To test the charging system, use the following special service tools:
• EXP-800 NI Battery and electrical diagnostic analyzer
• GR8-1200 NI Multitasking battery and electrical diagnostic station
NOTE:
Refer to the applicable Instruction Manual for proper charging system diagnosis procedures.

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CHG-4

< BASIC INSPECTION >

DIAGNOSIS AND REPAIR WORK FLOW

OVERALL SEQUENCE

DETAILED FLOW

NOTE:
To ensure a complete and thorough diagnosis, the battery, starter and alternator test segments must be done
as a set from start to finish.

PRELIMINARY INSPECTION

Perform the preliminary inspection. Refer to

CHG-24, "Inspection Procedure"

JMMIA1147GB

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DIAGNOSIS AND REPAIR WORK FLOW

CHG-5

< BASIC INSPECTION >

>> GO TO 2.

STOP POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM

Stop the operation of the power generation voltage variable control in either of the following procedures.
• After selecting “ENGINE” of “SELECT SYSTEM” using CONSULT, set the DUTY value of “ALTERNATOR

DUTY” to 0 % by selecting “ALTERNATOR DUTY” of “Active Test”. Continue “Active Test” until the end of
inspection. (When the DUTY value is 0 or 100 %, the normal power generation is performed according to the
characteristic of the IC voltage regulator of the alternator.)

• Turn the ignition switch OFF, and disconnect the battery current sensor connector. [However, DTC (P1550 -

P1554) of the engine might remain. After finishing the inspection, connect the battery current sensor connec-
tor and erase the self-diagnosis results history of the engine using CONSULT.]

>> GO TO 3.

DIAGNOSIS WITH EXP-800 NI OR GR8-1200 NI

Perform the charging system test using Multitasking battery and electrical diagnostic station GR8-1200 NI or
Battery and electrical diagnostic analyzer EXP-800 NI. Refer to the applicable Instruction Manual for proper
testing procedures.
Test result

NO PROBLEMS>>Charging system is normal and will also show “DIODE RIPPLE” test result.
NO VOLTAGE>>GO TO 4.
LOW VOLTAGE>>GO TO 12.
HIGH VOLTAGE>>GO TO 14.
EXCESSIVE RIPPLE, OPEN PHASE, OPEN DIODE or SHORTED DIODE>>Replace the alternator. Per-

form “DIODE RIPPLE” test again using Multitasking battery and electrical diagnostic station GR8-
1200 NI or Battery and electrical diagnostic analyzer EXP-800 NI to confirm repair.

INSPECTION WITH CHARGE WARNING LAMP (IGNITION SWITCH IS ON)

Turn the ignition switch ON.

Does the charge warning lamp illuminate?

YES

>> GO TO 6.

>> GO TO 5.

“L” TERMINAL CIRCUIT (OPEN) INSPECTION

Check “L” terminal circuit (open). Refer to

CHG-15, "Diagnosis Procedure"

Is the “L” terminal circuit normal?

YES

>> Replace alternator. Refer to

CHG-28, "Removal and Installation"

>> Repair as needed.

INSPECTION WITH CHARGE WARNING LAMP (IDLING)

Start the engine and run it at idle.

Does the charge warning lamp turn OFF?

YES

>> GO TO 9.

>> GO TO 7.

“L” TERMINAL CIRCUIT (SHORT) INSPECTION

Check “L” terminal circuit (short). Refer to

CHG-17, "Diagnosis Procedure"

Is the “L” terminal circuit normal?

YES

>> GO TO 8.

>> Repair as needed.

“S” TERMINAL CIRCUIT INSPECTION

Check “S” terminal circuit. Refer to

CHG-18, "Diagnosis Procedure"

Is the “S” terminal circuit normal?

YES

>> GO TO 10.

>> Repair as needed.

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< BASIC INSPECTION >

DIAGNOSIS AND REPAIR WORK FLOW

INSPECTION WITH CHARGE WARNING LAMP (ENGINE AT 3,000 RPM)

Increase and maintain the engine speed at 3,000 rpm.
Does the charge warning lamp remain off?

YES

>> GO TO 11.

>> GO TO 10.

10.

INSPECTION OF ALTERNATOR PULLEY

Check alternator pulley. Refer to

CHG-29, "Inspection"

Is alternator pulley normal?

YES

>> Replace alternator. Refer to

CHG-28, "Removal and Installation"

>> Repair as needed.

11.

“B” TERMINAL CIRCUIT INSPECTION

Check “B” terminal circuit. Refer to

CHG-14, "Diagnosis Procedure"

Is “B” terminal circuit normal?

YES

>> Replace alternator. Refer to

CHG-28, "Removal and Installation"

>> Repair as needed.

12.

“B” TERMINAL CIRCUIT INSPECTION

Check “B” terminal circuit. Refer to

CHG-14, "Diagnosis Procedure"

Is “B” terminal circuit normal?

YES

>> GO TO 13.

>> Repair as needed.

13.

INSPECTION OF ALTERNATOR PULLEY

Check alternator pulley. Refer to

CHG-29, "Inspection"

Is alternator pulley normal?

YES

>> Replace alternator. Refer to

CHG-28, "Removal and Installation"

>> Repair as needed.

14.

“S” TERMINAL CIRCUIT INSPECTION

Check “S” terminal circuit. Refer to

CHG-18, "Diagnosis Procedure"

Is the “S” terminal circuit normal?

YES

>> Replace alternator. Refer to

CHG-28, "Removal and Installation"

>> Repair as needed.

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DIAGNOSIS AND REPAIR WORK FLOW

CHG-7

< BASIC INSPECTION >

Work Flow (Without EXP-800 NI or GR8-1200 NI)

INFOID:0000000009347245

OVERALL SEQUENCE

DETAILED FLOW

PRELIMINARY INSPECTION

Perform the preliminary inspection. Refer to

CHG-24, "Inspection Procedure"

JMMIA1148GB

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CHG-8

< BASIC INSPECTION >

DIAGNOSIS AND REPAIR WORK FLOW

>> GO TO 2.

STOP POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM

• Turn the ignition switch OFF, and disconnect the battery current sensor connector. [However, DTC (P1550 -

P1554) of the engine might remain. After finishing the inspection, connect the battery current sensor connec-
tor and erase the self-diagnostic results history of the engine using CONSULT.]

>> GO TO 3.

INSPECTION WITH CHARGE WARNING LAMP (IGNITION SWITCH IS TURNED ON)

When ignition switch is turned ON
Does the charge warning lamp illuminate?

YES

>> GO TO 4.

>> GO TO 10.

INSPECTION WITH CHARGE WARNING LAMP (IDLING)

Start the engine and run it at idle.

Does the charge warning lamp turn OFF?

YES

>> GO TO 5.

>> GO TO 6.

INSPECTION WITH CHARGE WARNING LAMP (ENGINE AT 2,500 RPM)

Increase and maintain the engine speed at 2,500 rpm.

Does the charge warning lamp illuminate?

YES

>> GO TO 8.

>> INSPECTION END

“L” TERMINAL CIRCUIT (SHORT) INSPECTION

Check “L” terminal circuit (short). Refer to

CHG-17, "Diagnosis Procedure"

Is the inspection result normal?

YES

>> GO TO 7.

>> Repair as needed.

“S” TERMINAL CIRCUIT INSPECTION

Check “S” terminal circuit. Refer to

CHG-18, "Diagnosis Procedure"

Is the inspection result normal?

YES

>> GO TO 8.

>> Repair as needed.

MEASURE “B” TERMINAL VOLTAGE

Start engine. With engine running at 2,500 rpm, measure “B” terminal voltage.

What voltage does the measurement result show?

Less than 13.0 V>>GO TO 9.
More than 16.0 V>>Replace alternator. Refer to

CHG-28, "Removal and Installation"

“B” TERMINAL CIRCUIT INSPECTION

Check “B” terminal circuit. Refer to

CHG-14, "Diagnosis Procedure"

Is the inspection result normal?

YES

>> Replace alternator. Refer to

CHG-28, "Removal and Installation"

>> Repair as needed.

10.

INSPECTION WITH CHARGE WARNING LAMP (IGNITION SWITCH IS ON)

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DIAGNOSIS AND REPAIR WORK FLOW

CHG-9

< BASIC INSPECTION >

Disconnect alternator connector and apply ground to “L” terminal.

Turn the ignition switch ON.

Does the charge warning lamp illuminate?

YES

>> Replace alternator. Refer to

CHG-28, "Removal and Installation"

>> GO TO 11.

11.

CHECK “L” TERMINAL CIRCUIT (OPEN)

Check “L” terminal circuit (open). Refer to

CHG-15, "Diagnosis Procedure"

>> Repair as needed.

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CHG-10

< SYSTEM DESCRIPTION >

CHARGING SYSTEM

SYSTEM DESCRIPTION

CHARGING SYSTEM

System Diagram

INFOID:0000000007542141

System Description

INFOID:0000000007542142

The voltage output is controlled by the IC voltage regulator.

Component Parts Location

INFOID:0000000007542143

Component Description

INFOID:0000000007542144

JPMIA0426GB

Alternator

Charge warning lamp

Cylinder block left side

Combination meter

JPLIA0887ZZ

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CHARGING SYSTEM

CHG-11

< SYSTEM DESCRIPTION >

Component part

Description

Alternator

The alternator provides DC voltage to operate the vehicle's electri-
cal system and to keep the battery charged.

Combination meter (Charge warning lamp)

The IC voltage regulator warning function activates to illuminate
the charge warning lamp, if any of the following symptoms occur
while alternator is operating:
• Excessive voltage is produced.
• No voltage is produced.

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< SYSTEM DESCRIPTION >

POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM

POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM

System Diagram

INFOID:0000000007542145

System Description

INFOID:0000000007542146

By performing the power generation voltage variable control, the engine load due to the power generation of
the alternator is reduced and fuel consumption is decreased.
NOTE:
When any malfunction is detected in the power generation voltage variable control system, the power genera-
tion is performed according to the characteristic of the IC voltage regulator of the alternator.

Component Parts Location

INFOID:0000000007542147

JMMIA1072GB

ECM

IPDM E/R

Battery current sensor

Alternator

Engine room dash panel (LH)

Battery

Cylinder block left side

JPLIA0888ZZ

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POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM

CHG-13

< SYSTEM DESCRIPTION >

Component Description

INFOID:0000000007542148

Component part

Description

Battery current sensor

Battery current sensor is installed to the battery cable at the neg-
ative terminal, and it detects the charging/discharging current of
the battery and sends the voltage signal to ECM according to the
current value.

ECM

Battery current sensor detects the charging/discharging current of
the battery. ECM judges the battery condition based on this signal.
ECM judges whether to perform the power generation voltage
variable control according to the battery condition.
When performing the power generation voltage variable control,
ECM calculates the target power generation voltage according to
the battery condition and sends the calculated value as the power
generation command value to IPDM E/R.

IPDM E/R

IPDM E/R converts the received power generation command val-
ue into the power generation command signal (PWM signal) and
sends it to the IC voltage regulator.

Alternator (IC voltage regulator)

IC voltage regulator controls the power generation voltage by the
target power generation voltage based on the received power gen-
eration command signal.
When there is no power generation command signal, the alterna-
tor performs the normal power generation according to the char-
acteristic of the IC voltage regulator.

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< DTC/CIRCUIT DIAGNOSIS >

B TERMINAL CIRCUIT

DTC/CIRCUIT DIAGNOSIS

B TERMINAL CIRCUIT

Description

INFOID:0000000007542149

“B” terminal circuit supplies power to charge the battery and to operate the vehicle’s electrical system.

Diagnosis Procedure

INFOID:0000000007542150

CHECK “B” TERMINAL CONNECTION

Turn ignition switch OFF.

Check if “B” terminal is clean and tight.

Is the inspection result normal?

YES

>> GO TO 2.

>> Repair “B” terminal connection. Confirm repair by performing complete Charging system test

using EXP-800 NI or GR8-1200 NI (if available). Refer to the applicable Instruction Manual for
proper testing procedures.

CHECK “B” TERMINAL CIRCUIT

Check voltage between alternator “B” terminal and ground.

Is the inspection result normal?

YES

>> GO TO 3.

>> Check harness for open between alternator and fusible link.

CHECK “B” TERMINAL CONNECTION (VOLTAGE DROP TEST)

Start engine, then engine running at idle and warm.

Check voltage between battery positive terminal and alternator “B” terminal.

Is the inspection result normal?

YES

>> “B” terminal circuit is normal. Refer to

CHG-3, "Work Flow (With EXP-800 NI or GR8-1200 NI)"

CHG-7, "Work Flow (Without EXP-800 NI or GR8-1200 NI)"

>> Check harness between battery and alternator for poor continuity.

Terminals

Voltage (Approx.)

(+)

(–)

Alternator “B” terminal

Terminal

F59

Ground

Battery voltage

Terminals

Voltage (Approx.)

(+)

(–)

Alternator “B” terminal

Terminal

Battery positive terminal

F59

Less than 0.2 V

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L TERMINAL CIRCUIT (OPEN)

CHG-15

< DTC/CIRCUIT DIAGNOSIS >

L TERMINAL CIRCUIT (OPEN)

Description

INFOID:0000000007542151

The “L” terminal circuit controls the charge warning lamp. The charge warning lamp illuminates when the igni-
tion 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.

Diagnosis Procedure

INFOID:0000000007542152

CHECK “L” TERMINAL CONNECTION

Turn ignition switch OFF.

Check if “L” terminal is clean and tight.

Is the inspection result normal?

YES

>> GO TO 2.

>> Repair “L” terminal connection. Confirm repair by performing complete Charging system test

using EXP-800 NI or GR8-1200 NI (if available). Refer to the applicable Instruction Manual for
proper testing procedures.

CHECK “L” TERMINAL CIRCUIT (OPEN)

Disconnect alternator connector.

Apply ground to alternator harness connector terminal.

Check condition of the charge warning lamp with the ignition switch in the ON position.

Does it illuminate?

YES

>> “L” terminal circuit is normal. Refer to

CHG-3, "Work Flow (With EXP-800 NI or GR8-1200 NI)"

CHG-7, "Work Flow (Without EXP-800 NI or GR8-1200 NI)"

>> GO TO 3.

CHECK HARNESS CONTINUITY (OPEN CIRCUIT)

Disconnect the battery cable from the negative terminal.

Disconnect the combination meter connector.

Check continuity between alternator harness connector and combination meter harness connector.

Is the inspection result normal?

YES

>> GO TO 4.

>> Repair the harness or connector.

CHECK HARNESS CONTINUITY (OPEN CIRCUIT)

Check continuity between combination meter harness connector and fuse block.

Is the inspection result normal?

YES

>> GO TO 5.

>> Repair the harness.

Alternator harness connector

Terminal

Ground

Condition

Ignition switch position

Charge warning lamp

F60

illuminate

Alternator harness connector

Combination meter harness connector

Continuity

Connector No.

Terminal No.

Connector No.

Terminal No.

F60

M34

Existed

Combination meter harness connector

Fuse block

Continuity

Connector No.

Terminal No.

Connector No.

Terminal No.

M34

12C

Existed

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