MAN - 00162

Repair Manual Charging System Nov 2011/ Rev 2

CHARGING SYSTEM

CONTENTS

Description and Operation ..............................................................1

Service Tips and Precautions .........................................................1

Do’s and Dont’s of Charging System ................................................. 3

Incar Repairs ....................................................................................4

Battery Testing ................................................................................... 4
Visual Inspection ................................................................................ 4
Checking Battery Condition ............................................................... 4
Battery Charge Indicator .................................................................... 5
State of Charge .................................................................................. 5
a.Specific Gravity ........................................................................... 5
b.Open circuit voltage ................................................................... 6
Factors Affecting Battery Life ............................................................. 6
How to handle the battery .................................................................. 7
Jump Starting ..................................................................................... 7

Battery .......................................................................................... 8
Removal ............................................................................................. 8
Inspection ........................................................................................... 8
Installation .......................................................................................... 8

Alternator ..................................................................................... 9
Removal ............................................................................................. 9
Installation ........................................................................................ 10

Battery Tray ................................................................................10

Removal ........................................................................................... 10
Installation ........................................................................................ 10

Diagnosis and Testing ...................................................................11

Inspection and Verification ............................................................... 11
Troubleshooting Chart...................................................................... 12
Component Inspection and Action Table ......................................... 13

Technical Specification ................................................................13

Torque Specification ..................................................................... 14

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.

Repair Manual Charging System
Charging System
Description and Operation
The charging system consists of an alternator, regu-
lator and interconnecting wiring.
The charging system maintains charge in the vehi-
cle's battery and provides main source of electrical
energy while the engine is running. If the charging
system stop working, the battery's charge would
soon be depleted, leaving a "dead battery” in the
vehicle. If the battery is weak and the alternator is not
working, the engine may not have enough electrical
current to start the engine.
An alternator consists of two main electrical compo-
nents and they are rotor and stator. The rotor is con-
nected directly to the alternator pulley. The drive belt
drives the pulley, which in turn spins the rotor. The
stator is mounted to body of the alternator and
remains stationary. There is just enough space in the
center of the stator for the rotor to fit and be able to
spin without making any contact.
There is a group of electrical field coils mounted on
the rotor. The stator is a group of stationary coils that
line the perimeter of inner side of the alternator case.
When current is flowing in the rotor's coils, they
induce current flow in the stationary coils. The
induced current is an AC current. To convert this to
DC which is required for vehicle‘s electrical opera-
tions, the current passes through a bridge rectifier.
As long as the engine is running, all of the power for
the accessories is delivered by the alternator. The
only time that the battery would supply power with
the engine running is when the current capacity of
the alternator is exceeded or when engine is at a
very low idle.
There is a system to warn the driver if any problem
exists in the charging system through the warning
indicator in the instrument cluster.
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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
MAN - 00162
Nov 2011/ Rev 2
Service Tips and Precautions
The following points must be adhered to while han-
dling the charging system and its components.
• Swapping the battery connections even for a
short period can result in a non reversible dam-
age or functional failure of the alternator and this
is strictly impermissible.
• At any case, the alternator should be handled
carefully. It should not be dropped or exposed to
any shocks out of normal conditions. Even with
little stress caused by hitting, an invisible pre-
damage can occur, which leads to malfunction.
• The operation of the alternator is only permissi-
ble with an assembled regulator and with con-
nected 12V battery.
The following points should be followed while charg-
ing the battery
CAUTION
Do not reverse the connections to the alterna-
tor and never disconnect the output terminal
when the alternator is operating.
CAUTION
Do not short across or ground any of the ter-
minals in the charging circuit, except as
directed by the instructions.
CAUTION
Use only approved terminal probe adapters to
connect the meter leads and the jumper wires
with the connector terminals. Using improper
adapters may damage the terminals and the
charging system.
CAUTION
Batteries produce explosive gases which
may cause personal injury, do not allow
flames, sparks or lighted substances near the
battery.
10-1

Repair Manual Charging System
CAUTION
While charging or working near the battery
always shield your face and protect your
eyes. Failure to follow these instructions may
result in personal injury.
DANGER
In case of acid contact with the skin or eyes,
flush immediately for minimum of 15 minutes
and seek prompt medical attention. If the sul-
furic acid is swallowed accidentally, immedi-
ately make a call for the physician. Failure to
follow these instructions will result in personal
injury.
Maintenance
• Ensure correct electrolyte level in the battery.
• Check the general conditions of the battery.
• Cables should be examined for cuts, particularly
where the strands enter the terminal lugs.
• Ensure that battery ventilation slots are clear.
• Keep the alternator clean.
• Check and ensure the mounting bolts are torque
tightened.
• Ensure that belt of alternator is in good condi-
tion.
CAUTION
• Be sure the engine and all accessories are
turned OFF before performing maintenance
• When washing, ensure that the washing
solution does not get into the battery
• Do not remove the battery connection
while engine is running. This may cause
d a m a g e t o E C U a n d t o o t h e r e l e c t ro n i c
equipments.
• Always disconnect the negative terminal
c a b l e f i r s t f r o m t h e b a t t e r y. B u t w h e n
reconnecting, always connect positive cable
first.
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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
10-2 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
MAN - 00162
Nov 2011/ Rev 2
CAUTION
• Add only distilled water to the battery. Do
not add electrolyte
• Do not fill distilled water beyond the upper
mark level. Excessive electrolyte could squirt
out of the battery during heavy charging,
causing corrosion or damage.When washing,
ensure that the washing solution does not get
into the battery.
WARNING
• Do not expose the battery to flames or
electrical sparks. Hydrogen gas generated by
battery action is explosive. Do not allow
battery fluid to contact your skin, eyes,
fabrics, or painted surfaces. After touching a
battery or battery cap, do not touch or rub your
eyes. Thoroughly wash your hands. If the acid
contacts your eyes, skin or clothing,
immediately flush with water for at least 15
minutes and seek medical attention. Battery
terminals and related accessories contain
lead.
• Never disconnect the battery when the
engine is running.
CAUTION
Do not rely on the alternator to recharge a
completely discharged battery.
CAUTION
The battery with frozen electrolyte can
explode if it is used or charged. To prevent
the battery from freezing, maintain full charge
in the battery.
 MAN - 00162
Repair Manual Charging System Nov 2011/ Rev 2

Do’s and Dont’s of Charging System

Do’s
1. Ensure that all charging system electrical connections are clean and secure.

2. Ensure that no electrical connection in the circuit including the battery is open. Observe correct polarity
while connecting the battery to alternator i.e. connect negative to negative and positive to positive. Other-
wise the alternator will be damaged.

3. Disconnect all alternator terminals, while carrying out any form of welding on the vehicle.

4. Disconnect the battery earth cable before removing the alternator.

Dont’s

1. Do not flash the alternator output leads to check the working of the alternator.

2. Do not run the alternator with the disconnected battery, it might damage the electronic components.

3. Do not disconnect any lead of the alternator/regulator with the engine in running condition.

4. Do not disconnect the battery cables when the engine is running.

5. Never add acid to the battery.

6. Don't use unregulated high output battery chargers to charge batteries.

7. Don't disconnect battery cables while the engine is running.

8. Don't let a battery get hot to the touch and boil violently when charging.

9. Don't mix different size and types of batteries.

10.Don't add tap water as it may contain minerals that will contaminate the electrolyte.

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 10-3
component units and accessories from which the vehicles are manufactured.
 MAN - 00162
Repair Manual Charging System Nov 2011/ Rev 2

Incar Repairs
Battery Testing A
Battery testing includes two basic procedures. + -
1. Visual inspection

2. State of charge

a. Specific gravity

b. Open circuit voltage

1.Visual Inspection A - vent plugs

Battery service should begin with thorough visual
inspection. This inspection may reveal simple and Once battery is reconnected, following needs
easily correctable problems. to be reset
1. Check for cracks in the battery case and broken 7. Clock
terminals which allows electrolyte leakage. 8. AM, FM (channels memory)
Replace the battery if necessary. 9. Audio adjustments (Bass, Treble, Balance etc.)
2. Check for any cracked or broken cables/connec-
If volume is too high it will automatically come to
tions, and replace the cables if necessary.
normal level.
3. Check for corrosion on terminals and dirt/acid on
the battery case top. Clean the terminals and the Checking Electrolyte Level
battery case top with mixture of water and bak- Check the electrolyte level and specific gravity at
ing soda. A battery wire brush tool can also be intervals of three months. Check all the six cells for
used to clear heavy corrosion on the terminals. proper electrolyte level. If the level is below the lower
4. Check for a loose battery hold down and tighten marker, add distilled water until the level reaches the
it if necessary. upper marker.

5. Check the electrolyte level by viewing through Adding Distilled Water

the translucent plastic case or removing the vent • Remove the vent plugs
caps and looking directly into the battery. • Add distilled water to all the cells that require the
6. Check for cloudy or discolored electrolyte fluid
caused by overcharging or vibration of the bat- • Secure the plugs properly
tery. This will cause high self discharge. Correct
the cause or replace the battery if necessary.

Checking Battery Condition

Battery Exterior
Check the battery exterior for corroded / loose
terminal connections, cracks / loose hold down
clamp. If the battery terminal is corroded, wash it
with a solution of warm water and baking soda.
Prevent further corrosion by applying petroleum
jelly to the outside of the terminals.

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
10-4 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN - 00162
Repair Manual Charging System Nov 2011/ Rev 2

Battery Charge Indicator 2.State of Charge

Amaron Battery The state of the battery charge can be easily
checked in two ways:

O
K
GE
/CALL AMA a.Specific Gravity
RECH Y
AR
R

RO
BATTE

NHELPLIN Hydrometer is a float-type device used to determine

the State-of-Charge by measuring the specific gravity
of the electrolyte in each cell. It is an accurate way of
E

determining a battery's State-of-Charge and weak or

dead cells.
Battery contains following two different charge indi- Specific gravity test procedure
cators:
1. Wear suitable eye protectors (goggles).
BATTERY OK 2. Remove the vent caps or covers from the bat-
tery.
RECHARGE / CALL AMARON 3. Squeeze the hydrometer bulb and insert the
HELPLINE
pickup tube into the cell close to the battery pos-
Exide Battery itive terminal.
4. Slowly release the bulb to draw in only enough
INDICATOR electrolyte to cause the float to rise. Do not
OK

NEEDS
remove the tube from the battery.
CHARGING

ADD
DISTILLED
5. Read the specific gravity indicated on the float.
WATER
Be sure the float is drifting free, and does not
contact with sides of the barrel. Read the
hydrometer at eye level. Disregard the slight cur-
Battery contains following three different charge indi- vature of liquid on the float.
cators:
6. Note the reading for all the cells. The difference
in specific gravity readings should not be more
OK (Battery condition is good)
than 0.05.
NEEDS Specific gravity readings
CHARGING • By measuring the specific gravity of the
electrolyte, you can identify whether the
ADD DISTILLED WATER battery is fully charged, requires charging,
or must be replaced. The battery must be
Notice atleast 75% charged to perform load test or
each cell must have a specific gravity of
Battery charge indicator gives the indication 1.230 or higher to proceed with the load
of the closest cell where it is located. The bat- test.
tery may be defective in case there is any
internal shorting of other cells which needs SUCTION
the attention of the Authorised battery dealer. BULB

FLOAT
HYDROMETER

OUTER TUBE
PICKUP ELECTROLYTE
TUBE

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 10-5
component units and accessories from which the vehicles are manufactured.

Repair Manual
b.Open circuit voltage
1. Digital voltmeter checks the battery’s open cir-
cuit voltage. Analog meters do not show accu-
rate readings and should be avoided.
2. Turn ON the head lamp high beam for 30 sec-
onds to remove any surface charge.
3. Turn OFF the head lamp, disconnect the battery
and connect the digital voltmeter across the bat-
tery terminals.
4. Note the readings in the voltmeter. A fully
charged battery will have an open-circuit voltage
of 12.6V. On the other hand, a totally dead bat-
tery will have an open-circuit voltage less than
11.0V.
Notice
If the battery voltage is higher than or equal to
12.4V, proceed to heavy load test. If the battery
voltage is less than 12.4V, the battery must be
fully recharged. Before testing be sure to com-
pletely remove the surface charge.
Volt Meter
X10RPM
Hz
400
mA
The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
10-6 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
MAN - 00162
Charging System Nov 2011/ Rev 2
Factors Affecting Battery Life
Overcharging
• Any charging over and above the specified level
will result in overcharging. It severely corrodes
positive plate grids which weaken and finally dis-
integrate. Overcharging decomposes electrolyte
into hydrogen and oxygen which causes exces-
sive concentration of the electrolyte because of
loss of water from the mixture of the battery fluid.
This damages the plates and separators. High
temperatures also show adverse effects on
plates, separators and container. Excessive gas-
sing creates the possibility of the active metal
blowing away from the plate surface and fine
acid spray escaping from the battery.
Undercharging
• Perpetual undercharging results in sulfation of
plates and running down of cells. Sulfate depos-
its are seen on the cell separators, which leak
through and create short circuits between posi-
tive and negative plates. Undercharging also
leads to buckling of plates.
Idle battery
• When the battery is not used for a long time or if
left idle, self-discharge takes place and sulfation
12.4 is observed on battery terminals. Sulfation of the
OFF
battery reduces the life span of the battery.
VDC/AC
CAP
High Specific Gravity
20A
mA
• High specific gravity destroys positive and nega-
tive plates and also reduces life of the battery.
V Hz %
COM
Impure water top-up
• Impure water introduces impurities in the battery.
Iron and Chlorine in the impure water attack the
plates which affects overall life of the battery.
Chlorine bleaches the separators.
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 MAN - 00162
Repair Manual Charging System Nov 2011/ Rev 2

How to handle the battery attach one clamp to the negative terminal (A) of
the booster battery. Then attach the other end of
Methods of preventing over-discharge that cable to a solid metal part of the engine (eg.
engine lift bracket). Do not connect the cable to
any moving part.
CAUTION
After connecting the battery cables, ensure A B B
that they are securely clamped to battery ter-
minals.

• The battery surface (particularly its top) should

always be kept clean and dry.
GROUND
• The terminal connections should be clean and BOOSTER
secure. At every routine maintenance, clean, BATTERY
tighten and apply petroleum jelly on the termi-
DISCHARGED
nals. BATTERY
• When the vehicle is not going to be used over a A - Negative terminal B - Positive terminal
long period of time, disconnect the negative bat-
tery terminal. Check the charge condition of the
battery. Notice
Jump Starting Always use jump start cables with crocodile
Follow below steps while jump starting the vehicle: clips for connecting the terminals / grounding.

5. Start the engine of the booster battery and let it

run for a few minutes. This will help assure that
the booster battery is fully charged. During the
+ - jumping operation, run the engine in this vehicle
at about 2,000 rpm.
6. Start the engine of the discharged battery using
the normal starting procedure
7. Carefully remove the jumper cables in the
reverse order of attachment.

WARNING
• Improper jump starting procedure can result
1. Use only a 12V supply to start your vehicle. in battery explosion and acid burn hazard
2. If the booster battery is in another vehicle, posi-
tion the two vehicles to bring their batteries near • Connecting a jumper cable near moving
each other. Do not allow the two vehicles to parts (cooling fans, belts) is dangerous. The
touch each other. cable could get caught when the engine starts
and cause serious injury
3. Apply the parking brake.Turn OFF all electrical
systems which are not primarily required.
4. Attach the clamps of the jumper cable as shown
on the illustration. First, attach one clamp of the
jumper cable to the positive terminal (B) of the
CAUTION
discharged battery. Then attach the other end of Loosely connected battery cables could dam-
the same cable to the positive terminal (B) of the age the electronic control units.
booster battery. Next, using the other cable,

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 10-7
component units and accessories from which the vehicles are manufactured.
 MAN - 00162
Repair Manual Charging System Nov 2011/ Rev 2

Battery 2. Open the positive cable cover (A) of the

battery and loosen a 10mm lock nut of the
positive cable. Then disconnect the positive
cable.

The 12V battery is designed to provide safe,

efficient, reliable and mobile means of delivering
and storing electrical energy. This electrical energy 3. Remove the two 13mm mounting nuts (A) of
operates the engine starting system and other the battery holding bracket and remove the
vehicle accessory systems for limited durations bracket (B).
while the engine and/or the charging system are
not operating. The battery system is designed to
function as a resource of electrical energy to
supplement the charging system for short durations
while the engine is running and when the electrical
current demands of the vehicle exceed the output
A
of the charging system.

Removal
1. Loosen a 10mm lock nut (A) of the battery
negative cable and disconnect the negative
cable. B

4. Remove the battery from the battery tray.

Inspection
For additional information on Battery Inspection
Checking Battery Condition section.
A
Installation
1. To install, reverse the removal procedure.

Notice
Clean the battery positive and negative cables
before fixing to the battery.

Notice
Visualy inspect the battery for any damage
before installing.

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
10-8 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN - 00162
Repair Manual Charging System Nov 2011/ Rev 2

Alternator Notice
Remove the oil dipstick from the oil dipstick
pipe and place it aside.

5. Remove the 12mm alternator electrical connec-

tor nut (A) and disconnect the electrical connec-
tor from the alternator.

The alternator with internal cooling fans and an in

built regulator acts as a battery charger in the vehi-
cle. The alternator is designed and matched to form
a part of Integrated Battery Charging System for
automotive applications. This is a three-phase unit of
revolving field and stationary armature. It is venti-
lated and cooled by the two internal fans located on
either sides of the rotor. 6. Press the electrical connector (A) of the alterna-
tor towards inner side, press the lock and pull
Removal out the electrical connector.

CAUTION
Do not rely on the alternator to recharge a
completely discharged battery.
A
1. Remove the negative terminal of the battery. For
additional information refer to Battery
removal and installation section.
2. Remove the intercooler. For additional infor-
mation refer to Intercooler removal and
installation section.
3. Remove the accessory drive belt. For addi-
tional information refer to Accessory Drive
Belt removal and installation section.
4. Remove the radiator thermostat hoses.For addi-
tional information refer to Thermostat
removal and installation section.

Notice
Use the tray before removing the thermostat
hoses to avoid spilling of coolant in working
area.

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 10-9
component units and accessories from which the vehicles are manufactured.
 MAN - 00162
Repair Manual Charging System Nov 2011/ Rev 2

7. Remove 12mm mounting nuts (A) and bolts from Battery Tray
the alternator bracket, and Separately detach
the alternator assembly.

Removal
Installation 1. Remove the battery. For additional
1. To install, reverse the removal procedure. information refer to Battery removal and
installation section.
Notice 2. Loosen four 10mm mounting bolts (A) on the
battery tray, and separately detach the battery
Check the electrical connections are fixed tray.
properly before starting the engine.

Installation
1. To install, reverse the removal procedure.

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
10-10 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN - 00162
Repair Manual Charging System Nov 2011/ Rev 2

Diagnosis and Testing

Inspection and Verification
1. Verify the customer‘s concern.
2. Visually inspect the charging system for any
noticeable signs of mechanical or electrical
damage.
3. If any obvious cause is found, correct the
same before proceeding to the next step.
Mechanical
• Check for cracks in the battery case and
broken terminals.
• Check the electrolyte level in the battery.
• Check the battery plates for any sign of
sulfation, if required clean it.
Electrical
• Check whether the main fuse MF2 (150A) is
blown.
• Check the alternator cable terminal for
corrosion.
• Check for loose electrical connectors in the
alternator.
• Inspect the battery terminals for corrosion and
loose connection.
• Check the charging system warning indicator
connector for loose connection.

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 10-11
component units and accessories from which the vehicles are manufactured.

Repair Manual Charging System
Troubleshooting Chart
Symptom Possible Causes
1. Wiring connections are
loose.
2. Defective voltage regu-
lator.
3. Loose battery connec-
Charging indicator lamp does not glow tors.
when the ignition is switched ON 4. Loose alternator con-
nectors.
5. Indicator Lamp burned
out.
6. Electrical malfunction
1. Defective batteries or
battery terminal con-
nections.
2. Blown fuse or fusible
link.
3. Defective wiring har-
ness.
Battery low or not charging 4. Faulty alternator.
5. Loose battery connec-
tors.
6. Loose alternator con-
nectors.
7. Defective auto-ten-
sioner.
1. Battery is faulty.
2. Poor contact at voltage
Electrolyte spillage (battery electrolyte is detection point of the
alternator.
depleted in a short time)
3. Faulty voltage regula-
tor.
1. Faulty/damaged belt.
2. Faulty/damaged alter-
nator pulley.
Abnormal noise from alternator 3. Damaged/defective
tensioner.
4. Worn alternator bear-
ing.
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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
10-12 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
MAN - 00162
Nov 2011/ Rev 2
Remedy
1. Tighten the connections.
2. Replace the voltage regulator.
3. Tighten the battery connec-
tions.
4. Tighten the alternator connec-
tions.
5. Replace the instrument clus-
ter.
6. Investigate through diagnostic
tool.
1. Check the battery and battery
terminal connections.
2. Check the fuse or fusible link,
and replace if needed.
3. Check the voltage drop.
4. Replace the alternator.
5. Tighten the battery connec-
tions.
6. Tighten the alternator connec-
tions.
7. Replace the auto-tensioner.
1. Replace the faulty battery.
2. Tighten the connection mount-
ing.
3. Replace the voltage regulator.
1. Replace the alternator belt.
2. Replace the alternator pulley.
3. Rectify or replace the alterna-
tor belt auto-tensioner.
4. Replace the alternator.
 MAN - 00162
Repair Manual Charging System Nov 2011/ Rev 2

Component Inspection and Action Table

Component Inspection Action

1. Physical Damage. 1. Replace the alternator as-

sembly
Alternator
2. Undercharging or Overcharg- 2. Replace the alternator as-
ing. sembly

1. Physical Damage. 1. Replace the battery.

2. Battery dead or no charge. 2. Charge the battery as per
recommendation.
Battery 3. Electrolyte leakage from top. 3. Check for blocked vent holes
and clean.
4. Electrolyte leakage from 4. Check for cracks on body
sides. and replace battery.
5. Electrolyte discoloration. 5. Replace the battery.

1. Check for any sulfation at 1. Clean the connectors.

connectors.
Wiring Harness 2. Check for any kinks, chaffing 2. Replace the wiring harness
or any other damage to the assembly
wiring harness.

1. Check for physical damage. 1. Replace the belt if damaged.

FEAD Belt 2. Check for slackness of the 2. Replace the belt if required.
belt.

Technical Specification
Description Specification

System voltage 12V

Battery rating 90Ah

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 10-13
component units and accessories from which the vehicles are manufactured.
 MAN - 00162
Repair Manual Charging System Nov 2011/ Rev 2

Torque Specification
Torque in
Part Bolt Specification Place of Application Quantity
Nm

Mounting flanged
Earth on transaxle 1 24±1
bolt M8 x 1.25 x 10

M8 Eyelet ring Ground on side rail LH (Part of

1 15±1
terminal Battery Negative cable)
Battery Cable
Negative Ground on side rai LH near battery
M8 Eyelet ring
mtg area (Part of Battery Negative 1 15±1
terminal
cable)

NUT HEX FL
Battery negative nut on cable 1 6.5±0.5
M6X1X6X8 GR

Battery Cable NUT HEX FL

Battery positive nut on cable 1 6.5±0.5
Positive M6X1X6X8 GR

FLANGED BOLT
Battery tray 4 7±0.5
M6 X 1X 20
Battery Hold
NUT HEX FL
Hold on mounting 2 8±0.5
M8X1.25X8X8 GR

B+ Line input from BEC to Alterna-

NUT HEX FL tor
Alternator 1 15±1
M8X1.25X8X8 GR
(Part of engine wiring harness)

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
10-14 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.