CHARGING SYSTEM SECTION CHG CONTENTS ELECTRICAL & POWER CONTROL CHG-1 BASIC INSPECTION... 2 SYMPTOM DIAGNOSIS...17 FUNCTION DIAGNOSIS...

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1 TR & WR TR ST R SYSTM TTS S ST... 2 SS RR WRW... 2 Work low...2 UT SS... 3 R SYSTM... 3 System iagram...3 System escription...3 omponent escription...3 WR RT VT VR- TR SYSTM... 4 System iagram...4 System escription...4 omponent escription...4 MT SS... 5 R SYSTM RMRY - ST... 5 nspection rocedure...5 WR RT VT VR- TR SYSTM RT - ST... 6 nspection rocedure...6 TRM RUT... 8 escription...8 iagnosis rocedure...8 TRM RUT... 9 escription...9 iagnosis rocedure...9 S TRM RUT...10 escription...10 iagnosis rocedure...10 R SYSTM...11 Wiring iagram...11 SYMTM SS...17 R SYSTM...17 Symptom Table...17 RUT...18 RUTS...18 Supplemental Restraint System (SRS) "R " and "ST T R-TSR"...18 recautions ecessary for Steering Wheel Rotation after attery isconnect...18 recaution for ower eneration Voltage Variable ontrol System...18 RRT...20 RRT...20 Special Service Tool...20 ommercial Service Tool V RR...21 RTR...21 xploded View...21 Removal and nstallation...21 nspection...22 SRV T STS (SS)...23 SRV T STS (SS)...23 enerator

2 < S ST > SS RR WRW S ST SS RR WRW Work low : VR SQU WM1142-2

3 < UT SS > UT SS R SYSTM System iagram R SYSTM : M0207 System escription : The generator provides voltage to operate the vehicle's electrical system and to keep the battery charged. The voltage output is controlled by the regulator. omponent escription enerator omponent part Terminal 1 Terminal 2 Terminal 3 Terminal 4 ombination meter (harge warning lamp) M /R Refer to -8, "escription". Refer to -9, "escription". Refer to -10, "escription". escription : Used for the power generation voltage variable control system. Refer to -4, "System escription". The regulator warning function activates to illuminate the charge warning lamp if any of the following symptoms occur while generator is operating: xcessive voltage is produced. o voltage is produced. Used for the power generation voltage variable control system. Refer to -4, "System escription". -3

4 WR RT VT VR TR SYSTM < UT SS > WR RT VT VR TR SYSTM System iagram : M0057 System escription : ower generation variable voltage control system has been adopted. y varying the voltage to the generator, engine load due to power generation of the generator is reduced and fuel consumption is decreased. T: When any malfunction is detected in the power generation variable voltage control system, power generation is performed according to the characteristic of the regulator in the generator. omponent escription : omponent part attery current sensor M M /R enerator ( regulator) escription The battery current sensor is installed on the battery cable at the negative terminal. The battery current sensor detects the charging/discharging current of the battery and sends a voltage signal to the M according to the current value detected. The battery current sensor detects the charging/discharging current of the battery. The M judges the battery condition based on this signal. The M judges whether to request more output via the power generation voltage variable control according to the battery condition. When performing the power generation voltage variable control, the M calculates the target power generation voltage according to the battery condition and sends the calculated value as the power generation command value to the M /R. The M /R converts the received power generation command value into a pulse width modulated (WM) command signal and sends it to the regulator. The regulator controls the power generation voltage by the target power generation voltage based on the received WM command signal. When there is no WM command signal, the generator performs the normal power generation according to the characteristic of the regulator. -4

5 < MT SS > R SYSTM RMRY ST MT SS R SYSTM RMRY ST nspection rocedure 1. TTRY TRMS T heck if battery terminals are clean and tight. s the inspection result normal? YS >> T 2 >> Repair battery terminals connection. 2. US heck for blown fuse and fusible link. : Unit ower source (ower supply terminals) use or usible ink enerator attery (terminal 3) use 29 attery (terminal 1) usible ink ombination meter gnition switch (terminal 2) use 4 s the inspection result normal? YS >> T 3 >> e sure to eliminate cause of malfunction before installing new fuse or fusible link. 3. RTR RU TRM T heck if connector 230 terminal 5 (generator ground harness) is clean and tight. s the inspection result normal? YS >> T 4 >> Repair connection. 4. RV T TS heck drive belt tension. Refer to -22, "nspection". s the inspection result normal? YS >> nspection nd. >> Repair as needed. -5

6 WR RT VT VR TR SYSTM RT ST < MT SS > WR RT VT VR TR SYSTM R- T ST nspection rocedure : UT: When performing this inspection, always use a charged battery that has completed the battery inspection. (When the charging rate of the battery is low, the response speed of the voltage change will become slow. This can cause an incorrect inspection.) 1. M (SUT-) erform M self-diagnosis with SUT-. Refer to -123, "SUT- unction". Self-diagnostic results content o malfunction detected>> T 2 Malfunction detected>> heck applicable parts, and repair or replace corresponding parts. 2. RT WR RT VT VR TR SYSTM 1. onnect SUT- and start the engine. 2. The selector lever is in or position and all of the electric loads and /, etc. are turned. 3. Select TRTR UTY in ctive Test of, and then check the value of TTRY VT monitor when UTY value of TRTR UTY is set to 40.0 %. TTRY VT 2 seconds after setting the UTY value of TR- TR UTY to 40.0 % : V 4. heck the value of TTRY VT monitor when UTY value of TRTR UTY is set to 80.0%. TTRY VT 20 seconds after setting the UTY value of TR- TR UTY to 80.0 % : +0.5 V or more against the value of TTRY VT monitor when UTY value is 40.0 % s the measurement value within the specification? YS >> nspection nd. >> T 3 3. M /R (SUT-) erform M /R self-diagnosis with SUT-. Refer to S-15, "SUT - unction (M /R)". Self-diagnostic results content o malfunction detected>> T 4 Malfunction detected>> heck applicable parts, and repair or replace corresponding parts. 4. RSS TW RTR M /R 1. Turn ignition switch. 2. isconnect generator connector and M /R connector. -6

7 WR RT VT VR TR SYSTM RT ST < MT SS > 3. heck continuity between generator harness connector 7 () terminal 4 and M /R harness connector 10 () terminal 76. ontinuity onnector Terminal onnector Terminal Yes 4. heck continuity between generator harness connector 7 () terminal 4 and ground. onnector Terminal ontinuity 7 4 round o s the inspection result normal? YS >> Replace M /R. Refer to S-40, "Removal and nstallation". >> Repair harness or connector between M /R and generator. M0343ZZ -7

8 < MT SS > TRM RUT escription TRM RUT : The terminal 1 () circuit supplies power to charge the battery and operate the vehicle s electrical system. iagnosis rocedure : TRM 1 T 1. Turn ignition switch. 2. heck if terminal 1 is clean and tight. s the inspection result normal? YS >> T 2 >> Repair terminal 1 connection. onfirm repair by performing complete Starting/harging system test. Refer to diagnostic station instruction manual. 2. TRM 1 RUT heck voltage between generator connector 6 terminal 1 and ground. 1 - ground attery voltage s the inspection result normal? YS >> T 3 >> heck harness for open between generator and fusible link. 3. TRM 1 T (VT R TST) 1. Start engine, then engine running at idle and warm. 2. heck voltage between battery positive terminal and generator connector 6 terminal ess than 0.2V s the inspection result normal? YS >> Terminal 1 circuit is normal. Refer to -2, "Work low". >> heck harness between battery and generator for high resistance. M0344ZZ M0345ZZ -8

9 < MT SS > TRM RUT escription TRM RUT : The terminal 2 () circuit controls the charge warning lamp. The charge warning lamp illuminates when the ignition switch is set to or STRT. When the generator is providing sufficient voltage with the engine running, the charge warning lamp will go off. f the charge warning lamp illuminates with the engine running, a malfunction is indicated. iagnosis rocedure : R WR M RUT T heck to see if generator connector 7 terminal 2 is clean and tight. s the connection secure? YS >> T 2 >> Repair the connection. onfirm repair by performing complete Starting/harging system test. Refer to diagnostic station instruction manual. 2. R WR M RUT 1. isconnect generator connector pply ground to generator harness connector 7 terminal 2 with the ignition switch in the position. harge lamp should illuminate oes it illuminate? YS >> heck generator function. Refer to -2, "Work low". >> T 3 3. RSS TUTY ( RUT) 1. Turn ignition switch. 2. isconnect the generator connector isconnect the combination meter connector M heck continuity between generator harness connector 7 () terminal 2 and combination meter harness connector M24 () terminal 25. ontinuity onnector Terminal onnector Terminal 7 2 M24 25 Yes s continuity present? YS >> Replace the combination meter. Refer to MW-144, "Removal and nstallation". >> Repair the harness or connector. M0346ZZ WM0452ZZ -9

10 < MT SS > S TRM RUT escription S TRM RUT : The output voltage of the generator is controlled by the regulator at terminal 3 (S) detecting the input voltage. Terminal 3 circuit detects the battery voltage to adjust the generator output voltage with the regulator. iagnosis rocedure : VT RUTR RUT T heck to see if connector 7 terminal 3 is clean and tight. s the inspection result normal? YS >> T 2 >> Repair terminal connection. onfirm repair by performing complete Starting/harging system test. Refer to diagnostic station instruction manual. 2. VT RUTR RUT heck voltage between generator harness connector 7 terminal 3 and ground. 3 - ground attery voltage oes battery voltage exist? YS >> Refer to -2, "Work low". >> heck harness for open between generator and fuse. M0348ZZ -10

11 < MT SS > R SYSTM Wiring iagram R SYSTM : MW

12 < MT SS > R SYSTM M

13 < MT SS > R SYSTM M

14 < MT SS > R SYSTM M

15 < MT SS > R SYSTM M

16 < MT SS > R SYSTM M

17 < SYMTM SS > SYMTM SS R SYSTM Symptom Table R SYSTM : attery discharged Symptom The charge warning lamp does not illuminate when the ignition switch is set to. The charge warning lamp does not turn after the engine starts. The charging warning lamp turns when increasing the engine speed. Refer to -2, "Work low". Reference -17

18 < RUT > RUT RUTS RUTS Supplemental Restraint System (SRS) "R " and "ST T R-TS- R" : The Supplemental Restraint System such as R and ST T R-TSR, 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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. nformation necessary to service the system safely is included in the SR and S section of this Service Manual. WR: To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized SS/T dealer. mproper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. or removal of Spiral able and ir ag Module, see the SR section. o 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 harness connectors. recautions ecessary for Steering Wheel Rotation after attery isconnect -18 : T: efore removing and installing any control units, first turn the push-button ignition switch to the position, then disconnect both battery cables. fter finishing work, confirm that all control unit connectors are connected properly, then re-connect both battery cables. lways use SUT- to perform self-diagnosis as a part of each function inspection after finishing work. f a T is detected, perform trouble diagnosis according to self-diagnosis results. This vehicle is equipped with a push-button ignition switch and a steering lock unit. f the battery is disconnected or discharged, the steering wheel will lock and cannot be turned. f turning the steering wheel is required with the battery disconnected or discharged, follow the procedure below before starting the repair operation. RT RUR 1. onnect both battery cables. T: Supply power using jumper cables if battery is discharged. 2. arry the ntelligent ey or insert it to the key slot and turn the push-button ignition switch to position. (t this time, the steering lock will be released.) 3. isconnect both battery cables. The steering lock will remain released with both battery cables disconnected and the steering wheel can be turned. 4. erform the necessary repair operation. 5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn the push-button ignition switch from position to position, then to position. (The steering wheel will lock when the push-button ignition switch is turned to position.) 6. erform self-diagnosis check of all control units using SUT-. recaution for ower eneration Voltage Variable ontrol System : UT: or this model, the battery current sensor that is installed to the battery cable at the negative terminal measures the charging/discharging current of the battery, and performs various controls. f the electrical component or the ground wire is connected directly to the battery terminal, the current other than

19 RUTS < RUT > that being measured with the battery current sensor is charging to or discharging from the battery. This condition causes the malfunction of the control, and then the battery discharge may occur. o not connect the electrical component or the ground wire directly to the battery terminal. -19

20 < RRT > RRT RRT Special Service Tool RRT : The actual shapes of ent-moore tools may differ from those of special service tools illustrated here. Tool number (ent-moore o.) Tool name ( ) Model R-8 Multitasking attery iagnostic Station escription Tests batteries, starting and charging systems. or operating instructions, refer to diagnostic station instruction manual. ommercial Service Tool W1239ZZ : Tool name ower tool escription oosening bolts and nuts

21 < -V RR > -V RR RTR xploded View RTR : M0830ZZ Removal and nstallation VQ35 RMV 1. ower generator bolt 2. enerator stay bolt 3. enerator 4. ower generator nut 5. "" terminal nut 6. Upper generator bolt 7. enerator stay bracket 1. isconnect the negative battery terminal. 2. rain engine coolant. Refer to -10, "hanging ngine oolant". 3. Remove engine room cover. 4. Remove R front wheel and tire assembly. Refer to WT-62, "djustment". 5. Remove front/right-side engine undercover. 6. Remove air cleaner and duct assembly. Refer to M-23, "Removal and nstallation". 7. Remove battery tray. Refer to -67, "Removal and nstallation (attery Tray)". 8. Remove cooling fan assembly. Refer to -15, "Removal and nstallation". 9. vacuate / system. Refer to -34, "ollection and harge". 10. Remove the drive belt. Refer to M-14, "Removal and nstallation". 11. Remove the / compressor. Refer to -44, "Removal and nstallation for ompressor". 12. Remove idler pulley. 13. Remove / idler pulley. 14. isconnect the oil pressure switch. 15. isconnect the generator harness connectors. 16. Remove the generator bolt and nuts, using power tools. -21 :

22 < -V RR > 17. Slide the generator out and remove. RTR STT nstallation is in the reverse order of removal. Refer to -21, "xploded View" UT: e sure to tighten terminal nut carefully. nstall generator and check tension of belt. Refer to M-14, "hecking rive elts". or this model, the power generation voltage variable control system that controls the power generation voltage of the generator has been adopted. Therefore, the power generation voltage variable control system operation inspection should be performed after replacing the generator, and then make sure that the system operates normally. Refer to -3, "System escription". nspection RTR UY ST erform the following. Make sure that generator pulley does not rattle. Make sure that generator pulley nut is tight. : enerator pulley nut : 118 m (12.0 kg-m, 87 ft-lb) -22

23 SRV T STS (SS) < SRV T STS (SS) SRV T STS (SS) SRV T STS (SS) enerator : pplication Type ominal rating round polarity Minimum revolution under no-load (when 13.5 volts are applied) *: djustment range of power generation voltage variable control is V VQ35 003T1791Z atachi 12V-130 egative ess than 1,300 rpm More than 61/1800 rpm ot output current (when 13.5 volts are applied) More than109/2,500 rpm More than 129/5,000 rpm Regulated output voltage 20 Minimum length of brush More than 5 mm (0.24 in) rush spring pressure ( g, oz) Slip ring minimum outer diameter More than 22.1 mm (0.870 in) Rotor (ield coil) resistance ohms -23

CHARGING SYSTEM SECTION CHG CONTENTS ELECTRICAL & POWER CONTROL CHG-1 PRECAUTION... 2 PREPARATION... 3 BASIC INSPECTION... 4 FUNCTION DIAGNOSIS...

CHARGING SYSTEM SECTION CHG CONTENTS ELECTRICAL & POWER CONTROL CHG-1 PRECAUTION... 2 PREPARATION... 3 BASIC INSPECTION... 4 FUNCTION DIAGNOSIS... TR & WR TR ST R SYSTM TTS RUT... 2 RUTS... 2 Supplemental Restraint System (SRS) "R " and "ST T R-TSR"...2 recaution for ower eneration Variable Voltage ontrol System...2 RRT... 3 RRT... 3 Special Service