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Juke F15 (2012 year). Service Repair Manual - part 52

CHG

POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM OPERATION

INSPECTION

CHG-19

< BASIC INSPECTION >

Check continuity between alternator harness connector and ground.

Is the inspection result normal?

YES

>> Replace IPDM E/R.

>> Repair harness or connector between IPDM E/R and alternator.

Alternator harness connector

Ground

Continuity

Connector

Terminal

F15

Not existed

CHG-20

< DTC/CIRCUIT DIAGNOSIS >

B TERMINAL CIRCUIT

DTC/CIRCUIT DIAGNOSIS

B TERMINAL CIRCUIT

Description

INFOID:0000000006532107

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

Diagnosis Procedure

INFOID:0000000006532108

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.

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-12, "GASOLINE ENGINE MODELS : Work Flow"

(gasoline engine models) or

CHG-15, "DIESEL ENGINE MODELS : Work Flow"

(diesel engine

models).

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

Terminals

Voltage (Approx.)

(+)

(–)

Alternator “B” terminal

Terminal

F14 (HR16DE, K9K)

E68 (MR16DDT)

Ground

Battery voltage

Terminals

Voltage (Approx.)

(+)

(–)

Alternator “B” terminal

Terminal

Battery positive terminal

F14 (HR16DE, K9K)

E68 (MR16DDT)

Less than 0.2 V

CHG

L TERMINAL CIRCUIT (OPEN)

CHG-21

< DTC/CIRCUIT DIAGNOSIS >

L TERMINAL CIRCUIT (OPEN)

Description

INFOID:0000000006532109

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:0000000006532110

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.

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-12, "GASOLINE ENGINE MODELS : Work Flow"

(gasoline engine models) or

CHG-15, "DIESEL ENGINE MODELS : Work Flow"

(diesel engine

models).

>> 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 M34 terminal 28 and 10A fuse [No.5 located
in the fuse block (J/B)].
Does continuity exist?

YES

>> GO TO 5.

>> Repair the harness.

CHECK POWER SUPPLY CIRCUIT

Connect the battery cable to the negative terminal.

Check voltage between combination meter harness connector and ground.

Alternator harness connector

Terminal

Ground

Condition

Ignition switch position

Charge warning lamp

F15 (HR16DE, MR16DDT)

F56 (K9K)

Illuminate

Alternator harness connector

Combination meter harness connector

Continuity

Connector No.

Terminal No.

Connector No.

Terminal No.

F15 (HR16DE,

MR16DDT)

F56 (K9K)

M34

Existed

CHG-22

< DTC/CIRCUIT DIAGNOSIS >

L TERMINAL CIRCUIT (OPEN)

Is the inspection result normal?

YES

>> Replace combination meter.

>> Inspect the power supply circuit. Refer to

PG-15, "Wiring Diagram - IGNITION POWER SUPPLY -

Terminals

Condition

Voltage (Approx.)

(+)

(–)

Combination meter

harness connector

Terminal

M34

Ground

When the ignition switch is in

ON position

Battery voltage

CHG

L TERMINAL CIRCUIT (SHORT)

CHG-23

< DTC/CIRCUIT DIAGNOSIS >

L TERMINAL CIRCUIT (SHORT)

Description

INFOID:0000000006532111

Diagnosis Procedure

INFOID:0000000006532112

CHECK “L” TERMINAL CIRCUIT (SHORT)

Turn ignition switch OFF.

Disconnect alternator connector.

Turn ignition switch ON.

Does charge warning lamp illuminate?

YES

>> GO TO 2.

>> Refer to

CHG-12, "GASOLINE ENGINE MODELS : Work Flow"

(gasoline engine models) or

CHG-15, "DIESEL ENGINE MODELS : Work Flow"

(diesel engine models).

CHECK HARNESS CONTINUITY (SHORT CIRCUIT)

Turn the ignition switch OFF.

Disconnect the battery cable from the negative terminal.

Disconnect combination meter connector.

Check continuity between combination meter harness connector and ground.

Is the inspection result normal?

YES

>> Replace combination meter.

>> Repair the harness.

Combination meter harness connector

Ground

Continuity

Connector No.

Terminal No.

M34

Not existed

CHG-24

< DTC/CIRCUIT DIAGNOSIS >

S TERMINAL CIRCUIT

S TERMINAL CIRCUIT

Description

INFOID:0000000006532113

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:0000000006532114

CHECK “S” TERMINAL CONNECTION

Turn ignition switch OFF.

Check if “S” terminal is clean and tight.

Is the inspection result normal?

YES

>> GO TO 2.

>> Repair “S” terminal connection.

CHECK “S” TERMINAL CIRCUIT

Check voltage between alternator harness connector and ground.

Is the inspection result normal?

YES

>> Refer to

CHG-12, "GASOLINE ENGINE MODELS : Work Flow"

>> Check harness for open between alternator and fuse.

Terminals

Voltage (Approx.)

(+)

(–)

Alternator harness connector

Terminal

F15

Ground

Battery voltage

CHG

CHARGING SYSTEM

CHG-25

< SYMPTOM DIAGNOSIS >

SYMPTOM DIAGNOSIS

CHARGING SYSTEM

Symptom Table

INFOID:0000000006532115

Symptom

Reference

Discharged battery

Refer to

CHG-12, "GASOLINE ENGINE MODELS : Work Flow"

(gasoline engine models) or

CHG-15, "DIESEL ENGINE MODELS

: Work Flow"

(diesel engine models).

The charge warning lamp does not illuminate when the ignition
switch is set to ON.

The charge warning lamp does not turn OFF after the engine
starts.

The charging warning lamp turns ON when increasing the engine
speed.

CHG-26

< REMOVAL AND INSTALLATION >

ALTERNATOR

REMOVAL AND INSTALLATION

ALTERNATOR

HR16DE

HR16DE : Exploded View

INFOID:0000000006601086

REMOVAL

DISASSEMBLY

Alternator bracket mounting bolt

Alternator bracket

Alternator mounting bolt

Alternator

“B” terminal harness

“B” terminal nut

Alternator connector

: N·m (kg-m, ft-lb)

JSMIA0093GB

CHG

ALTERNATOR

CHG-27

< REMOVAL AND INSTALLATION >

Type: A002TJ1291ZE

HR16DE : Removal and Installation

INFOID:0000000006601087

REMOVAL

Disconnect the battery cable from the negative terminal. Refer to

PG-124, "Removal and Installation"

Remove radiator reservoir tank. Refer to

CO-17, "Exploded View"

Remove drive belt. Refer to

EM-155, "Removal and Installation"

Disconnect alternator connector.

Remove “B” terminal nut and disconnect “B” terminal harness.

Remove alternator mounting bolts.

Remove alternator upward from the vehicle.

INSTALLATION

Note the following items, and then install in the reverse order of removal.

CAUTION:

• 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.

• 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.

• Be careful to tighten “B” terminal nut carefully.
• Install alternator, and check tension of belt. Refer to

EM-154, "Checking"

NOTE:

JMMIA0558GB

Rear bearing

Rotor assembly

Retainer

Front bearing

Front bracket assembly

Pulley

Pulley nut

Stator assembly

IC voltage regulator assembly

10. Diode assembly

11.

Rear bracket assembly

12. Terminal set

: Do not reuse

: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

CHG-28

< REMOVAL AND INSTALLATION >

ALTERNATOR

Tighten mounting bolts according to the following procedures for installing alternator bracket.
1.

Temporarily tighten mounting bolt (1).

Temporarily tighten mounting bolt (2).

Tighten mounting bolts in numerical order as shown in the fig-
ure.

HR16DE : Disassembly and Assembly

INFOID:0000000006532118

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.

ASSEMBLY

Rear Bearing

CAUTION:

• Never reuse rear bearing. Replace with a new one.
• Never lubricate rear bearing outer race.

Rear Cover Installation

Fit brush assembly, diode assembly, regulator assembly and
stator.

JMMIA0463ZZ

SEL032Z

SKIB4529E

CHG

ALTERNATOR

CHG-29

< REMOVAL AND INSTALLATION >

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

HR16DE : Inspection

INFOID:0000000006532119

INSPECTION

Rotor Check

Resistance test

• Replace the rotor if the measurement value is outside of the

specified range.

Insulator test
• Replace the rotor if continuity exists.

Check slip ring for wear.

• Replace the rotor if the measurement value is outside of the specified range.

Brush Check

Check smooth movement of brush.
• Check brush holder and clean if it is not smooth.

Check brush for wear.
• Replace brush if it is worn down to the limit line.

Stator Check

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

SKIB4530E

Resistance

: Refer to SDS

CHG-35, "Alternator"

Slip ring minimum
outer diameter

: Refer to SDS

CHG-35, "Alterna-

tor"

SKIB4525E

SKIB4526E

SKIB4527E

CHG-30

< REMOVAL AND INSTALLATION >

ALTERNATOR

Ground test
• Replace the stator if continuity exists.

MR16DDT

MR16DDT : Exploded View

INFOID:0000000006601092

REMOVAL

DISASSEMBLY

SKIB4528E

Alternator connector

Alternator mounting bolt (upper)

Alternator mounting bolt (lower)

Alternator

“B” terminal harness

“B” terminal nut

: N·m (kg-m, ft-lb)

JMMIA0534GB

CHG

ALTERNATOR

CHG-31

< REMOVAL AND INSTALLATION >

Type: A002TJ1381

MR16DDT : Removal and Installation

INFOID:0000000006601093

REMOVAL

Disconnect the battery cable from the negative terminal. Refer to

PG-124, "Removal and Installation"

Remove charge air cooler. Refer to

EM-31, "Removal and Installation"

Remove drive belt. Refer to

EM-20, "Removal and Installation"

Disconnect alternator connector.

Remove “B” terminal nut and disconnect “B” terminal harness.

Remove alternator mounting bolt (upper).

Completely loosen alternator mounting bolt (lower), 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 thermostat hous-
ing bolt hole cutout.

Remove alternator forward from the vehicle.

INSTALLATION

Note the following items, and then install in the reverse order of removal.

CAUTION:

• 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.

JMMIA0559GB

Rear bearing

Rotor assembly

Retainer

Front bearing

Front bracket assembly

Pulley

Pulley cap

Stator assembly

IC voltage regulator assembly

10. Diode assembly

11.

Rear bracket assembly

12. Terminal set

: Do not reuse

: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

CHG-32

< REMOVAL AND INSTALLATION >

ALTERNATOR

• 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.

• Be careful to tighten “B” terminal nut carefully.
• Install alternator, and check tension of belt. Refer to

EM-20, "Checking"

• For this model, the power generation voltage variable control system that controls the power gener-

ation voltage of the alternator has been adopted. Therefore, the power generation voltage variable
control system operation inspection should be performed after replacing the alternator, and then
make sure that the system operates normally. Refer to

CHG-18, "Inspection Procedure"

MR16DDT : Disassembly and Assembly

INFOID:0000000006601094

DISASSEMBLY

Rear Cover

C (86

F) with a soldering iron (200W capacity).

CAUTION:

Never use a heat gun, as if can damage diode assembly.

Front Cover

Set rotor to the vise.

CAUTION:

• Be careful not to damage the rotor.
• Use copper plate or thick cloth for rotor in the vise.

Remove pulley cap, using suitable tool.

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

ASSEMBLY

Rear Bearing

CAUTION:

• Never reuse rear bearing. Replace with a new one.
• Never lubricate rear bearing outer race.

Rear Cover Installation

SEL032Z

SKIB0531E

SKIB0731E

CHG

ALTERNATOR

CHG-33

< REMOVAL AND INSTALLATION >

Fit brush assembly, diode assembly, regulator assembly and
stator assembly.

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

MR16DDT : Inspection

INFOID:0000000006532123

INSPECTION AFTER DISASSEMBLY

Rotor Check

Resistance test

• Replace the rotor if the measurement value is outside of the

specified range.

Insulator test
• Replace the rotor if continuity exists.

Check slip ring for wear.

• Replace the rotor if the measurement value is outside of the specified range.

Brush Check

Check smooth movement of brush.
• Check brush holder and clean if it is not smooth.

Check brush for wear.
• Replace brush if it is worn down to the limit line.

Stator Check

SKIB4529E

SKIB4530E

Resistance

: Refer to SDS

CHG-35, "Alternator"

Slip ring minimum
outer diameter

: Refer to SDS

CHG-35, "Alterna-

tor"

SKIB4525E

SKIB4526E

CHG-34

< REMOVAL AND INSTALLATION >

ALTERNATOR

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

Ground test
• Replace the stator if continuity exists.

SKIB4527E

SKIB4528E

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