charging NISSAN NAVARA 2005 Repair Repair Manual

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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.

CHARGING SYSTEM
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Wiring Diagram — CHARGE —EKS00MZB
MKWA3624E

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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
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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.

SC-20
CHARGING SYSTEM
INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION
CAUTION:
Check them using charged battery performed battery inspection.
1.VOLTAGE INSPECTION
1. Increase engine speed to 2,500 rpm.
2. Turn electrical load to ON. (Headlamp LO turns on, blower fan
motor maximum airflow amount)
3. Check battery voltage.
Is the inspection result 12.8V to 15.1V?
YES >> GO TO 2.
NO >> Replace alternator. (Alternator power generation error.)
2.CURRENT INSPECTION
1. Turn ignition switch OFF.
2. Disconnect the battery ground cable.
3. Attach current measurement probe for CONSULT-II to the harness for alternator terminal B.
(If the probe can not be attached properly, then connect the sub-
harness between alternator terminal B and the vehicle side har-
ness as shown in figure, and attach the probe to sub-harness.)
4. Connect battery ground cable.
5. Increase engine speed to 2,500 rpm.
6. Turn electrical load to ON. (Headlamp LO turns on, blower fan
motor maximum airflow amount, rear window defogger)
7. Check alternator terminal B current.
CAUTION:
Be careful of rotating parts because the engine is running.
Is the inspection result 30A or more?
YES >> GO TO dark current inspection. Refer toSC-21, "DARK CURRENT INSPECTION". (Alternator is
normal. Do not replace.)
NO >> Replace alternator. (Alternator power generation error.)
INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION
1.ALTERNATOR VOLTAGE INSPECTION
1. Increase engine speed to 2,500 rpm.
2. Check battery voltage.
Is the inspection result 16V or less?
YES >> GO TO 2.
NO >> Replace alternator. (Excessive alternator power genera-
tion.)
MKIA0067E
MKIA0068E
MKIA0067E

CHARGING SYSTEM
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2.BATTERY VOLTAGE INSPECTION
1. Turn ignition switch OFF.
2. Disconnect alternator connector.
3. Turn ignition switch ON.
4. Check voltage between alternator connector terminal 4 and
ground.
Is the inspection result 12V or more?
YES >> Replace alternator. (Alternator power generation error)
NO >> GO TO 3.
3.CHECK FUSE
Check if any of the following fuses in the alternator are blown.
lCheck 15A fuse
OK or NG
OK >> Repair the harnesses.
NG >> If fuse is blownout, be sure to eliminate cause of malfunction befer installing new fuse.
DARK CURRENT INSPECTION
Dark Current: Small current while ignition switch is “OFF”.
NOTE:
lIf battery ground cable is disconnected from battery terminal, a large dark current may not be reproduced.
When battery discharge occurs, never disconnect battery terminal while using ammeter.
lDo not connect CONSULT-II CONVERTER to data link connector when measuring dark current. CON-
SULT-II power should be supplied using AC adapter or internal battery.
1. Attach current measurement probe for CONSULT-II to battery
ground cable. Refer toSC-22, "
OPERATION PROCEDURE OF
CURRENT MEASUREMENT PROBE FOR CONSULT-II".
2. Check that all electrical equipment is turned OFF.
3. Remove key. Close and lock doors. Check that room lamp turns
off.
4. Measure dark current. Is it 50mA or less? Refer toSC-22,
"OPERATION PROCEDURE OF CURRENT MEASUREMENT
PROBE FOR CONSULT-II".
NOTE:
Dark current stable time is different due to equipment and use of
the vehicle. If it is not 50mA or less after leaving for 1 minute, measure dark current again after leaving for
30 minutes or more.
If YES, GO TO 7. If NO, GO TO 5.
5. Remove and install fuses one by one. Search for the fuse that greatly changes dark current.
NOTE:
If dark current is greatly reduced when removing the fuse, and even if dark current is not greatly increased
when installing it again, the fuse circuit may be the cause.
6. Check that dark current changes when moving the suspect circuit harness. If dark current changes, check
harness for short. If dark current does not change, electronic unit in the circuit may not be entering the
energy-saving mode when it turns OFF. If it does not enter the energy-saving mode, replace electronic
unit.
7. No malfunction for alternator and electrical equipment. Electric load may be larger than alternator generat-
ing ability. Check the customer's usage.4 - Ground : 12V or more
MKIB1726E
MKIA0070E

SC-22
CHARGING SYSTEM
OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II
For details, refer to the supplied “CONSULT-II Current Probe Operation Manual”.
1. Turn current probe power supply OFF and connect to CONSULT-II. (Red: CH1, Black: Ground)
2. Touch “SUB MODE”.
3. Touch “Extending Measurement Mode” on “SUB MODE” screen.
4. CAUTION is displayed, touch “OK”.
5. Set current probe range switch at the range to measure, turn
current probe power supply ON. When measuring dark current,
set 4A range. (Check that POWER indicator turns on. Refer to
CONSULT-II Current Probe Operation Manual.)
6. Touch the same measuring range at CONSULT-II.
NOTE:
If current probe measuring range is different from CONSULT-II
measuring range, incorrect value is displayed.
7. Adjust 0 point of current probe or CONSULT-II. (Do not clamp
anything to probe.)
NOTE:
If 0 point is dislocated greatly, adjust at current probe side gen-
erally.
8. Align current direction mark, clamp harness, and measure cur-
rent. If current direction is incorrect, it is displayed negative
value.
NOTE:
lWhen current is measured, close probe joint securely.
lIf multiple harnesses are clamped, measurement cannot be
performed. Always clamp only one.
MKIA0071E
MKIA0072E
MKIA0073E
MKIA0074E

CHARGING SYSTEM
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Removal and InstallationEKS00MZE
REMOVAL
1. Disconnect negative battery cable.
2. Remove intercooler hose and duct
3. Disconnect alternator harness.
4. Remove drive belt. Refer toEM-12, "
Checking Drive Belts".
5. Remove alternator upper mounting bolt.
6. Remove alternator lower mounting nut and bolt .
7. Remove alternator.
INSTALLATION
Install in the reverse order of removal, taking care of the following point.
lInstall alternator, and check tension of drive belt. Refer toEM-13, "Deflection Adjustment".
CAUTION:
Be sure to tighten alternator terminal 1 mounting nut carefully.
Disassembly and AssemblyEKS00PD1
LHD MODELS
MKIB1992E
YD engine models - B terminal nut:
: 7.9 - 11.0 N·m (0.8 - 1.11 kg-m, 70 - 97 in-lb)
1. Rear bearing 2. Rotor 3. Retainer
4. Front bearing 5. Through bolt 6. Front cover
7. Washer 8. Pulley 9. Stator
10. IC voltage regulator assembly 11. Diode assembly 12. Rear cover
13. B terminal
MKIB2000E