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CH–1

CHARGING (5S–FE) – CHARGING SYSTEM

CHARGING SYSTEM
CH02U–01

ON–VEHICLE INSPECTION
CAUTION: z Check that the battery cables are connected to the correct terminals. z Disconnect the battery cables when the battery is given a quick charge. z Do not perform tests with a high voltage insulation resistance tester. z Never disconnect the battery while the engine is running. 1. CHECK BATTERY ELECTROLYTE LEVEL Check the electrolyte quantity of each cell. Maintenance–Free Battery: If under the lower level, replace the battery (or add distilled water if possible). Check the charging system. Except Maintenance–Free Battery: If under the lower level, add distilled water.
Except Maintenance–Free Battery

2.

Except Maintenance–Free Battery: CHECK BATTERY SPECIFIC GRAVITY Check the specific gravity of each cell. Standard specific gravity: 1.25 – 1.29 at 20°C (68°F) If the specific gravity is less than specification, charge the battery.
Z11577

Maintenance–Free Battery Voltmeter

Z11556

Maintenance–Free Battery: CHECK BATTERY VOLTAGE (a) After having driven the vehicle and in the case that 20 minutes have not passed after having stopped the engine, turn the ignition switch ON and turn on the electrical system (headlight, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge. (b) Turn the ignition switch OFF and turn off the electrical systems. (c) Measure the battery voltage between the negative (–) and positive (+) terminals of the battery. Standard voltage: 12.5 – 12.9 V at 20°C (68°F) If the voltage is less than specification, charge the battery.

3.

Author :

Date :

1748

CH–2
CHARGING (5S–FE) – CHARGING SYSTEM

Maintenance–Free Battery Type A
CLEAR EYE or LIGHT YELLOW

GREEN EYE

DARK EYE

CHARGED

DISCHARGED ADD WATER

HINT: Check the indicator as shown in the illustration. 4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES (a) Check that the battery terminals are not loose or corroded. If the terminals are corroded, clean the terminals. (b) Check the fusible link, H–fuses, M–fuse and fuses for continuity.

Type B Blue White Red

OK

Charging Insufficient Necessary Water
Z18811

5. (a)

INSPECT DRIVE BELTS Visually check the drive belt for excessive wear, frayed cords etc. If any defect has been found, replace the drive belt. HINT: Cracks on the rib side of a drive belt are considered acceptable. If the drive belt has chunks missing from the ribs, it should be replaced.
Z00015

DENSO

Borroughs

(b)

Using a belt tension gauge, measure the belt tension. Belt tension gauge: DENSO BTG–20 (95506–00020) Borroughs No. BT–33–73F Drive belt tension:
New belt Used belt New belt Used belt 165 ± 25 lbf 110 ± 10 lbf 125 ± 25 lbf 95 ± 20 lbf

w/ A/C

w/o A/C
Z00038

CORRECT

WRONG

CH0086

If the belt tension is not as specified, adjust it. HINT: z ”New belt” refers to a belt which has been used less than 5 minutes on a running engine. z ”Used belt” refers to a belt which has been used on a running engine for 5 minutes or more. z After installing a belt, check that it fits properly in the ribbed grooves. z Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley.

Author :

Date :

1749

CH–3
CHARGING (5S–FE) – CHARGING SYSTEM

After installing a new belt, run the engine for about 5 minutes and recheck the belt tension. 6. VISUALLY CHECK GENERATOR WIRING AND LISTEN FOR ABNORMAL NOISES (a) Check that the wiring is in good condition. (b) Check that there is no abnormal noise from the generator while the engine is running. 7. CHECK CHARGE WARNING LIGHT CIRCUIT (a) Warm up the engine and then turn it off. (b) Turn off all accessories. (c) Turn the ignition switch ”ON”. Check that the charge warning light is lit. (d) Start the engine. Check that the light goes off. If the light does not go off as specified, troubleshoot the charge light circuit.

z

Ammeter

Disconnect Wire from Terminal B

Battery

Voltmeter B Generator
Z03473

8. INSPECT CHARGING CIRCUIT WITHOUT LOAD HINT: If a battery/generator tester is available, connect the tester to the charging circuit as per manufacturer’s instructions. (a) If a tester is not available, connect a voltmeter and ammeter to the charging circuit as follows: (1) Disconnect the wire from terminal B of the generator, and connect it to the negative (–) tester probe of the ammeter. (2) Connect the positive (+) tester probe of the ammeter to terminal B of the generator. (3) Connect the positive (+) tester probe of the voltmeter to terminal B of the generator. (4) Ground the negative (–) tester probe of the voltmeter. (b) Check the charging circuit as follows: With the engine running from idling to 2,000 rpm, check the reading on the ammeter and voltmeter. Standard amperage: 10 A or less Standard voltage: 13.5 – 15.1 V If the voltmeter reading is more than standard voltage, replace the voltage regulator.

Author :

Date :

1750

(b) Check the reading on the ammeter. INSPECT CHARGING CIRCUIT WITH LOAD (a) With the engine running at 2.000 rpm. start the engine and check the voltmeter reading of terminal B. z If the voltmeter reading is less than standard voltage. check the voltage regulator and generator as follows: z With terminal F grounded. z If the voltmeter reading is more than standard voltage. Standard amperage: 30 A or more If the ammeter reading is less than the standard amperage. the indication will sometimes be less than standard amperage. repair the generator. Author : Date : 1751 . check the generator.CH–4 CHARGING (5S–FE) – CHARGING SYSTEM Terminal F P14433 If the voltmeter reading is less than standard voltage. 9. HINT: If the battery is fully charged. turn on the high beam headlights and place the heater blower switch at ”HI”. replace the voltage regulator.

CH–5 CHARGING (5S–FE) – GENERATOR GENERATOR CH02V–03 COMPONENTS Adjusting Lock Bolt Generator Wire Rubber Cap Pivot Bolt Generator Connector Wire Clamp Generator Drive Belt S05342 z Front Bearing Rotor Pulley Bearing Cover Bearing Cover Generator Washer z Rear Bearing Seal Plate Brush Holder Terminal Insulator Rubber Insulator Wire Clip Voltage Regulator Brush Holder Cover Rectifier End Flame z Non–reusable part Rear End Cover Plate Terminal S05076 Drive End Flame (Starter) Rectifier Holder Bearing Cover Author : Date : 1752 .

38 ft·lbf) Adjusting lock bolt (w/ A/C) or adjusting bolt (w/o A/C) 18 N·m (185 kgf·cm. Remove the rubber cap and nut. (a) (b) (c) B02375 DISCONNECT CONNECTOR AND WIRE FROM GENERATOR Disconnect the wire clamp from the wire clip on the rectifier end frame. 13 ft·lbf) Remove the drive belt. Remove the generator. Pivot Bolt Adjusting Lock Bolt B02376 B02377 B02693 Author : Date : 1753 . Remove the adjusting lock bolt (w/ A/C) or adjusting bolt (w/o A/C) and pivot bolt. Torque: Pivot bolt: 52 N·m (530 kgf·cm. Disconnect the generator connector. and disconnect the generator wire. adjusting bolt and pivot bolt.CH–6 CHARGING (5S–FE) – GENERATOR CH02W–03 REMOVAL 1. w/ A/C Pivot Bolt Adjusting Bolt 2. (a) Adjusting Lock Bolt w/o A/C (b) (c) (d) REMOVE GENERATOR Loosen the adjusting lock bolt (w/ A/C).

(a) (b) (c) REMOVE BRUSH HOLDER AND VOLTAGE REGULATOR Remove the brush holder cover from the brush holder. Insert SST (B) into SST (C). (a) Turn SST (A) (b) REMOVE PULLEY Hold SST (A) with a torque wrench.CH–7 CHARGING (5S–FE) – GENERATOR CH02X–01 DISASSEMBLY 1. Z18636 3. SST (B) P13597 (c) (d) SST (B) SST (C) Insert Mount SST (C) in a vise. (a) (b) REMOVE RECTIFIER HOLDER Remove the 4 screws and rectifier holder. 29 ft·lbf) Check that SST (A) is secured to the rotor shaft. Remove the 4 rubber insulators. Remove the bolt. 3 nuts. and tighten SST (B) clockwise to the specified torque. B02378 4. (a) (b) REMOVE REAR END COVER Remove the nut and terminal insulator. SST 09820–63010 Torque: 39 N·m (400 kgf·cm. plate terminal and end cover. Remove the seal plate from the rectifier end frame. P10834 Author : Date : 1754 . and attach the pulley nut to SST (C). Z18635 2. Remove the 5 screws. brush holder and voltage regulator.

(a) REMOVE RECTIFIER END FRAME Remove the 4 nuts and wire clip. and remove SST (A and B). S05070 (b) SST (c) 6. REMOVE ROTOR FROM DRIVE END FRAME P13490 Author : Date : 1755 . do not loosen the pulley nut more than one–half of a turn. remove the rectifier end frame. Remove the pulley nut and pulley. NOTICE: To prevent damage to the rotor shaft.CH–8 CHARGING (5S–FE) – GENERATOR (e) SST (C) SST (A) To loosen the pulley nut. SST 09286–46011 Remove the generator washer from the rotor. Turn Turn P10827 (g) (h) SST (A) Turn SST (B). turn SST (A) in the direction shown in the illustration. Using SST. SST (B) P13598 5. (f) Remove the generator from SST (C).

replace the rotor. (a) INSPECT STATOR (DRIVE END FRAME) Check the stator for open circuit.) If the diameter is less than minimum. CH0784 1. P13565 Author : Date : 1756 . P13482 Ohmmeter No Continuity (b) Check the stator for ground.7 – 3. replace the rotor. CH1023 Ohmmeter Continuity 2. Standard diameter: 14. If rough or scored. (d) Using vernier calipers. If there is no continuity. (a) Ohmmeter Continuity (b) Check the rotor for ground. check that there is no continuity between the coil lead and drive end frame. If there is continuity.1 Ω at 20°C (68°F) If there is no continuity. replace the drive end frame assembly. check that there is continuity between the coil leads.8 mm (0. Using an ohmmeter.559 – 0. check that there is continuity between the slip rings. If there is continuity. replace the drive end frame assembly.4 mm (0. replace the rotor. replace the rotor. Standard resistance: 2.) Minimum diameter: 12.504 in. Ohmmeter No Continuity CH0783 (c) Check that the slip rings are not rough or scored. measure the slip ring diameter. check that there is no continuity between the slip ring and rotor. Using an ohmmeter.CH–9 CHARGING (5S–FE) – GENERATOR CH02Y–01 INSPECTION INSPECT ROTOR Check the rotor for open circuit. Using an ohmmeter. Using an ohmmeter.2 – 14.567 in.

P13535 Ohmmeter Positive (+) Terminal Rectifier Terminal P13568 Ohmmeter Negative (–) Terminal P13566 INSPECT RECTIFIERS (RECTIFIRE HOLDER) Check the positive (+) rectifire.CH–10 CHARGING (5S–FE) – GENERATOR Length 3. If continuity is not as specified. (2) Reverse the polarity of the tester probes and repeat step (a). 5. connect one tester probe to each negative (–) terminal and the other to each rectifier terminal. (3) Check that one shows continuity and the other shows no continuity. If continuity is not as specified.) If the exposed length is less than minimum. (See page CH–11) 4. (b) Check the negative (–) rectifire. (1) Using an ohmmeter. (1) Using an ohmmeter. Standard exposed length: 10. replace the bearing. If necessary. replace the rectifier holder.413 in. (a) Author : Date : 1757 . measure the exposed brush length.) Minimum exposed length: 1. INSPECT BRUSHES Using vernier calipers.5 mm (0.059 in. replace the brush holder assembly.5 mm (0. INSPECT BEARING Check the bearing is not rough or worn. replace the rectifier holder. (3) Check that one shows continuity and the other shows no continuity. (2) Reverse the polarity of the tester probes and repeat step (a). connect one tester probe to the positive (+) terminal and the other to each rectifier terminal.

press in a new bearing. SST 09950–60010 (09951–00500) Install the bearing retainer with the 4 screws. N00581 (b) (c) Remove the bearing cover (inside). P13567 Author : Date : 1758 . 27 in. P00100 SST (c) (d) Using SST and a press. press out the bearing. remove the bearing cover (outside) and bearing. bearing retainer and bearing.0 N·m (31 kgf·cm. SST 09820–00021 NOTICE: Be careful not to damage the fan. (a) REPLACE FRONT BEARING Remove the 4 screws. (a) SST REPLACE REAR BEARING Using SST. Torque: 3. Place the bearing cover (inside) on the rotor.·lbf) Downward P13479 2. CH0827 Socket Wrench (b) Using a socket wrench and press.CH–11 CHARGING (5S–FE) – GENERATOR CH02Z–01 REPLACEMENT 1.

press in a new bearing.CH–12 CHARGING (5S–FE) – GENERATOR (d) SST Using SST and a press. SST 09820–00030 N00578 (e) Using SST. push in the bearing cover (outside). SST 09285–76010 SST P00074 Author : Date : 1759 .

48 in.·lbf) Nut B: 5. and tighten SST (B) clockwise to the specified torque. (a) Turn (b) SST (A) SST (B) P13597 (c) INSTALL PULLEY Install the pulley to the rotor shaft by tightening the pulley nut by hand. P01364 2. 40 in. Install the rotor to the rectifier end frame. SST 09820–63010 Torque: 39 N·m (400 kgf·cm. Hold SST (A) with a torque wrench.5 N·m (46 kgf·cm. 29 ft·lbf) Check that SST (A) is secured to the pulley shaft. Z18637 29 mm Socket Wrench (b) Using a 29 mm socket wrench and press. Torque: Nut A: 4. (a) INSTALL RECTIFIER END FRAME Place the generator washer on the rotor.CH–13 CHARGING (5S–FE) – GENERATOR CH030–01 REASSEMBLY Pulley 1.4 N·m (55 kgf·cm. (a) (b) INSTALL ROTOR TO DRIVE END FRAME Place the rectifier end frame on the pulley. slowly press in the rectifier end frame.·lbf) A A Z19213 3. Author : Date : 1760 . P13487 B (c) A Install the wire clip and 4 nuts.

and remove SST (A and B). SST (C) P04210 (f) SST (C) (g) To torque the pulley nut. and attach the pulley nut to SST (C).125 kgf·cm. turn SST (A) in the direction shown in the illustration.CH–14 CHARGING (5S–FE) – GENERATOR (d) (e) Mount SST (C) in a vise.·lbf) S05074 Author : Date : 1761 . Turn SST (A) P04395 Turn (h) Turn SST (B). S05075 (b) Push Install the rectifier holder while pushing it with the 4 screws. Insert SST (B) into SST (C). SST (A) SST (B) P13598 Inside 4. NOTICE: Be careful of the rubber insulators installation direction. INSTALL RECTIFIER HOLDER (a) Install the 4 rubber insulators on the lead wires. 26 in. Torque: 110.9 N·m (30 kgf·cm. Torque: 2.5 N·m (1. 81 ft·lbf) Remove the generator from SST (C).

0 N·m (20 kgf·cm.·lbf) Bolt: 3. Install the terminal insulator with the nut. Z18638 (b) Upward Place the voltage regulator and brush holder on the rectifier end frame. 18 in. NOTICE: Be careful of the holder installation direction. 35 in.1 N·m (42 kgf·cm.9 N·m (39 kgf·cm.·lbf) S05461 (d) Place the brush holder cover on the brush holder. Torque: 4. (a) INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER Place the seal plate on the rectifier end frame.·lbf) Z18635 (b) 7. Torque: Nut: 4.CH–15 CHARGING (5S–FE) – GENERATOR 5.·lbf) CHECK THAT ROTOR ROTATES SMOOTHLY S05069 Author : Date : 1762 .4 N·m (45 kgf·cm. Z18640 6. (c) Install the 5 screws. Torque: 2. 36 in. (a) INSTALL REAR END COVER Install the end cover and plate terminal with the bolt and 3 nuts. 39 in.

CH–16 CHARGING (5S–FE) – GENERATOR CH031–01 INSTALLATION Installation is in the reverse order of removal. (See page CH–6) Author : Date : 1763 .

CHECK BATTERY ELECTROLYTE LEVEL Check the electrolyte quantity of each cell.5 – 12. charge the battery. (2) Except Maintenance–Free Battery: If under the lower level. Turn the ignition switch OFF and turn off the electrical systems. z Do not perform tests with a high voltage insulation resistance tester. add distilled water. (a) (b) Z11556 Maintenance–Free Battery: CHECK BATTERY VOLTAGE After having driven the vehicle and in the case that 20 minutes have not passed after having stopped the engine. Measure the battery voltage between the negative (–) and positive (+) terminals of the battery. Check the charging system. Standard specific gravity: 1. (1) Maintenance–Free Battery: If under the lower level. z Never disconnect the battery while the engine is running. turn the ignition switch ON and turn on the electrical system (headlight. 2. blower motor. replace the battery (or add distilled water if possible). Except Maintenance–Free Battery Z11577 Maintenance–Free Battery Voltmeter 3. rear defogger etc.) for 60 seconds to remove the surface charge.9 V at 20°C (68°F) If the voltage is less than specification. charge the battery. Except Maintenance–Free Battery: CHECK BATTERY SPECIFIC GRAVITY Check the specific gravity of each cell. (c) Author : Date : 1764 . 1. Standard voltage: 12.29 at 20°C (68°F) If the specific gravity is less than specification.CH–1 CHARGING (1MZ–FE) – CHARGING SYSTEM CHARGING SYSTEM CH01D–01 ON–VEHICLE INSPECTION CAUTION: z Check that the battery cables are connected to the correct terminals. z Disconnect the battery cables when the battery is given a quick charge.25 – 1.

(a) INSPECT DRIVE BELTS Visually check the drive belt for excessive wear. measure the belt tension. replace the drive belt. HINT: Cracks on the rib side of a drive belt are considered acceptable.CH–2 CHARGING (1MZ–FE) – CHARGING SYSTEM Maintenance–Free Battery Type A GREEN EYE DARK EYE CLEAR EYE or LIGHT YELLOW CHARGED DISCHARGED ADD WATER HINT: Check the indicator as shown in the illustration. (b) Check the fusible link. After installing a belt. M–fuse and fuses for continuity. 4. Author : Date : 1765 . If any defect has been found. it should be replaced. adjust it. FUSIBLE LINK AND FUSES (a) Check that the battery terminals are not loose or corroded. H–fuses. Type B Blue White Red OK Charging Insufficient Necessary Water Z18811 5. CHECK BATTERY TERMINALS. Z00015 DENSO Borroughs (b) Using a belt tension gauge. Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley. BT–33–73F Drive belt tension: New belt Used belt 175 ± 5 lbf 115 ± 20 lbf If the belt tension is not as specified. Belt tension gauge: DENSO BTG–20 (95506–00020) Borroughs No. frayed cords etc. ”Used belt” refers to a belt which has been used on a running engine for 5 minutes or more. clean the terminals. Z00038 HINT: z z z z CH0086 CORRECT WRONG ”New belt” refers to a belt which has been used less than 5 minutes on a running engine. check that it fits properly in the ribbed grooves. If the drive belt has chunks missing from the ribs. If the terminals are corroded.

replace the voltage regulator. If the light does not go off as specified. Author : Date : 1766 . check the reading on the ammeter and voltmeter. 7.CH–3 CHARGING (1MZ–FE) – CHARGING SYSTEM After installing a new belt.000 rpm. (b) Check the charging circuit as follows: With the engine running from idling to 2. Standard amperage: 10 A or less Standard voltage: 13. VISUALLY CHECK GENERATOR WIRING AND LISTEN FOR ABNORMAL NOISES (a) Check that the wiring is in good condition. (a) If a tester is not available. CHECK DISCHARGE WARNING LIGHT CIRCUIT (a) Warm up the engine and then turn it off. and connect it to the negative (–) tester probe of the ammeter. Check that the light goes off. INSPECT CHARGING CIRCUIT WITHOUT LOAD HINT: If a battery/generator tester is available. connect the tester to the charging circuit as per manufacturer’s instructions. 6.1 V If the voltmeter reading is more than standard voltage. (c) Turn the ignition switch ”ON”. z Connect the positive (+) tester probe of the voltmeter to terminal B of the generator. z Ground the negative (–) tester probe of the voltmeter. z Ammeter Disconnect Wire from Terminal B Battery Voltmeter Generator Z03473 8.5 – 15. troubleshoot the discharge light circuit. (b) Check that there is no abnormal noise from the generator while the engine is running. connect a voltmeter and ammeter to the charging circuit as follows: z Disconnect the wire from terminal B of the generator. (b) Turn off all accessories. Check that the discharge warning light is lit. (d) Start the engine. run the engine for about 5 minutes and recheck the belt tension. z Connect the positive (+) tester probe of the ammeter to terminal B of the generator.

check the voltage regulator and generator as follows: z With terminal F grounded. z If the voltmeter reading is more than standard voltage. HINT: If the battery is fully charged. start the engine and check the voltmeter reading of terminal B. Standard amperage: 30 A or more If the ammeter reading is less than the standard amperage. the indication will sometimes be less than standard amperage. repair the generator. 9.CH–4 CHARGING (1MZ–FE) – CHARGING SYSTEM Terminal F P14228 If the voltmeter reading is less than standard voltage. INSPECT CHARGING CIRCUIT WITH LOAD (a) With the engine running at 2. (b) Check the reading on the ammeter.000 rpm. Author : Date : 1767 . z If the voltmeter reading is less than standard voltage. check the generator. turn on the high beam headlights and place the heater blower switch at ”HI”. replace the voltage regulator.

CH–5 CHARGING (1MZ–FE) – GENERATOR GENERATOR CH01E–01 COMPONENTS Plate Washer Generator Wire Pivot Bolt Generator Connector Adjusting Bolt Generator Adjusting Lock Bolt Drive Belt S05218 z Front Bearing Retainer Drive End Flame (Stator) Pulley Bearing Cover Generator Washer Bearing Cover z Rear Bearing Plate Terminal Rotor Terminal Insulator Rectifire End Flame Seal Plate Cord Clip Rear End Cover Brush Holder Cover Brush Holder Voltage Regulator Rectifire Holder z Non–reusable part Robber Insulator x 4 S05077 Author : Date : 1768 .

and adjusting bolt. Remove the pivot bolt. 13 ft·lbf) Adjusting Bolt Adjusting Lock Bolt P14226 2. Disconnect the wire harness from the clip. REMOVE DRIVE BELT Loosen the pivot bolt. plate washer. and disconnect the generator wire. 41 ft·lbf) Lock bolt: 18 N·m (180 kgf·cm. (a) (b) (c) (d) REMOVE GENERATOR Disconnect the generator connector. and remove the drive belt. Remove the nut. adjusting lock bolt and generator.CH–6 CHARGING (1MZ–FE) – GENERATOR CH01F–01 Pivot Bolt REMOVAL 1. Torque: Pivot bolt: 56 N·m (570 kgf·cm. adjusting lock bolt. P14227 Author : Date : 1769 .

Remove the screw. (a) (b) REMOVE REAR END COVER Remove the nut and terminal insulator. (a) Turn SST (A) (b) SST (B) P10835 REMOVE PULLEY Hold SST (A) with a torque wrench. 3 nuts. SST 09820–63010 Torque: 39 N·m (400 kgf·cm. (a) (b) (c) REMOVE RECTIFIER HOLDER Remove the 4 screws and rectifier holder. 29 ft·lbf) Check that SST (A) is secured to the rotor shaft. Insert SST (B) into SST (C). (c) (d) SST (B) SST (C) Insert Mount SST (C) in a vise. Remove the 5 screws.CH–7 CHARGING (1MZ–FE) – GENERATOR CH01G–01 DISASSEMBLY Plate Terminal 1. and attach the pulley nut to SST (C). brush holder and voltage regulator. Remove the 4 rubber insulators. Remove the seal plate. plate terminal and end cover. S05072 4. P10834 Author : Date : 1770 . and tighten SST (B) clockwise to the specified torque. (a) (b) REMOVE BRUSH HOLDER AND VOLTAGE REGULATOR Remove the brush holder cover from the brush holder. P14234 3. P14233 2.

(f) Remove the generator from SST (C). REMOVE ROTOR FROM DRIVE END FRAME P01762 Author : Date : 1771 . Turn P10827 Turn (g) (h) SST (A) Turn SST (B). remove the rectifier end frame.CH–8 CHARGING (1MZ–FE) – GENERATOR (e) SST (C) SST (A) To loosen the pulley nut. and remove SST (A and B). SST Using SST. SST (B) P10836 5. SST 09286–46011 Remove the generator washer. turn SST (A) in the direction shown in the illustration. Remove the pulley nut and pulley. S05073 (b) (c) 6. NOTICE: To prevent damage to the rotor shaft. (a) REMOVE RECTIFIER END FRAME Remove the 4 nuts and cord clip. do not loosen the pulley nut more than one–half of a turn.

Using an ohmmeter. (a) Ohmmeter INSPECT STATOR (DRIVE END FRAME) Check the stator for open circuit. Using an ohmmeter. P00484 (b) Continuity Check the stator for ground.1 – 2. If there is continuity. replace the rotor. replace the drive end frame assembly. measure the slip ring diameter. check that there is no continuity between the slip ring and rotor. Using an ohmmeter.8 mm (0. CH0784 1.5 Ω at 20°C (68°F) If there is no continuity. Ohmmeter P00482 Author : Date : 1772 . replace the rotor.) Minimum diameter: 12. replace the rotor. Standard diameter: 14. replace the drive end frame assembly. Ohmmeter No Continuity CH0783 (c) Check that the slip rings are not rough or scored.504 in. (d) Using vernier calipers.567 in.4 mm (0. If rough or scored.2 – 14. If there is no continuity. Using an ohmmeter. If there is continuity.) If the diameter is less than minimum. CH0192 Continuity 2. check that there is continuity between the slip rings.CH–9 CHARGING (1MZ–FE) – GENERATOR CH01H–01 INSPECTION INSPECT ROTOR Check the rotor for open circuit. check that there is no continuity between the coil lead and drive end frame.559–0. replace the rotor. check that there is continuity between the coil leads. Standard resistance: 2. (a) Ohmmeter Continuity (b) Check the rotor for ground.

replace the rectifier holder.413 in. If continuity is not as specified.) If the exposed length is less than minimum. connect one tester probe to each negative (–) terminal and the other to each rectifier terminal. P13535 Ohmmeter Positive (+) Terminal Rectifire Terminal P00480 Negative (–) Treminal Ohmmeter P00481 INSPECT RECTIFIERS (RECTIFIRE HOLDER) Check the positive (+) rectifire. If necessary. (2) Reverse the polarity of the tester probes and repeat step (a). If continuity is not as specified. (3) Check that one shows continuity and the other shows no continuity. (3) Check that one shows continuity and the other shows no continuity.5 mm (0. (a) Author : Date : 1773 . connect one tester probe to the positive (+) terminal and the other to each rectifier terminal. (1) Using an ohmmeter. replace the bearing. (See page CH–11) 4. Standard exposed length: 10. measure the exposed brush length.5 mm (0. 5. INSPECT BEARING Check the bearing is not rough or worn.059 in. INSPECT BRUSHES Using a vernier caliper.CH–10 CHARGING (1MZ–FE) – GENERATOR Length 3. replace the rectifier holder. replace the brushes and brush holder assembly. (2) Reverse the polarity of the tester probes and repeat step (a).) Minimum exposed length: 1. (b) Check the negative (–) rectifire. (1) Using an ohmmeter.

SST 09950–60010 (09951–00500) Install the bearing retainer with the 4 screws. SST 09820–00021 NOTICE: Be careful not to damage the fan. P14225 (b) Socket Wrench Using a socket wrench and press.·lbf) P00479 2. N00581 (c) Place the bearing cover (inside) on the rotor. (a) SST REPLACE REAR BEARING Using SST. remove the bearing cover (outside) and bearing. bearing retainer and bearing. 27 in. Torque: 3.0 N·m (31 kgf·cm.CH–11 CHARGING (1MZ–FE) – GENERATOR CH01I–01 REPLACEMENT 1. (a) REPLACE FRONT BEARING Remove the 4 screws. press out the bearing. P00628 (c) SST (d) Using SST and a press. P13567 Author : Date : 1774 . (b) Remove the bearing cover (inside). press in a new bearing.

press in a new bearing.CH–12 CHARGING (1MZ–FE) – GENERATOR (d) SST Using SST and a press. SST 09820–00030 N00578 (e) Using SST. SST 09285–76010 SST P00074 Author : Date : 1775 . push in the bearing cover (outside).

Author : Date : 1776 . 29 ft·lbf) Check that SST (A) is secured to the pulley shaft.5 N·m (46 kgf·cm. Install the rotor to the rectifier end frame.·lbf) Nut B: 5. 40 in. 48 in.·lbf) A A Z19214 3. P00427 29 mm Socket Wrench (b) Using a 29 mm socket wrench and press. (a) INSTALL RECTIFIER END FRAME Place the generator washer on the rotor.CH–13 CHARGING (1MZ–FE) – GENERATOR CH01J–01 REASSEMBLY Pulley 1. Hold SST (A) with a torque wrench. Torque: Nut A: 4. (a) (b) INSTALL ROTOR TO DRIVE END FRAME Place the rectifier end frame on the pulley. P01364 2. SST 09820–63010 Torque: 39 N·m (400 kgf·cm.4 N·m (55 kgf·cm. and tighten SST (B) clockwise to the specified torque. slowly press in the rectifier end frame. P01763 B A (c) Install the cord clip with the 4 nuts. (a) Turn (b) SST (A) SST (B) P10835 (c) INSTALL PULLEY Install the pulley to the rotor shaft by tightening the pulley nut by hand.

SST (A) SST (B) P10836 4. 81 ft·lbf) Remove the generator from SST (C). Insert SST (B) into SST (C). P00428 (b) Install the 4 rubber insulators on the lead wires. P10829 Turn (h) Turn SST (B).5 N·m (1. and attach the pulley nut to SST (C). (a) INSTALL RECTIFIER HOLDER Place the seal plate on the rectifier end frame. Torque: 110. P10834 (f) SST (C) SST (A) Turn (g) To torque the pulley nut. P00645 Author : Date : 1777 . and remove SST (A and B). turn SST (A) in the direction shown in the illustration.CH–14 CHARGING (1MZ–FE) – GENERATOR (d) (e) SST (A) SST (C) Insert Mount SST (C) in a vise.125 kgf·cm.

CH–15 CHARGING (1MZ–FE) – GENERATOR (c) Install the rectifier holder with the 4 screws. P14235 6.·lbf) Nut: 4. 26 in. Upward INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER (a) Place the voltage regulator and brush holder on the rectifier end frame. 36 in.·lbf) P14233 (b) 7. 35 in. NOTICE: Be careful of the holder installation direction.9 N·m (30 kgf·cm. Install the terminal insulator with the nut. Torque: 2. (a) Plate Terminal INSTALL REAR END COVER Install the end cover and plate terminal with the 3 nuts and screw.0 N·m (20 kgf·cm.9 N·m (39 kgf·cm.1 N·m (42 kgf·cm. (b) Install the 5 screws. 18 in.·lbf) S05460 (c) Place the brush holder cover on the brush holder. Torque: Screw: 3. 39 in. Torque: 4.·lbf) S05072 5.·lbf) CHECK THAT ROTOR ROTATES SMOOTHLY S05071 Author : Date : 1778 .4 N·m (45 kgf·cm. Torque: 2.

CH–16 CHARGING (1MZ–FE) – GENERATOR CH01K–01 INSTALLATION Installation is in the reverse order of removal. (See page ST–5) Author : Date : 1779 .