPTOM DIAGNOSIS .............................. 16 K

SYSTEM .............................................................. 5 CHARGING SYSTEM ....................................... 16

Symptom Table .......................................................16 L
CHARGING SYSTEM .................................................. 5
CHARGING SYSTEM : System Description ............. 5 REMOVAL AND INSTALLATION ............... 17
WARNING/INDICATOR/CHIME LIST ......................... 5 ALTERNATOR .................................................. 17 CHG
WARNING/INDICATOR/CHIME LIST : Warning Exploded View .........................................................17
Lamps/Indicator Lamps ............................................. 5 Removal and Installation .........................................19
Disassembly and Assembly .....................................21 N
WIRING DIAGRAM ....................................... 6
Inspection ................................................................22
CHARGING SYSTEM .......................................... 6
Wiring Diagram ......................................................... 6
SERVICE DATA AND SPECIFICATIONS
O
(SDS) ............................................................ 24
BASIC INSPECTION .................................... 9
SERVICE DATA AND SPECIFICATIONS
DIAGNOSIS AND REPAIR WORK FLOW ......... 9 (SDS) ................................................................. 24 P
Work Flow ................................................................. 9 Alternator .................................................................24

Revision: 2014 April CHG-1 AD0

 PRECAUTIONS
< PRECAUTION >
PRECAUTION
PRECAUTIONS
Precautions for Removing Battery Terminal INFOID:0000000010281872

• When removing the 12V battery terminal, turn OFF the ignition
switch and wait at least 30 seconds.
NOTE:
ECU may be active for several tens of seconds after the ignition
switch is turned OFF. If the battery terminal is removed before ECU
stops, then a DTC detection error or ECU data corruption may
occur.
• For vehicles with the 2-batteries, be sure to connect the main bat-
tery and the sub battery before turning ON the ignition switch.
NOTE:
If the ignition switch is turned ON with any one of the terminals of
SEF289H
main battery and sub battery disconnected, then DTC may be
detected.
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE:
The removal of 12V battery may cause a DTC detection error.
Precaution for Procedure without Cowl Top Cover INFOID:0000000010994396

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield.

PIIB3706J

Revision: 2014 April CHG-2 AD0

 PREPARATION
< PREPARATION >
PREPARATION A
PREPARATION
Commercial Service Tools INFOID:0000000010040083
B

Tool name Description

C

D
Power tool Loosening bolts, nuts and screws

E
PIIB1407E

CHG

Revision: 2014 April CHG-3 AD0

 COMPONENT PARTS
< SYSTEM DESCRIPTION >
SYSTEM DESCRIPTION
COMPONENT PARTS
CHARGING SYSTEM
CHARGING SYSTEM : Component Parts Location INFOID:0000000010040084

JSMIA1641ZZ

No. Component Function

The IC voltage regulator warning function activates to illuminate the charge warning lamp, if any
of the following symptoms occur while alternator is operating:
Combination meter
• Excessive voltage is produced.
(Charge warning lamp)
• No voltage is produced.
Refer to MWI-10, "WARNING LAMPS/INDICATOR LAMPS : Charge Warning Lamp".
Alternator Refer to CHG-4, "CHARGING SYSTEM : Alternator".

CHARGING SYSTEM : Alternator INFOID:0000000010305126

The alternator provides DC voltage to operate the vehicle's electrical

system and to keep the battery charged. The voltage output is con-
trolled by the IC voltage regulator.

JMMIA1018ZZ

Revision: 2014 April CHG-4 AD0

 SYSTEM
< SYSTEM DESCRIPTION >
SYSTEM
A
CHARGING SYSTEM
CHARGING SYSTEM : System Description INFOID:0000000010305135
B
SYSTEM DIAGRAM
C

JPMIA0426GB
J
SYSTEM DESCRIPTION
• “B” terminal circuit supplies power to charge the battery and to operate the vehicle’s electrical system.
• “L” terminal circuit controls the charge warning lamp. The charge warning lamp illuminates when the ignition K
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. L
Refer to MWI-10, "WARNING LAMPS/INDICATOR LAMPS : Charge Warning Lamp".
• “S” terminal circuit detects the battery voltage to adjust the alternator output voltage with the IC voltage reg-
ulator.
CHG
WARNING/INDICATOR/CHIME LIST
WARNING/INDICATOR/CHIME LIST : Warning Lamps/Indicator Lamps INFOID:0000000010560835 N

Item Design Reference O

For layout, refer to MWI-5, "METER SYSTEM : Design".
Charge warning lamp For function, refer to MWI-10, "WARNING LAMPS/INDICATOR LAMPS : Charge
Warning Lamp". P

Revision: 2014 April CHG-5 AD0

 CHARGING SYSTEM
< WIRING DIAGRAM >
WIRING DIAGRAM
CHARGING SYSTEM
Wiring Diagram INFOID:0000000010040092

JRMWF0923GB

Revision: 2014 April CHG-6 AD0

 CHARGING SYSTEM
< WIRING DIAGRAM >

CHG

JRMWF5105GB

Revision: 2014 April CHG-7 AD0

 CHARGING SYSTEM
< WIRING DIAGRAM >

JRMWF5106GB

Revision: 2014 April CHG-8 AD0

 DIAGNOSIS AND REPAIR WORK FLOW
< BASIC INSPECTION >
BASIC INSPECTION A
DIAGNOSIS AND REPAIR WORK FLOW
Work Flow INFOID:0000000010040093
B

1.PRELIMINARY INSPECTION
Perform the preliminary inspection. Refer to CHG-11, "Inspection Procedure". C

>> GO TO 2.
2.INSPECTION WITH CHARGE WARNING LAMP (IGNITION SWITCH IS ON) D

Turn the ignition switch ON.

Does the charge warning lamp illuminate? E
YES >> GO TO 3.
NO >> GO TO 10.
3.INSPECTION WITH CHARGE WARNING LAMP (IDLING) F
Start the engine and run it at idle.
Does the charge warning lamp turn OFF?
G
YES >> GO TO 4.
NO >> GO TO 5.
4.INSPECTION WITH CHARGE WARNING LAMP H
Increase and maintain the engine speed at 2,500 rpm.
Does the charge warning lamp illuminate?
YES >> GO TO 7. I
NO >> INSPECTION END
5.“L” TERMINAL CIRCUIT (SHORT) INSPECTION J
Check “L” terminal circuit (short). Refer to CHG-14, "Diagnosis Procedure".
Is the inspection result normal?
YES >> GO TO 6. K
NO >> Repair as needed.
6.“S” TERMINAL CIRCUIT INSPECTION
L
Check “S” terminal circuit. Refer to CHG-15, "Diagnosis Procedure".
Is the inspection result normal?
YES >> GO TO 7.
CHG
NO >> Repair as needed.
7.MEASURE “B” TERMINAL VOLTAGE
Start engine. When keeping engine running at 2,500 rpm, measure “B” terminal voltage. N
What voltage does the measurement result show?
Less than 13.0 V>>GO TO 8.
More than 16.0 V>>Replace IC voltage regulator. O
8.“B” TERMINAL CIRCUIT INSPECTION
Check “B” terminal circuit. Refer to CHG-12, "Diagnosis Procedure". P
Is the inspection result normal?
YES >> GO TO 9.
NO >> Repair as needed.
9.DISASSEMBLE AND CHECK ALTERNATOR
Check the following conditions.
• Rotor coil

Revision: 2014 April CHG-9 AD0

 DIAGNOSIS AND REPAIR WORK FLOW
< BASIC INSPECTION >
• Rotor slip ring
• Brush
• Stator coil
Refer to CHG-22, "Inspection".
Are these normal?
YES >> Replace IC voltage regulator and/or diode assembly.
NO >> Repair as needed.
10.INSPECTION WITH CHARGE WARNING LAMP (IGNITION SWITCH IS ON)
1. Disconnect alternator connector and ground “L” harness side.
2. Turn the ignition switch ON.
Does the charge warning lamp illuminate?
YES >> GO TO 11.
NO >> GO TO 12.
11.DISASSEMBLE AND CHECK ALTERNATOR
Check the following conditions.
• Rotor coil
• Rotor slip ring
• Brush
Refer to CHG-22, "Inspection".
Are these normal?
YES >> Replace IC voltage regulator.
NO >> Repair as needed.
12.CHECK “L” TERMINAL CIRCUIT (OPEN)
Check “L” terminal circuit (open). Refer to CHG-13, "Diagnosis Procedure".

>> Repair as needed.

Revision: 2014 April CHG-10 AD0

 CHARGING SYSTEM PRELIMINARY INSPECTION
< BASIC INSPECTION >
CHARGING SYSTEM PRELIMINARY INSPECTION
A
Inspection Procedure INFOID:0000000010040094

1.CHECK BATTERY TERMINALS CONNECTION B

Check if battery terminals are clean and tight.
Is the inspection result normal?
C
YES >> GO TO 2.
NO >> Repair battery terminals connection.
2.CHECK FUSE D
Check for blown fuse and fusible link.

Unit Power source (Power supply terminals) Fuse No. E

Alternator Battery (“S” terminal) 32
Combination meter Ignition switch ON (“L” terminal) 5
Is the inspection result normal? F
YES >> GO TO 3.
NO >> Be sure to eliminate the cause of malfunction before installing new fuse.
G
3.CHECK “E” TERMINAL CONNECTION (ALTERNATOR GROUND)
Check if “E” terminal (alternator ground) is clean and tight.
Is the inspection result normal? H
YES >> GO TO 4.
NO >> Repair “E” terminal (alternator ground) connection.
4.CHECK DRIVE BELT TENSION I

Check drive belt tension. Refer to EM-17, "Inspection".

Is the inspection result normal? J
YES >> INSPECTION END
NO >> Repair as needed.
K

CHG

Revision: 2014 April CHG-11 AD0

 B TERMINAL CIRCUIT
< DTC/CIRCUIT DIAGNOSIS >
DTC/CIRCUIT DIAGNOSIS
B TERMINAL CIRCUIT
Diagnosis Procedure INFOID:0000000010040097

1.CHECK “B” TERMINAL CONNECTION

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

(+)
Alternator (–) Voltage (Approx.)
Connector Terminal
F122 1 Ground Battery voltage
Is the inspection result normal?
YES >> GO TO 3.
NO >> Check harness for open between alternator and fusible link.
3.CHECK “B” TERMINAL CONNECTION (VOLTAGE DROP TEST)
1. Start engine, keep engine running at idle and warm.
2. Check voltage between battery positive terminal and alternator “B” terminal.

(–)
(+) Alternator Voltage (Approx.)
Connector Terminal
Battery positive terminal F122 1 Less than 0.2 V
Is the inspection result normal?
YES >> “B” terminal circuit is normal. Refer to CHG-9, "Work Flow".
NO >> Check harness between battery and alternator for poor continuity.

Revision: 2014 April CHG-12 AD0

 L TERMINAL CIRCUIT (OPEN)
< DTC/CIRCUIT DIAGNOSIS >
L TERMINAL CIRCUIT (OPEN)
A
Diagnosis Procedure INFOID:0000000010040099

1.CHECK “L” TERMINAL CONNECTION B

1. Turn ignition switch OFF.
2. Check if “L” terminal is clean and tight.
Is the inspection result normal? C
YES >> GO TO 2.
NO >> Repair “L” terminal connection.
2.CHECK “L” TERMINAL CIRCUIT (OPEN) D

1. Disconnect alternator connector.

2. Apply ground to alternator harness connector terminal. E
3. Check condition of the charge warning lamp with the ignition switch in the ON position.

Alternator Condition
F
Connector Terminal Ground Ignition switch position Charge warning lamp
F15 3 ON Illuminates
Does it illuminate? G
YES >> “L” terminal circuit is normal. Refer to CHG-9, "Work Flow".
NO >> GO TO 3.
3.CHECK HARNESS CONTINUITY (OPEN CIRCUIT) H

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. I

Alternator Combination meter

Continuity
Connector Terminal Connector Terminal J
F15 3 M34 15 Existed
Is the inspection result normal? K
YES >> Replace combination meter.
NO >> Repair harness or connector.
L

CHG

Revision: 2014 April CHG-13 AD0

 L TERMINAL CIRCUIT (SHORT)
< DTC/CIRCUIT DIAGNOSIS >
L TERMINAL CIRCUIT (SHORT)
Diagnosis Procedure INFOID:0000000010040101

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-9, "Work Flow".
2.CHECK HARNESS CONTINUITY (SHORT CIRCUIT)
1. Turn ignition switch OFF.
2. Disconnect the battery cable from the negative terminal.
3. Disconnect combination meter connector.
4. Check continuity between combination meter harness connector and ground.

Combination meter
Continuity
Connector Terminal Ground
M34 15 Not existed
Is the inspection result normal?
YES >> Replace combination meter.
NO >> Repair or replace the harness.

Revision: 2014 April CHG-14 AD0

 S TERMINAL CIRCUIT
< DTC/CIRCUIT DIAGNOSIS >
S TERMINAL CIRCUIT
A
Diagnosis Procedure INFOID:0000000010040103

1.CHECK “S” TERMINAL CONNECTION B

1. Turn ignition switch OFF.
2. Check if “S” terminal is clean and tight.
Is the inspection result normal? C
YES >> GO TO 2.
NO >> Repair “S” terminal connection.
2.CHECK “S” TERMINAL CIRCUIT D

Check voltage between alternator harness connector and ground.

E
(+)
Alternator (–) Voltage (Approx.)
Connector Terminal F
F15 4 Ground Battery voltage
Is the inspection result normal?
G
YES >> Refer to CHG-9, "Work Flow".
NO >> Check harness for open between alternator and fuse.

CHG

Revision: 2014 April CHG-15 AD0

 CHARGING SYSTEM
< SYMPTOM DIAGNOSIS >
SYMPTOM DIAGNOSIS
CHARGING SYSTEM
Symptom Table INFOID:0000000010040104

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-9, "Work Flow".
starts.
The charge warning lamp turns ON when increasing the engine
speed.

Revision: 2014 April CHG-16 AD0

 ALTERNATOR
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION A
ALTERNATOR
Exploded View INFOID:0000000010040105
B

REMOVAL
C

J
JMMIA0372GB

Alternator bracket Alternator bracket mounting bolt Alternator mounting bolt (upper) K
Alternator mounting bolt (lower) Alternator “B” terminal harness
“B” terminal nut Alternator connector
L
: N·m (kg-m, ft-lb)

DISASSEMBLY
CHG

Revision: 2014 April CHG-17 AD0

 ALTERNATOR
< REMOVAL AND INSTALLATION >
Type: 2619888

JSMIA1667GB

Rotor assembly Retainer screw Retainer

Front bearing Front bracket assembly Spacer
Pulley Pulley nut Stator assembly
Rear bracket assembly Assembly screw Regulator assembly

Screw Stud bolt Cover

: Always replace after every disassembly.

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

Revision: 2014 April CHG-18 AD0

 ALTERNATOR
< REMOVAL AND INSTALLATION >
Type: A005TG2991ZJ
A

H
JSMIA1855GB

Rear bearing Rotor assembly Retainer

I
Front bearing Front cover Through bolt
Pulley Pulley cap Stator assembly
IC voltage regulator assembly Diode assembly Rear cover J
Terminal set
: Always replace after every disassembly.
K
: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

L
Removal and Installation INFOID:0000000010040106

REMOVAL CHG
1. Disconnect the battery cable from the negative terminal. Refer to PG-71, "Removal and Installation".
2. Remove air duct (inlet). Refer to EM-25, "Removal and Installation".
3. Remove drive belt. Refer to EM-16, "Removal and Installation". N

4. Disconnect alternator connector .

: Vehicle front
O

JSMIA1673ZZ

Revision: 2014 April CHG-19 AD0

 ALTERNATOR
< REMOVAL AND INSTALLATION >
5. Remove “B” terminal nut and disconnect “B” terminal harness
.

: Vehicle front

JSMIA1674ZZ

6. Remove the radiator core support upper, and then temporarily put top on engine and secure work space.
Refer to DLK-39, "Removal and Installation".
7. Remove alternator upper mounting bolt and lower mounting
bolt .

JSMIA1675ZZ

8. Remove alternator upward from the vehicle.

: Vehicle front

JSMIA1676ZZ

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-17, "Inspection".
NOTE:
Tighten mounting bolts according to the following procedures for installing alternator bracket.

Revision: 2014 April CHG-20 AD0

 ALTERNATOR
< REMOVAL AND INSTALLATION >
• Tighten mounting bolts in the order from 1 to 4 as shown in the fig-
ure. A

JMMIA0495ZZ

D
Disassembly and Assembly INFOID:0000000010040107

DISASSEMBLY E
Rear Bracket Assembly
NOTE:
Rear bracket assembly may be hard to remove because a ring is F
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) using a soldering iron
(200W capacity). G
CAUTION:
Never use a heat gun, as it can damage diode assembly.
H

SEL032Z I
ASSEMBLY
Rear Bearing J
CAUTION:
• Never reuse rear bearing. Replace with a new one.
• Never lubricate rear bearing outer race.
K
Rear Bracket Assembly Installation
1. Fit brush assembly, diode assembly, regulator assembly and
stator. L

CHG

SKIB4529E

Revision: 2014 April CHG-21 AD0

 ALTERNATOR
< REMOVAL AND INSTALLATION >
2. Push brushes up with fingers and install them to rotor.
NOTE:
Take care not to damage slip ring sliding surface.

SKIB4530E

Inspection INFOID:0000000010040108

INSPECTION AFTER DISASSEMBLY

Rotor Check
1. Resistance test

Resistance : Refer to SDS CHG-24, "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-24, "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

Revision: 2014 April CHG-22 AD0

 ALTERNATOR
< REMOVAL AND INSTALLATION >
2. Ground test
• Replace the stator if continuity exists. A

SKIB4528E

CHG

Revision: 2014 April CHG-23 AD0

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Alternator INFOID:0000000010040115

2619888 A005TG2991ZJ
Type
VALEO make MITSUBISHI make
Nominal rating [V - A] 12 - 70
Ground polarity Negative
Minimum revolution under no-load (When 13.5 V is applied) [rpm] Less than 1,300
More than 55/2,500 More than 61/2,500
Hot output current (When 13.5 V is applied) [A/rpm]
More than 68/5,000 More than 72/5,000
Regulated output voltage [V] 14.1 - 14.7
Minimum length of brush [mm (in)] 13.85 - 14.55 (0.54 - 0.57) 5 (0.20)
1.76 - 3.1 4.8 - 6
Brush spring pressure [N (g, oz)] (179.52 - 316.20, (489.60 - 612,
6.31 - 11.5) 17.26 - 21.58)
Slip ring minimum outer diameter [mm (in)] More than 14.6 (0.563) More than 22.1 (0.870)
Rotor (Field coil) resistance [Ω] 2.04 - 2.26 1.90 - 2.20

Revision: 2014 April CHG-24 AD0