ELECTRICAL & POWER CONTROL

SECTION CHG
CHARGING SYSTEM
B

E
CONTENTS
BASIC INSPECTION .................................... 3 PRECAUTIONS ................................................. 20 F
Precaution for Supplemental Restraint System
DIAGNOSIS AND REPAIR WORKFLOW .......... 3 (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
Work Flow ................................................................. 3 SIONER" .................................................................20 G
FUNCTION DIAGNOSIS ............................... 6 PREPARATION ........................................... 21
CHARGING SYSTEM .......................................... 6 PREPARATION ................................................. 21 H
System Diagram ........................................................ 6 Special Service Tools ..............................................21
System Description ................................................... 6
Component Parts Location ........................................ 6 ON-VEHICLE MAINTENANCE .................... 22 I
Component Description ............................................ 7
CHARGING SYSTEM PRELIMINARY IN-
COMPONENT DIAGNOSIS .......................... 8 SPECTION ........................................................ 22
Inspection Procedure ...............................................22 J
B TERMINAL CIRCUIT ....................................... 8
Description ................................................................ 8 ON-VEHICLE REPAIR ................................. 23
Diagnosis Procedure ................................................. 8 K
ALTERNATOR .................................................. 23
L TERMINAL CIRCUIT (OPEN) .......................... 9
Description ................................................................ 9 M9R MODELS ............................................................23
Diagnosis Procedure ................................................. 9 M9R MODELS : Exploded View ..............................23 L
M9R MODELS : Removal and Installation ..............24
L TERMINAL CIRCUIT (SHORT) .......................11 M9R MODELS : Disassembly and Assembly ..........25
Description .............................................................. 11 M9R MODELS : Inspection .....................................26
CHG
Diagnosis Procedure ............................................... 11
MR20DE MODELS .....................................................26
S TERMINAL CIRCUIT ......................................12 MR20DE MODELS : Exploded View .......................27
Description .............................................................. 12 MR20DE MODELS : Removal and Installation .......28 N
Diagnosis Procedure ............................................... 12 MR20DE MODELS : Disassembly and Assembly....28
MR20DE MODELS : Inspection ..............................29
CHARGING SYSTEM .........................................13
Wiring Diagram - CHARGING SYSTEM (GASO- QR25DE MODELS .....................................................30 O
LINE ENGINE MODELS) - ...................................... 13 QR25DE MODELS : Exploded View .......................30
Wiring Diagram - CHARGING SYSTEM (DIESEL QR25DE MODELS : Removal and Installation ........32
ENGINE MODELS) - ............................................... 16 QR25DE MODELS : Disassembly and Assembly....32 P
QR25DE MODELS : Inspection ...............................33
SYMPTOM DIAGNOSIS .............................. 19
SERVICE DATA AND SPECIFICATIONS
CHARGING SYSTEM .........................................19 (SDS) ............................................................ 35
Symptom Table ....................................................... 19
SERVICE DATA AND SPECIFICATIONS
PRECAUTION .............................................. 20 (SDS) ................................................................. 35

CHG-1 GETtheMANUALS.org
Alternator ................................................................ 35

CHG-2 GETtheMANUALS.org
 DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION >
BASIC INSPECTION A
DIAGNOSIS AND REPAIR WORKFLOW
Work Flow INFOID:0000000001208694
B

OVERALL SEQUENCE
C

CHG

P
JPMIA0425GB

DETAILED FLOW
1.PRELIMINARY INSPECTION
Perform the preliminary inspection. Refer to CHG-22, "Inspection Procedure" .

CHG-3 GETtheMANUALS.org
 DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION >
>> GO TO 2.
2.INSPECTION WITH CHARGE WARNING LAMP (IGNITION SWITCH IS ON)
Turn the ignition switch ON.
Does the charge warning lamp illuminate?
YES >> GO TO 3.
NO >> GO TO 10.
3.INSPECTION WITH CHARGE WARNING LAMP (IDLING)
Start the engine and run it at idle.
Does the charge warning lamp turn OFF?
YES >> GO TO 4.
NO >> GO TO 5.
4.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 7.
NO >> INSPECTION END
5.“L” TERMINAL CIRCUIT (SHORT) INSPECTION
Check “L” terminal circuit (short). Refer to CHG-11, "Diagnosis Procedure".
Is the inspection result normal?
YES >> GO TO 6.
NO >> Repair as needed.
6.“S” TERMINAL CIRCUIT INSPECTION
Check “S” terminal circuit. Refer to CHG-12, "Diagnosis Procedure".
Is the inspection result normal?
YES >> GO TO 7.
NO >> Repair as needed.
7.MEASURE “B” TERMINAL VOLTAGE
Start engine. When keeping engine running at 2,500 rpm, measure “B” terminal voltage.
What voltage does the measurement result show?
Less than 13.0 V>>GO TO 8.
More than 16.0 V>>Replace IC voltage regulator.
8.“B” TERMINAL CIRCUIT INSPECTION
Check “B” terminal circuit. Refer to CHG-8, "Diagnosis Procedure" .
Is the inspection result normal?
YES >> GO TO 9.
NO >> Repair as needed.
9.DISASSEMBLE AND CHECK ALTERNATOR
Check the following conditions.
• Rotor coil
• Rotor slip ring
• Brush
• Stator coil
Refer to the following.
• CHG-26, "M9R MODELS : Inspection" (M9R models)
• CHG-29, "MR20DE MODELS : Inspection" (MR20DE models)
• CHG-33, "QR25DE MODELS : Inspection" (QR25DE models)
Are these normal?
YES >> Replace IC voltage regulator and/or diode assembly.
NO >> Repair as needed.

CHG-4 GETtheMANUALS.org
 DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION >
10.INSPECTION WITH CHARGE WARNING LAMP (IGNITION SWITCH IS ON) A
1. Disconnect alternator connector and ground “L” harness side.
2. Turn the ignition switch ON.
Does the charge warning lamp illuminate? B
YES >> GO TO 11.
NO >> GO TO 12.
11.DISASSEMBLE AND CHECK ALTERNATOR C
Check the following conditions.
• Rotor coil
• Rotor slip ring D
• Brush
Refer to the following.
• CHG-26, "M9R MODELS : Inspection" (M9R models) E
• CHG-29, "MR20DE MODELS : Inspection" (MR20DE models)
• CHG-33, "QR25DE MODELS : Inspection" (QR25DE models)
Are these normal?
F
YES >> Replace IC voltage regulator.
NO >> Repair as needed.
12.CHECK “L” TERMINAL CIRCUIT (OPEN) G
Check “L” terminal circuit (open). Refer to CHG-9, "Diagnosis Procedure".

>> Repair as needed. H

CHG

CHG-5 GETtheMANUALS.org
 CHARGING SYSTEM
< FUNCTION DIAGNOSIS >
FUNCTION DIAGNOSIS
CHARGING SYSTEM
System Diagram INFOID:0000000001208695

JPMIA0426GB

System Description INFOID:0000000001208696

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 voltage regulator.
Component Parts Location INFOID:0000000001208697

JPMIA0274ZZ

1. Battery 2. Alternator 3. Charge warning lamp

A. Engine room (left side) B. Engine C. Combination meter

CHG-6 GETtheMANUALS.org
 CHARGING SYSTEM
< FUNCTION DIAGNOSIS >
Component Description INFOID:0000000001208698

Component part Description

“B” terminal Refer to CHG-8, "Description". B
Alternator “S” terminal Refer to CHG-12, "Description".
“L” terminal Refer to CHG-9, "Description".
C
The IC voltage regulator warning function activates to illuminate
the charge warning lamp, if any of the following symptoms occur
Combination meter (Charge warning lamp) while alternator is operating:
• Excessive voltage is produced. D
• No voltage is produced.

CHG

CHG-7 GETtheMANUALS.org
 B TERMINAL CIRCUIT
< COMPONENT DIAGNOSIS >
COMPONENT DIAGNOSIS
B TERMINAL CIRCUIT
Description INFOID:0000000001208699

“B” terminal circuit supplies power to charge the battery and to operate the vehicle’s electrical system.
Diagnosis Procedure INFOID:0000000001208700

1.CHECK “B” TERMINAL CONNECTION

1. Turn ignition switch OFF.
2. Check if “B” terminal is clean and tight.
Is the inspection result normal?
YES >> GO TO 2.
NO >> Repair “B” terminal connection.
2.CHECK “B” TERMINAL CIRCUIT
Check voltage between alternator “B” terminal and ground.

Terminals
(+) Voltage (Approx.)
(–)
Alternator “B” terminal Terminal
F59 (QR25DE)
1 Ground Battery voltage
F14 (M9R/MR20DE)
Is the inspection result normal?
YES >> GO TO 3.
NO >> Check harness for open between alternator and fusible link.
3.CHECK “B” TERMINAL CONNECTION (VOLTAGE DROP TEST)
1. Start engine, then engine running at idle and warm.
2. Check voltage between battery positive terminal and alternator “B” terminal.

Terminals
(–) Voltage (Approx.)
(+)
Alternator “B” terminal Terminal
F59 (QR25DE)
Battery positive terminal 1 Less than 0.2 V
F14 (M9R/MR20DE)
Is the inspection result normal?
YES >> “B” terminal circuit is normal. Refer to CHG-3, "Work Flow".
NO >> Check harness between battery and alternator for poor continuity.

CHG-8 GETtheMANUALS.org
 L TERMINAL CIRCUIT (OPEN)
< COMPONENT DIAGNOSIS >
L TERMINAL CIRCUIT (OPEN)
A
Description INFOID:0000000001208701

The “L” terminal circuit controls the charge warning lamp. The charge warning lamp illuminates when the igni- B
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.
C
Diagnosis Procedure INFOID:0000000001208702

1.CHECK “L” TERMINAL CONNECTION D

1. Turn ignition switch OFF.
2. Check if “L” terminal is clean and tight.
Is the inspection result normal? E
YES >> GO TO 2.
NO >> Repair “L” terminal connection.
2.CHECK “L” TERMINAL CIRCUIT (OPEN) F
1. Disconnect alternator connector.
2. Apply ground to alternator harness connector terminal.
3. Check condition of the charge warning lamp with the ignition switch in the ON position. G

Condition
Alternator harness connector Terminal H
Ignition switch position Charge warning lamp
Ground
F60 (QR25DE)
3 ON Illuminate
F15 (M9R/MR20DE)
I
Does it illuminate?
YES >> “L” terminal circuit is normal. Refer to CHG-3, "Work Flow".
NO >> GO TO 3. J
3.CHECK HARNESS CONTINUITY (OPEN CIRCUIT)
1. Disconnect the battery cable from the negative terminal.
2. Disconnect the combination meter connector. K
3. Check continuity between alternator harness connector and combination meter harness connector.

Alternator harness connector Combination meter harness connector L

Continuity
Connector No. Terminal No. Connector No. Terminal No.
F60 (QR25DE)
3 M34 25 Existed
F15 (M9R/MR20DE) CHG
Is the inspection result normal?
YES >> GO TO 4.
NO >> Repair the harness or connector. N

4.CHECK HARNESS CONTINUITY (OPEN CIRCUIT)

Check continuity between combination meter harness connector M34 terminal 2 and 10A fuse [No.3, located O
in the fuse block(J/B)].
Does continuity exist?
YES >> GO TO 5. P
NO >> Repair the harness.
5.CHECK POWER SUPPLY CIRCUIT
1. Connect the battery cable to the negative terminal.
2. Check voltage between combination meter harness connector and ground.

CHG-9 GETtheMANUALS.org
 L TERMINAL CIRCUIT (OPEN)
< COMPONENT DIAGNOSIS >

Terminals
(+)
Condition Voltage (Approx.)
Combination meter (–)
Terminal
harness connector
When the ignition switch is in
M34 2 Ground Battery voltage
ON position
Is the inspection result normal?
YES >> Replace combination meter.
NO >> Inspect the power supply circuit. Refer to PG-52, "Wiring Diagram - IGNITION POWER SUPPLY -
".

CHG-10 GETtheMANUALS.org
 L TERMINAL CIRCUIT (SHORT)
< COMPONENT DIAGNOSIS >
L TERMINAL CIRCUIT (SHORT)
A
Description INFOID:0000000001208703

The “L” terminal circuit controls the charge warning lamp. The charge warning lamp illuminates when the igni- B
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.
C
Diagnosis Procedure INFOID:0000000001208704

1.CHECK “L” TERMINAL CIRCUIT (SHORT) D

1. Turn ignition switch OFF.
2. Disconnect alternator harness connector.
3. Turn ignition switch ON. E
Does charge warning lamp illuminate?
YES >> GO TO 2.
NO >> Refer to CHG-3, "Work Flow". F
2.CHECK HARNESS CONTINUITY (SHORT CIRCUIT)
1. Turn the ignition switch OFF.
2. Disconnect the battery cable from the negative terminal. G
3. Disconnect combination meter connector.
4. Check continuity between combination meter harness connector and ground.
H
Combination meter harness connector
Continuity
Connector No. Terminal No. Ground
M34 25 Not existed I
Is the inspection result normal?
YES >> Replace combination meter.
J
NO >> Repair the harness.

CHG

CHG-11 GETtheMANUALS.org
 S TERMINAL CIRCUIT
< COMPONENT DIAGNOSIS >
S TERMINAL CIRCUIT
Description INFOID:0000000001208705

The output voltage of the alternator is controlled by the IC voltage regulator at the “S” terminal detecting the
input voltage.
The “S” terminal circuit detects the battery voltage to adjust the alternator output voltage with the IC voltage
regulator.
Diagnosis Procedure INFOID:0000000001208706

1.CHECK “S” TERMINAL CONNECTION

1. Turn ignition switch OFF.
2. Check if “S” terminal is clean and tight.
Is the inspection result normal?
YES >> GO TO 2.
NO >> Repair “S” terminal connection.
2.CHECK “S” TERMINAL CIRCUIT
Check voltage between alternator harness connector and ground.

Terminals
(+) Voltage (Approx.)
(–)
Alternator harness connector Terminal
F60 (QR25DE)
4 Ground Battery voltage
F15 (M9R/MR20DE)
Is the inspection result normal?
YES >> Refer to CHG-3, "Work Flow" .
NO >> Check harness for open between alternator and fuse.

CHG-12 GETtheMANUALS.org
 CHARGING SYSTEM
< COMPONENT DIAGNOSIS >
CHARGING SYSTEM
A
Wiring Diagram - CHARGING SYSTEM (GASOLINE ENGINE MODELS) - INFOID:0000000001208707

CHG

P
JCMWA0519GB

CHG-13 GETtheMANUALS.org
 CHARGING SYSTEM
< COMPONENT DIAGNOSIS >

JCMWA0520GB

CHG-14 GETtheMANUALS.org
 CHARGING SYSTEM
< COMPONENT DIAGNOSIS >

CHG

JCMWA0521GB

CHG-15 GETtheMANUALS.org
 CHARGING SYSTEM
< COMPONENT DIAGNOSIS >
Wiring Diagram - CHARGING SYSTEM (DIESEL ENGINE MODELS) - INFOID:0000000001208708

JCMWA0522GB

CHG-16 GETtheMANUALS.org
 CHARGING SYSTEM
< COMPONENT DIAGNOSIS >

CHG

JCMWA0523GB

CHG-17 GETtheMANUALS.org
 CHARGING SYSTEM
< COMPONENT DIAGNOSIS >

JCMWA0524GB

CHG-18 GETtheMANUALS.org
 CHARGING SYSTEM
< SYMPTOM DIAGNOSIS >
SYMPTOM DIAGNOSIS A
CHARGING SYSTEM
Symptom Table INFOID:0000000001208709
B

Symptom Reference
C
Discharged battery
The charge warning lamp does not illuminate when the ignition
switch is set to ON.
D
The charge warning lamp does not turn OFF after the engine Refer to CHG-3, "Work Flow".
starts.
The charge warning lamp turns ON when increasing the engine E
speed.

CHG

CHG-19 GETtheMANUALS.org
 PRECAUTIONS
< PRECAUTION >
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000001308692

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, 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. Information necessary to service the system safely is included in the “SRS AIRBAG” and
“SEAT BELT” of this Service Manual.
WARNING:
• 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 NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the “SRS AIRBAG”.
• Do 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 har-
ness connectors.

CHG-20 GETtheMANUALS.org
 PREPARATION
< PREPARATION >
PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000001208711
B

Tool number
Description C
Tool name
KV10118200 (included in the adapter Removing and installing alternator pulley
kit: Mot. 1732)
Alternator pulley adapter D

E
PKIA1241E

CHG

CHG-21 GETtheMANUALS.org
 CHARGING SYSTEM PRELIMINARY INSPECTION
< ON-VEHICLE MAINTENANCE >
ON-VEHICLE MAINTENANCE
CHARGING SYSTEM PRELIMINARY INSPECTION
Inspection Procedure INFOID:0000000001208712

1.CHECK BATTERY TERMINALS CONNECTION

Check if battery terminals are clean and tight.
Is the inspection result normal?
YES >> GO TO 2.
NO >> Repair battery terminals connection.
2.CHECK FUSE
Check for blown fuse.

Unit Power source (Power supply terminals) Fuse No.

Alternator Battery (“S” terminal) 34
Combination meter Ignition switch ON (“L” terminal) 3
Is the inspection result normal?
YES >> GO TO 3.
NO >> Be sure to eliminate the cause of malfunction before installing new fuse.
3.CHECK “E” TERMINAL CONNECTION
Check if “E” terminal (alternator ground harness) is clean and tight.
Is the inspection result normal?
YES >> GO TO 4.
NO >> Repair “E” terminal connection.
4.CHECK DRIVE BELT TENSION
Check drive belt tension. Refer to the following.
• EM-257, "Checking" (M9R)
• EM-15, "Checking" (MR20DE)
• EM-138, "Checking" (QR25DE)
Is the inspection result normal?
YES >> INSPECTION END
NO >> Repair as needed.

CHG-22 GETtheMANUALS.org
 ALTERNATOR
< ON-VEHICLE REPAIR >
ON-VEHICLE REPAIR A
ALTERNATOR
M9R MODELS
B
M9R MODELS : Exploded View INFOID:0000000001208713

REMOVAL C

JPMIA0307GB

I
1. Alternator connector 2. Alternator mounting bolt 3. Alternator
4. “B” terminal harness 5. “B” terminal nut
Refer to GI-4, "Components" for symbols in the figure.
J
DISASSEMBLY
Type: A3TJ2481
K

CHG

CHG-23 GETtheMANUALS.org
 ALTERNATOR
< ON-VEHICLE REPAIR >

JPMIA0264GB

1. Rear bearing 2. Rotor assembly 3. Retainer

4. Front bearing 5. Front bracket assembly 6. Washer
7. Pulley 8. Stator assembly 9. IC voltage regulator assembly
10. Diode assembly 11. Rear bracket assembly 12. Terminal set
Refer to GI-4, "Components" for symbols in the figure.

M9R MODELS : Removal and Installation INFOID:0000000001208714

REMOVAL
1. Disconnect the battery cable from the negative terminal.
2. Remove engine cover. Refer to EM-265, "Exploded View".
3. Remove RH fender protector partially.
4. Remove drive belt. Refer to EM-257, "Exploded View".
5. Remove air inlet tube (1). Refer to EM-266, "Exploded View".
6. Get air inlet hose (2) out of alternator removal area.
7. Remove reservoir tank hose bracket mounting bolts (A) and res-
ervoir tank hose bracket.
8. Disconnect alternator connector (B).
9. Remove “B” terminal nut (C) and “B” terminal harness.
10. Remove upper alternator mounting bolt (D).
11. Completely loosen lower alternator mounting bolt (E), and pull it
out until the bolt head is in contact with the side member. And
then, remove the alternator by pulling it forward. JPMIA0351ZZ

NOTE:
The alternator can be removed together with the bolts by pulling it forward and using the alternator bracket
bolt hole cutout.
12. Remove alternator upward from the vehicle.
INSTALLATION
Install in the reverse order of removal.
CHG-24 GETtheMANUALS.org
 ALTERNATOR
< ON-VEHICLE REPAIR >
CAUTION:
Be sure to tighten “B” terminal nut carefully. A
• Temporarily tighten the alternator bolts in order from the lower to the upper, and then tighten them in order
from the upper to the lower.
CAUTION:
B
For the alternator, the front side (pulley side) surface is the reference surface. Fit the reference sur-
face to the alternator mounting part, and then tighten the bolts.
• Install alternator, and check tension of belt. Refer to EM-257, "Checking".
C
M9R MODELS : Disassembly and Assembly INFOID:0000000001208922

DISASSEMBLY D
Rear Cover
NOTE:
Rear cover may be hard to remove because a ring is used to lock E
outer race of rear bearing. To facilitate removal of rear cover, heat
only the bearing box section until the temperature increases to
approximately 30°C (86°F) with a soldering iron (200W capacity).
CAUTION: F
Never use a heat gun, as if can damage diode assembly.

SEL032Z H
ASSEMBLY
Rear Bearing
I
CAUTION:
• Never reuse rear bearing. Replace with a new one.
• Never lubricate rear bearing outer race.
J
Rear Cover Installation
1. Fit brush assembly, diode assembly, regulator assembly and
stator assembly. K

CHG

SKIB4529E

N
2. Push brushed up with fingers and install them to rotor.
NOTE:
Take care not damage slip ring sliding surface. O

SKIB4530E

CHG-25 GETtheMANUALS.org
 ALTERNATOR
< ON-VEHICLE REPAIR >
M9R MODELS : Inspection INFOID:0000000001208923

INSPECTION AFTER DISASSEMBLY

Rotor Check
1. Resistance test

Resistance Refer to SDS CHG-35, "Al-

ternator".
• Replace the rotor if the measurement value is outside of the
specified range.
2. Insulator test
• Replace the rotor if continuity exists.
3. Check slip ring for wear.
SKIB4525E

Slip ring minimum outer : Refer to SDS CHG-35,

diameter "Alternator".
• Replace the rotor if the measurement value is outside of the specified range.
Brush Check
1. Check smooth movement of brush.
• Check brush holder and clean if it is not smooth.
2. Check brush for wear.
• Replace brush if it is worn down to the limit line.

SKIB4526E

Stator Check
1. Continuity test
• Replace the stator if continuity does not exist.

SKIB4527E

2. Ground test
• Replace the stator if continuity exists.

SKIB4528E

MR20DE MODELS
CHG-26 GETtheMANUALS.org
 ALTERNATOR
< ON-VEHICLE REPAIR >
MR20DE MODELS : Exploded View INFOID:0000000001208715

A
REMOVAL

PKID0787E G

1. Alternator connector 2. Alternator mounting bolt 3. Alternator

4. “B” terminal harness 5. “B” terminal nut H
Refer to GI-4, "Components" for symbols in the figure.

DISASSEMBLY
I
Type: LR1140-802C

CHG

JPMIA0343GB

1. Stator assembly 2. Rotor assembly 3. Rotor spacer

4. Retainer 5. Front bearing 6. Front bracket assembly

CHG-27 GETtheMANUALS.org
 ALTERNATOR
< ON-VEHICLE REPAIR >
7. Pulley 8. Pulley cap 9. Rear bracket assembly
10. Diode assembly 11. Double labyrinth seal 12. IC voltage regulator assembly
13. Rear cover 14. Bush 15. “B” terminal nut
Refer to GI-4, "Components" for symbols in the figure.

MR20DE MODELS : Removal and Installation INFOID:0000000001208716

REMOVAL
1. Disconnect the battery cable from the negative terminal.
2. Remove engine cover. Refer to EM-27, "Exploded View".
3. Remove drive belt. Refer to EM-15, "Exploded View".
4. Disconnect alternator connector (A).
5. Remove “B” terminal nut (B) and “B” terminal harness.
6. Remove upper alternator mounting bolt (C).
7. Completely loosen lower alternator mounting bolt (D), and pull it
out until the bolt head is in contact with the side member. And
then, remove the alternator by pulling it forward.
NOTE:
The alternator can be removed together with the bolts by pulling
it forward and using the alternator bracket bolt hole cutout.
8. Remove alternator upward from the vehicle. JPMIA0352ZZ

INSTALLATION
Install in the reverse order of removal.
CAUTION:
Be sure to tighten “B” terminal nut carefully.
• Temporarily tighten the alternator bolts in order from the lower to the upper, and then tighten them in order
from the upper to the lower.
CAUTION:
For the alternator, the front side (pulley side) surface is the reference surface. Fit the reference sur-
face to the alternator mounting part, and then tighten the bolts.
• Install alternator, and check tension of belt. Refer to EM-15, "Checking".
MR20DE MODELS : Disassembly and Assembly INFOID:0000000001208717

DISASSEMBLY
Rear Bracket Assembly
1. Remove rear cover.
2. Remove IC voltage regulator assembly.
3. Separate front bracket assembly, stator assembly and rear bracket assembly.
NOTE:
• Raise the temperature of the center of the rear bracket assem-
bly approximately between 30°C (86°F) and 50°C (122°F).
• Insert the tip of the suitable tool into the clearance between
front cover and stator core, and then separate front side (front
bracket assembly, rotor assembly) and rear side (rear bracket
assembly, stator assembly, diode assembly).
CAUTION:
Be careful not to damage stator assembly.

PKIC1176E

Front Cover

CHG-28 GETtheMANUALS.org
 ALTERNATOR
< ON-VEHICLE REPAIR >
1. Set rotor to the vise.
CAUTION: A
• Be careful not to damage the rotor.
• Use copper plate or thick cloth for rotor in the vise.
2. Remove pulley cap, using suitable tool. B

SKIB0531E

D
3. Remove alternator pulley, using alternator pulley adaptor [SST].

G
SKIB0731E

ASSEMBLY H
Rear Bearing
CAUTION:
• Never reuse rear bearing. Replace with a new one. I
• Never lubricate rear bearing outer race.
Rear Cover Installation
1. Fit brush assembly, diode assembly, regulator assembly and J
stator assembly.

SKIB4529E
CHG

2. Push brushed up with fingers and install them to rotor.

NOTE: N
Take care not damage slip ring sliding surface.

SKIB4530E

MR20DE MODELS : Inspection INFOID:0000000001208718

INSPECTION AFTER DISASSEMBLY

CHG-29 GETtheMANUALS.org
 ALTERNATOR
< ON-VEHICLE REPAIR >
Rotor Check
1. Resistance test

Resistance Refer to SDS CHG-35, "Al-

ternator".
• Replace the rotor if the measurement value is outside of the
specified range.
2. Insulator test
• Replace the rotor if continuity exists.
3. Check slip ring for wear.
SKIB4525E

Slip ring minimum outer : Refer to SDS CHG-35,

diameter "Alternator".
• Replace the rotor if the measurement value is outside of the specified range.
Brush Check
1. Check smooth movement of brush.
• Check brush holder and clean if it is not smooth.
2. Check brush for wear.
• Replace brush if it is worn down to the limit line.

SKIB4526E

Stator Check
1. Continuity test
• Replace the stator if continuity does not exist.

SKIB4527E

2. Ground test
• Replace the stator if continuity exists.

SKIB4528E

QR25DE MODELS
QR25DE MODELS : Exploded View INFOID:0000000001208719

REMOVAL
CHG-30 GETtheMANUALS.org
 ALTERNATOR
< ON-VEHICLE REPAIR >

JPMIA0318GB F

1. Alternator bracket 2. Upper alternator mounting bolt 3. Lower alternator mounting bolt
4. Alternator 5. “B” terminal harness 6. “B” terminal nut
G
7. Alternator connector
Refer to GI-4, "Components" for symbols in the figure.

DISASSEMBLY H

Type: LR1110-713C
I

CHG

P
JPMIA0344GB

1. Stator 2. Rear bearing 3. Rotor

4. Retainer 5. Front bearing 6. Front cover
7. Pulley 8. Fan guide 9. Labyrinth seal
10. IC voltage regulator assembly 11. Diode assembly 12. Rear cover

CHG-31 GETtheMANUALS.org
 ALTERNATOR
< ON-VEHICLE REPAIR >
13. Terminal assembly 14. “B” terminal nut
Refer to GI-4, "Components" for symbols in the figure.

QR25DE MODELS : Removal and Installation INFOID:0000000001208720

REMOVAL
1. Disconnect the battery cable from the negative terminal.
2. Remove drive belt. Refer to EM-138, "Exploded View".
3. Disconnect alternator connector (A).
4. Remove “B” terminal nut (B) and “B” terminal harness.
5. Remove harness clip (C) from the harness bracket.
6. Remove upper alternator mounting bolt (D).
7. Remove lower alternator mounting bolt (E).

JPMIA0353ZZ

8. Remove alternator upward from the vehicle.

INSTALLATION
Note the following, and installation is the reverse order of removal.
• Install alternator, and check tension of belt. Refer to EM-138, "Checking".
CAUTION:
Be sure to tighten “B” terminal nut carefully.
QR25DE MODELS : Disassembly and Assembly INFOID:0000000001208721

DISASSEMBLY
Rear Cover
NOTE:
Rear cover may be hard to remove because a ring is used to lock
outer race of rear bearing. To facilitate removal of rear cover, heat
only the bearing box section until the temperature increases to
approximately 30°C (86°F) with a soldering iron (200W capacity).
CAUTION:
Never use a heat gun, as if can damage diode assembly.

SEL032Z

Front Cover
1. Set rotor to the vise.
CAUTION:
• Be careful not to damage the rotor.
• Use copper plate or thick cloth for rotor in the vise.
2. Remove pulley cap, using suitable tool.

SKIB0531E

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 ALTERNATOR
< ON-VEHICLE REPAIR >
3. Remove alternator pulley, using alternator pulley adaptor [SST].
A

SKIB0731E

D
ASSEMBLY
Rear Bearing
CAUTION: E
• Never reuse rear bearing. Replace with a new one.
• Never lubricate rear bearing outer race.
Rear Cover Installation F
1. Fit brush assembly, diode assembly, regulator assembly and
stator.
G

I
SKIB4529E

2. Push brushed up with fingers and install them to rotor. J

NOTE:
Take care not damage slip ring sliding surface.
K

SKIB4530E
CHG

QR25DE MODELS : Inspection INFOID:0000000001208722

N
INSPECTION AFTER DISASSEMBLY
Rotor Check
1. Resistance test O

Resistance Refer to SDS CHG-35, "Al-

ternator". P
• Replace the rotor if the measurement value is outside of the
specified range.
2. Insulator test
• Replace the rotor if continuity exists.
3. Check slip ring for wear.
SKIB4525E

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 ALTERNATOR
< ON-VEHICLE REPAIR >

Slip ring minimum outer : Refer to SDS CHG-35,

diameter "Alternator".
• Replace the rotor if the measurement value is outside of the specified range.
Brush Check
1. Check smooth movement of brush.
• Check brush holder and clean if it is not smooth.
2. Check brush for wear.
• Replace brush if it is worn down to the limit line.

SKIB4526E

Stator Check
1. Continuity test
• Replace the stator if continuity does not exist.

SKIB4527E

2. Ground test
• Replace the stator if continuity exists.

SKIB4528E

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 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) A
SERVICE DATA AND SPECIFICATIONS (SDS)
Alternator INFOID:0000000001208723
B

Applied model M9R MR20DE QR25DE

C
A3TJ2481 LR1140-802C LR1110-713C
Type
MITSUBISHI make HITACHI make
Nominal rating [V - A] 12 - 150 12 - 140 12 - 110 D
Ground polarity Negative
Minimum revolution under no-
[rpm] Less than 1,300 Less than 1,200 Less than 1,100 E
load (When 13.5 V is applied)
More than 31/1,300 More than 56/1,500 More than 70/1,800
Hot output current (When 13.5
[A/rpm] More than 122/2,500 More than 114/2,500 More than 91/2,500
V is applied)
More than 144/5,000 More than 139/5,000 More than 110/5,000 F
Regulated output voltage [V] 14.1 - 14.7
Minimum length of brush [mm (in)] More than 5.00 (0.197) More than 6.00 (0.236)
4.1 - 5.3 (418 - 541, 14.7 - 1.1 - 3.7 (112 - 377, 4.00 - 1.00 - 3.43 (102 - 350, 3.60 G
Brush spring pressure [N (g, oz)]
19.1) 13.3) - 12.34)
Slip ring minimum outer diam-
[mm (in)] More than 22.1 (0.870) More than 14.7 (0.579) More than 26.0 (1.024) H
eter
Rotor (Field coil) resistance [Ω] 1.7 - 2.0 1.61 - 1.91 2.16 - 2.46

CHG

CHG-35 GETtheMANUALS.org