PART 4 : CHARGING SYSTEM

Alternator Overhaul

Drive Belt Replacement

Drive Belt Inspection and Adjustment

Alternator Replacement (Without ETCS)

Alternator Replacement (With ETCS)

Charging System Component Location Index

Charging System Circuit Diagram

Charging Circuit Troubleshooting

Alternator Overhaul
Exploded View

Special Tools Required

Handle driver ( 07749-0010000)
NOTE: Refer to the Exploded View as needed during this procedure.

1. Test the alternator and regulator before you remove them.

2. Remove the alternator.

3. Remove the four through bolts

4. Heat the rear bearing seat with a 1,000 W hair drier for about 5 minutes (50-60°C, 129-140°F)
5. Separate the rear housing from the drive-end housing by inserting a flat tip screwdriver into
the openings and prying them apart.

NOTE: Be careful not to damage the stator with the tip of the screwdriver.

6. Separate the rear housing (A) and drive-end housing (B) with the stator (C) attached to the rear
housing.
7. If you are not replacing the front bearing and/or rear bearing, go to 15. Clamp the rotor in a soft-
jawed vise, then remove the pulley locknut.

8. Remove the rotor using a puller as shown.

9. Inspect the rotor shaft for scoring, and inspect the bearing journal surface in the drive-end housing
for seizure marks.

 If either the rotor or drive-end housing is damaged, replace the alternator.

 If both the rotor and the drive-end housing are OK, go to 10.

10. Remove the rear bearing using the puller as shown

11. Use a hand press to install the new rear bearing. Apply pressure only on the inner race to
avoid damaging the bearing

12. Remove the front bearing retainer plate.

13. Support the drive-end housing in a vise, and drive out the front bearing with a brass drift (A)
and hammer
14. With a hammer and the special tools, install a new front bearing in the drive-end housing

Alternator Brush Inspection

15. Measure the length of both brushes with a vernier caliper.

 If either brush is shorter than the service limit, replace the rear housing assembly.
 If brush length is OK, go to 16.

Alternator Brush Length:

Standard (New): 19.0 mm (0.75 in.)

Service Limit: 5 mm (0.2 in.)

Rotor Slip Ring Test

16. Check that there is continuity between the slip rings (A).

 If there is continuity, go to 17.

 If there is no continuity, replace the rotor assembly.

17. Check that there is no continuity between each slip ring (A) and the rotor (B) and the rotor shaft (C).

 If there is no continuity, replace the rear housing assembly, go to 18.

 If there is continuity, replace the rotor assembly

Alternator Reassembly
18. If you removed the pulley, put the rotor in the drive-end housing, then tighten its locknut to 111 N·m
(11.3 kgf·m, 81.7 lbf·ft).
19. Remove any grease or any oil from the slip rings.

20. Push the brushes (A) in, then insert a pin or drill bit (B) (about 1.8 mm (0.77 in.) diameter) to hold
them there.

21. Heat the rear bearing seat with a 1,000 W hair drier for about 5 minutes (50-60°C, 129-
140°F).

22. Put the rear housing assembly (A) and drive-end housing/rotor assembly (B) together, tighten
the four through bolts (C) and pull out the pin (D).

23. After assembling the alternator, turn the pulley by hand to make sure the rotor rotates smoothly
and without noise.

24. Install the alternator, and adjust its belt tension.

Drive Belt Replacement

1. Loosen the lock bolt (A), mounting bolt (B) and adjusting bolt (C),then remove the drive belt
 (D).

2. Install the drive belt in the reverse order of removal.

3. Adjust the drive belt tension

Drive Belt Inspection and Adjustment

Special Tools Required
Belt tension gauge ( 07JGG-0010100

Belt Tension Gauge Method

Inspection
1. Attach the belt tension gauge to the belt and measure the tension. Follow the gauge manufacturer's
instructions. If the belt is worn or damaged, replace it. If the belt needs adjustment, go to step 2.

Tension:
 Used Belt: 440-590 N (45-60 kgf, 99-130 lbf)

New Belt: 981-1,130 N (100-115 kgf, 220-254 lbf)

With A/C compressor:

Without A/C compressor:

Adjustment
2. Loosen the lock bolt (A) and mounting bolt (B).
3. Turn the adjusting bolt (C) to obtain the proper belt tension, then retighten the lock bolt and
mounting bolt.

4. Recheck the belt tension.

5. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt
specification.

Deflection Method

Inspection
1. Apply a force of 98 N (10 kgf, 22 lbf), and measure the deflection at the mid point (A) between the
A/C compressor (alternator for without A/C compressor) and crankshaft pulley. If the belt is worn or
damaged, replace it. If the belt needs adjustment, go to step 2.

Deflection:

With A/C compressor:

Used Belt: 5.5-8.5 mm (0.22-0.33 in.)

New Belt: 3.5-5.0 mm (0.14-0.20 in.)

Without A/C compressor:

Used Belt: 7.5-10.5 mm (0.30-0.41 in.)

New Belt: 4.5-6.0 mm (0.18-0.24 in.)

With A/C compressor:

Without A/C compressor:

Adjustment
2. Loosen the lock bolt (A) and mounting bolt (B).

3. Turn the adjusting bolt (C) to obtain the proper belt tension, then retighten the lock bolt and
 mounting bolt.

4. Recheck the belt tension.

5. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt
specification

Alternator Replacement (Without ETCS)

1. Disconnect the battery negative cable from the battery.

2. Remove the intake manifold.

3. Disconnect the alternator connector (A), WHT wire (B) and harness clamp (C) from the alternato

4. Remove the intake manifold

5. Remove the lock bolt (A) and mounting bolt (B), then remove the alternator.
6. Install the alternator in the reverse order of removal.

7. Adjust the drive belt tension.

Alternator Replacement (With ETCS)

1. Disconnect the battery negative cable from the battery.

2. Remove the intake manifold.

3. Disconnect the alternator connector (A), WHT wire (B) and harness clamp (C) from the alternator.
4. Remove the drive belt.

5. Remove the lock bolt (A) and mounting bolt (B), then remove the alternator
6. Install the alternator in the reverse order of removal.

7. Adjust the drive belt tension.

Charging System Component Location Index

Charging System Circuit Diagram

Charging Circuit Troubleshooting
If the charging system indicator does not come on or does not go off, or the battery is dead or low, test
the following items in the order listed below:

Battery
Charging system indicator
Alternator/regulator circuit
Alternator control system
Charging System Indicator Test

1. Turn the ignition switch ON (II).

Does the charging system indicator come on?

YES - Go to 2.

NO - Go to 9.

2. Start the engine.

Does the charging system indicator go off?

YES - Charging system indicator circuit is OK.

NO - Go to 3.
3. Turn the ignition switch OFF.

4. Disconnect the alternator 4P connector from the alternator.

5. Turn the ignition switch ON (II).

Does the charging system indicator come on?

YES -

 Without navigation system: Turn the ignition switch OFF, and repair the short in the WHT/BLU
wire. If the WHT/BLU wire is shorted to ground, the voltage regulator in the alternator may
be damaged.
 With navigation system: Go to 6.
 NO - Repair the alternator components.

6. Turn the ignition switch OFF.

7. Disconnect the 12P connector from the AVN unit.

8. Turn the ignition switch ON (II).

Does the charging system indicator come on?

YES - Turn the ignition switch OFF, and repair the short in the WHT/BLU wire. If the
WHT/BLU wire is shorted to ground, the voltage regulator in the alternator may be
damaged.

NO - Check that the terminals are firmly seated at the connectors. If OK, substitute a known-
good AVN unit and recheck.
9. Connect the alternator 4P connector terminal No. 3 to body ground with a jumper wire. Turn the
ignition switch ON (II).

Does the charging system indicator come on?

YES - Go to 10.

NO - Turn the ignition switch OFF. Check for a blown No. 3 (7.5 A) fuse and a blown charging
system indicator bulb. If the fuse and bulb are OK, repair the open in the YEL or BLK/YEL wire
to the indicator bulb.
10. Measure the voltage at the No. 1 terminal of the alternator 4P connector with the ignition switch ON
(II).

Is there battery voltage?

YES - Go to alternator and regulator circuit test.

NO - Repair open in the YEL or BLK/YEL wire between the alternator and the under-dash
fuse/relay box.

Alternator and Regulator Circuit Test

1. Be sure the battery is sufficiently charged and in good condition.

2. Hook up the following equipment:

 Ammeter, 0-400 A
 Voltmeter, 0-20 V (accurate within 0.1 V)
3. Start the engine. Hold the engine at 3,000 rpm (min-1) with no load shift lever in Park or Neutral, until
the radiator fan comes on then let it idle.

4. Raise the engine speed to 2,000 rpm (min-1) and hold it there.

5. Turn the headlights (high beam) on, and measure voltage at the alternator terminal.

Is the voltage between 13.9 and 15.1 V?

YES - Go to 6.

NO - Repair the alternator components.

6. Read the voltage at 13.5 V.

NOTE: Adjust the voltage by turn the blower motor, rear window defogger, brake lights and etc. on.

Is the voltage 60 A or more?

YES - Alternator/regulator operation is OK.

 NO - Repair the alternator components.

Alternator Control System Test

1. Check for proper operation of the Electrical Load Detecter (ELD) by checking that the Malfunction
Indicator Lamp (MIL) is off and there is no Diagnostic Trouble Code (DTC) for ELD failure:

 Without ETCS.
 With ETCS.

2. Disconnect the alternator 4P connector from the alternator.

3. Start the engine, and turn the headlights (high beam) ON.

4. Measure voltage between the alternator 4P connector terminal No. 2 and the positive terminal of the
battery

Is there 1 V or less?

YES - Go to 9.

NO - Go to 5.

5. Turn the headlight and ignition switch OFF.

6. Disconnect the negative cable from the battery.

7. Disconnect Engine Control Module (ECM)/Powertrain Control Module (PCM) connector B (24P).

8. Check for continuity between ECM/PCM connector terminal B18 and body ground.

Is there continuity?

YES - Repair short to ground in the wire between the alternator and ECM/ PCM.

NO - Check that the terminals are firmly seated at the connectors. If OK, substitute a known-
good ECM/PCM, and recheck. If prescribed voltage is now available, replace the original
ECM/ PCM.

9. Turn the headlight and ignition switch OFF.

10. Disconnect the negative cable from the battery.

11. Disconnect ECM/PCM connector B (24P).

12. Check for continuity between ECM/PCM connector terminal B18 and alternator 4P connector
terminal No.
Is there continuity?

YES - Repair the alternator.

NO - Repair open in the wire between the alternator and ECM/ PCM.