alternator NISSAN NAVARA 2005 Repair Owner's Manual

ENGINE MAINTENANCE
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A/C COMPRESSOR, ALTERNATOR AND WATER PUMP BELT
1. Loosen idler pulley lock nut (D).
2. Turn adjusting nut (C) to adjust. Refer toMA-18, "
Deflection Adjustment".
3. Tighten lock nut (D).
Changing Engine CoolantELS001JQ
WARNING:
lTo avoid being scalded, do not change engine coolant when engine is hot.
lWrap a thick cloth around cap and carefully remove radiator cap. First, turn radiator cap a quarter
of a turn to release built-up pressure. Then turn the cap all the way.
DRAINING ENGINE COOLANT
1. Open radiator drain plug (1) at the bottom of radiator, and
remove radiator cap.
CAUTION:
Be careful not to allow engine coolant to contact drive belts.
When draining all engine coolant in the system, also perform the following steps.
2. Remove air relief plug (1) on heater feed tube.
lLHD models
lRHD models
3. Open cylinder block drain plug. Refer toEM-110, "
CYLINDER BLOCK".
4. Remove reservoir tank, drain engine coolant, then clean reservoir tank.
5. Check drained engine coolant for contaminants such as rust, corrosion or discoloration.
If contaminated, flush engine cooling system. Refer toMA-21, "
FLUSHING COOLING SYSTEM". Nut D:
: 45.0 N·m (4.6 kg-m, 33 ft-lb)
2 : Engine undercover front
A : Loosen.
: Vehicle front
PBIC3634E
2 : Water hose (from reservoir tank)
3:Fuelfilter
: Vehicle front
PBIC3348E
2 : Water hose (from reservoir tank)
: Vehicle front
PBIC3635E

SERVICE DATA AND SPECIFICATIONS (SDS)
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Standard and LimitELS001J8
BELT DEFLECTION
*: When engine is cold.
RESERVOIR TANK
Unit:kPa(bar,kg/cm2, psi)
ENGINE COOLANT CAPACITY (APPROXIMATE)
Unit: (lmp qt)
ENGINE OIL CAPACITY (APPROXIMATE)
Unit: (lmp qt) Applied beltBelt deflection with 98 N (10 kg, 22 lb) force applied* mm (in)
New Adjusted Limit for re-adjusting
A/C compressor, alternator and water
pump belt2.9 - 3.4 (0.114 - 0.134) 3.9 - 4.4 (0.154 - 0.173) 8.5 (0.335)
Power steering oil pump belt 4.6 - 5.4 (0.181 - 0.213) 7.1 - 7.7 (0.280 - 0.303) 11.3 (0.445)
Cap relief pressureStandard 98.2 - 117.8 (0.98 - 1.18, 1.0 - 1.2, 14 - 17)
Limit 59 (0.59, 0.6, 9)
Leakage test pressure 157 (1.57, 1.6, 23)
Engine coolant capacity (With reser-
voir tank at “MAX” level)LHD models 9.9 (8-3/4)
RHD models 10.2 (9)
Reservoir tank coolant capacity (At “MAX” level) 0.8 (3/4)
Drain and refillWith oil filter change 7.6 (6-5/8)
Without oil filter change 7.1 (6-1/4)
Dry engine (Overhaul)7.9 (7)

MTC-122
REFRIGERANT LINES
Removal and Installation for Compressor
EJS005HC
A/C Compressor Mounting
REMOVAL
1. Discharge the refrigerant. Refer toMTC-118, "HFC-134a (R-134a) Service Procedure".
2. Remove the front right wheel and tire assembly. Refer toWT-5, "
Rotation".
3. Remove the engine under cover and the splash shield using power tool.
4. Remove the engine air cleaner and air ducts. Refer toEM-15, "
AIR CLEANER AND AIR DUCT".
5. Remove the drive belt. Refer toEM-12, "
DRIVE BELTS".
6. Disconnect the compressor electrical connector.
7. Disconnect the high-pressure flexible hose and low-pressure flexible hose from the compressor.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
8. Remove the compressor bolts and nut using power tools.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
lReplace the O-ring of the low-pressure flexible hose and high-pressure flexible hose with a new
one, apply compressor oil to the O-rings before installation.
lAfter recharging the A/C system with refrigerant, check for leaks.
MJIB0179E
1. Compressor 2. Alternator and A/C compressor
bracket3. Timing chain case
4. Cylinder block

SC-1
STARTING & CHARGING SYSTEM
K ELECTRICAL
CONTENTS
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SECTIONSC
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STARTING & CHARGING SYSTEM
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 3
Wiring Diagrams and Trouble Diagnosis .................. 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
BATTERY .................................................................... 5
How to Handle Battery ............................................. 5
METHODS OF PREVENTING OVER-DIS-
CHARGE ............................................................... 5
CHECKING ELECTROLYTE LEVEL .................... 5
SPECIFIC GRAVITY CHECK ............................... 6
Battery Test and Charging Chart .............................. 7
CHART I ................................................................ 7
CHART II ............................................................... 8
A: SLOW CHARGE ............................................... 9
B: STANDARD CHARGE .................................... 10
C: QUICK CHARGE ............................................ 12
Removal and Installation ........................................ 13
CHARGING SYSTEM ............................................... 14
System Description ................................................ 14
Wiring Diagram — CHARGE — ............................. 15
Trouble Diagnosis .................................................. 16
DIAGNOSIS PROCEDURE ................................ 16
PRE-DIAGNOSIS INSPECTION ......................... 16
DIAGNOSIS CHART BY SYMPTOM .................. 16
INSPECTION FLOW BY CHARGE WARNING
LAMP .................................................................. 16
CHARGE WARNING LAMP LINE INSPECTION... 17
VOLTAGE DETECTION LINE AND CHARGE
WARNING LAMP INSPECTION ......................... 18
INSPECTION OF INSUFFICIENT ALTERNA-
TOR POWER GENERATION .............................. 20
INSPECTION OF EXCESSIVE ALTERNATOR
POWER GENERATION ...................................... 20
DARK CURRENT INSPECTION ......................... 21
OPERATION PROCEDURE OF CURRENT
MEASUREMENT PROBE FOR CONSULT-II ..... 22
Removal and Installation ........................................ 23REMOVAL ........................................................... 23
INSTALLATION ................................................... 23
Disassembly and Assembly .................................... 23
LHD MODELS ..................................................... 23
RHD MODELS .................................................... 24
Disassembly ........................................................... 24
REAR COVER ..................................................... 24
REAR BEARING ................................................. 24
Inspection ............................................................... 25
ROTOR CHECK .................................................. 25
BRUSH CHECK .................................................. 25
PULLEY CHECK (WITH CLUTCH TYPE) ........... 25
STATOR CHECK ................................................. 25
Assembly ................................................................ 26
RING FITTING IN REAR BEARING .................... 26
REAR COVER INSTALLATION ........................... 26
STARTING SYSTEM ................................................. 27
System Description ................................................. 27
A/T MODELS ....................................................... 27
M/T MODELS ...................................................... 27
Wiring Diagram — START — ................................. 28
A/T MODELS ....................................................... 28
M/T MODELS ...................................................... 29
Trouble Diagnoses ................................................. 30
Removal and Installation ........................................ 31
REMOVAL ........................................................... 31
INSTALLATION ................................................... 31
Disassembly and Assembly .................................... 32
Inspection ............................................................... 32
MAGNETIC SWITCH CHECK ............................. 32
PINION/CLUTCH CHECK ................................... 33
BRUSH CHECK .................................................. 33
YOKE CHECK ..................................................... 34
ARMATURE CHECK ........................................... 35
Assembly ................................................................ 36
PINION PROTRUSION LENGTH ADJUST-
MENT .................................................................. 36
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 37
Battery .................................................................... 37

SC-2
Starter ..................................................................... 37
Alternator ................................................................ 37

SC-14
CHARGING SYSTEM
CHARGING SYSTEM
PFP:00011
System DescriptionEKS00MZA
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 to alternator terminal 4 through:
l15A fuse (No. 30, located in the fuse and fusible link box).
Terminal 1 supplies power to charge the battery and operate the vehicle's electrical system. Output voltage is
controlled by the IC regulator at terminal 4 detecting the input voltage. The charging circuit is protected by the
140A fusible link (letter "A", located in the fuse and fusible link box) .
The alternator is grounded to the engine block.
With the ignition switch in the ON or START position, power is supplied
l10A fuse [No. 14, located in the fuse block (J/B)]
lto combination meter terminal 16 for the charge warning lamp.
Ground is supplied With power and ground supplied
lto terminal 2 of the combination meter
lthrough terminal 3 of the alternator.
If the charge warning lamp illuminates with the engine running, a fault is indicated.
The charge warning lamp will illuminate. When the alternator is providing sufficient voltage with the engine
running, the ground is opened and the charge warning lamp will go off.

SC-16
CHARGING SYSTEM
Trouble Diagnosis
EKS00MZD
DIAGNOSIS PROCEDURE
1. Check malfunction symptoms or customer's remarks.
2. Perform pre-diagnosis inspection. Refer toSC-16, "
PRE-DIAGNOSIS INSPECTION".
3. Perform trouble diagnosis for each trouble symptom. Refer toSC-16, "
DIAGNOSIS CHART BY SYMP-
TOM"
4. Repair or replace parts indicated inspection flow based on the charge warning lamp. Refer toSC-16,
"INSPECTION FLOW BY CHARGE WARNING LAMP".
5. End
PRE-DIAGNOSIS INSPECTION
1. Perform alternator belt inspection. Refer toEM-12, "DRIVE BELTS".
2. Inspect battery.
3. Check alternator terminal 1 for loose or improper connection.
4. Check alternator connector 4 and 3 terminals for loose connection, disconnection and bend.
5. Check connecting condition of harness for charging system harness (fusible link terminal and battery ter-
minal).
6. After performing 1 to 5 above, go to trouble diagnosis for symptoms. Refer toSC-16, "
DIAGNOSIS
CHART BY SYMPTOM".
DIAGNOSIS CHART BY SYMPTOM
INSPECTION FLOW BY CHARGE WARNING LAMP
1.CHARGE WARNING LAMP INSPECTION
1. Turn ignition switch ON.
2. Check if charge warning lamp illuminates.
Does charge warning lamp illuminate?
YES >> GO TO 2.
NO >> Go toSC-17, "
CHARGE WARNING LAMP LINE
INSPECTION".
2.CHARGE WARNING LAMP INSPECTION
1. Start engine.
2. Check if charge warning lamp goes off.
Does charge warning lamp goes off?
YES >> GO TO 3.
NO >> Go toSC-18, "
VOLTAGE DETECTION LINE AND
CHARGE WARNING LAMP INSPECTION".
Symptom Reference page
Battery dischargeRefer toSC-16, "
INSPECTION FLOW BY CHARGE WARN-
ING LAMP".
Charge warning lamp illuminates.Refer toSC-16, "
INSPECTION FLOW BY CHARGE WARN-
ING LAMP".
Other than the above symptoms (splashing out of battery fluid,
nasty smell and others)SC-20, "
INSPECTION OF EXCESSIVE ALTERNATOR
POWER GENERATION".
MKIB0555E
MKIB0556E

CHARGING SYSTEM
SC-17
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3.CHARGE WARNING LAMP INSPECTION
1. Set engine speed at 2,500 rpm.
2. Check if charge warning lamp illuminates.
Does charge warning lamp illuminate?
YES >> Go toSC-20, "INSPECTION OF EXCESSIVE ALTER-
NATOR POWER GENERATION".
NO >> Go toSC-20, "
INSPECTION OF INSUFFICIENT
ALTERNATOR POWER GENERATION".
CHARGE WARNING LAMP LINE INSPECTION
CAUTION:
If open circuit is detected in alternator connector terminal 3, alternator cannot start generating.
INSPECTION PROCEDURE
1.CHARGE WARNING LAMP INSPECTION
1. Turn ignition switch OFF.
2. Remove alternator connector.
3. Connect alternator connector terminal 3 to ground.
4. Turn ignition switch ON.
Does charge warning lamp illuminate?
YES >> GO TO 4.
NO >> GO TO 2.
2.CONNECTOR INSPECTION
1. Turn ignition switch OFF.
2. Check combination meter and terminals (meter side, and harness side) for damage, deformation or
improper connection.
OK or NG
OK >> GO TO 3.
NG >> Repair terminals and connectors.
MKIB0555E
MKIB1725E
MKIB0555E

SC-18
CHARGING SYSTEM
3.CONTINUITY INSPECTION
1. Disconnect combination meter connector.
2. Check continuity between combination meter connector terminal 2 and alternator connector terminal 3.
OK or NG
OK >> Replace combination meter. (Do not replace alternator, since it is normal.)
NG >> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.)
4.CHARGE WARNING LAMP INSPECTION
1. Turn ignition switch OFF.
2. Connect alternator connector.
3. Turn ignition switch ON.
Does charge warning lamp illuminate?
YES >> Repair alternator connector. (Poor connection and inter-
mittent problem) (Do not replace alternator, since it is
normal.)
NO >> Replace alternator. (circuit malfunction in alternator)
VOLTAGE DETECTION LINE AND CHARGE WARNING LAMP INSPECTION
INSPECTION PROCEDURE
1.CHARGE WARNING LAMP INSPECTION
1. Turn ignition switch OFF.
2. Remove alternator connector.
3. Turn ignition switch ON.
Does charge warning lamp stay ON?
YES >> GO TO 6.
NO >> GO TO 2.
2.VOLTAGE INSPECTION
Check voltage between alternator connector terminal 4 and ground.
Is the inspection result 12V or more?
YES >> Replace alternator.
NO >> GO TO 3.2 - 3 : Continuity should exist.
MKIB0555E
MKIB0555E
4 - Ground : 12V or more
MKIB1726E

CHARGING SYSTEM
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3.CONNECTOR INSPECTION
1. Turn ignition switch OFF.
2. Check alternator connector and terminal 4 (alternator side, and harness side) for damage, deformation or
improper connection.
OK or NG
OK >> GO TO 4.
NG >> Repair terminals and connectors.
4.CHECK FUSE
Check if any of the following fuses in the alternator are blown.
lCheck 15A fuse
OK or NG
OK >> GO TO 5.
NG >> If fuse is blownout, be sure to eliminate cause of malfunction befer installing new fuse.
5.CONTINUITY INSPECTION
1. Turn ignition switch OFF.
2. Disconnect combination meter connector.
3. Check continuity between combination meter connector terminal 2 and ground, and combination meter
connector terminal 2 and alternator terminal 3.
OK or NG
OK >> Replace combination meter. (Do not replace alternator, since it is normal.)
NG >> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.)2 - Ground : Continuity should not exist.
2 - 3 : Continuity should exist.