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2AZ-FE Charging PDF
2AZ-FE Charging PDF
CHARGING SYSTEM
PRECAUTION
1. Check that the battery cables are connected to the
correct terminals.
2. Disconnect the battery cables when the battery is
given a quick charge.
3. Do not perform tests with a high voltage insulation
resistance tester.
4. Never disconnect the battery while the engine is
running.
5. Check that the charging cable nut is tightened on
terminal B of the generator and the engine room R/B.
CH
CH2 2AZ-FE CHARGING CHARGING SYSTEM
PARTS LOCATION
COMBINATION METER
GENERATOR
-ALT-S FUSE
A135520E01
CH
2AZ-FE CHARGING CHARGING SYSTEM CH3
SYSTEM DIAGRAM
ECM
ALT-S
From Battery
GAUGE No. 1
From IG1 Relay
Combination Meter
Generator
ALT 1 4
B L
C19 C18
2
IG
C18
IC
Regulator
1
S
C18
FL MAIN 50
3
M
C18 C24 ALT
Battery
A135064E01
CH
CH4 2AZ-FE CHARGING CHARGING SYSTEM
CH
2AZ-FE CHARGING CHARGING SYSTEM CH5
ON-VEHICLE INSPECTION
1. CHECK BATTERY ELECTROLYTE LEVEL
(a) Check the electrolyte level.
(1) If the electrolyte level is low, replace the battery
(or add distilled water) and check the charging
system.
2. CHECK BATTERY SPECIFIC GRAVITY
(a) Check the color of the indicator.
Green Dark Clear or Light Yellow Result
Indicator color Condition
Green Good
Dark Charging necessary
Clear or light yellow Replacement necessary
CH
CH8 2AZ-FE CHARGING CHARGING SYSTEM
(a) Check the lock function with the pulley installed in the
vehicle.
(1) Visually check that the rotor in the generator
operates with the engine started.
(b) Check the lock function with the pulley removed from the
vehicle.
(1) Remove the generator pulley cap. Using SST, hold
the generator rotor.
(2) Turn the clutch pulley clockwise and check that the
outer ring locks.
OK:
The outer ring locks.
Free Lock
SST 09820-63020
NG REPLACE CLUTCH PULLEY
A130538E01
OK
OK
CH
2AZ-FE CHARGING CHARGING SYSTEM CH9
OK
OK
(a) Check the clutch pulley groove for wear or other defects.
OK:
The clutch pulley groove is not damaged.
NG REPLACE CLUTCH PULLEY
OK
OK
CH
REPLACE GENERATOR ASSEMBLY
2AZ-FE CHARGING GENERATOR CH9
GENERATOR
2AZ-FE CHARGING
ENGINE
COMPONENTS
V-RIBBED BELT
52 (530, 38)
21 (215, 16)
GENERATOR ASSEMBLY
A133568E01
CH
CH10 2AZ-FE CHARGING GENERATOR
GENERATOR WASHER
x4
BEARING
RETAINER PLATE
GENERATOR DRIVE
111 (1,125, 81)
END FRAME BEARING
GENERATOR
CLUTCH PULLEY
GENERATOR
PULLEY CAP GENERATOR DRIVE END FRAME
GENERATOR BRUSH
HOLDER ASSEMBLY
GENERATOR TERMINAL
INSULATOR 1.8 (18, 16 in.*lbf)
x3
x2
GENERATOR REAR
END COVER
CH
N*m (kgf*cm, ft.*lbf) : Specified torque
Non-reusable part
A135515E01
2AZ-FE CHARGING GENERATOR CH11
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2. REMOVE FRONT WHEEL RH
3. REMOVE ENGINE UNDER COVER RH
4. REMOVE FRONT FENDER APRON SEAL RH
5. REMOVE V-RIBBED BELT (See page EM-6)
6. REMOVE GENERATOR ASSEMBLY
(a) Disconnect the generator connector.
(b) Remove the nut and disconnect the wire harness
from terminal B.
(c) Remove the bolt and wire harness clamp bracket.
(d) Remove the wire harness clamps.
A135170
A133567
DISASSEMBLY
1. REMOVE GENERATOR CLUTCH PULLEY
(a) Using a screwdriver, puncture the center of the
generator pulley cap and pry it off.
NOTICE:
Do not reuse the generator pulley cap.
A126771
CH
A124115E01
CH12 2AZ-FE CHARGING GENERATOR
Rotor Shaft
SST (A)
SST (B)
A128605E01
SST (B)
SST (B)
A128606E01
SST (B)
A128607E01
A128608
CH
A128610
2AZ-FE CHARGING GENERATOR CH13
A128609
A128611
A128612
A128613
SST
A128614E01
CH14 2AZ-FE CHARGING GENERATOR
A118365E01
A128615
A128617
SST
A128618E01
INSPECTION
1. INSPECT GENERATOR CLUTCH PULLEY
(a) Hold the center of the pulley, and confirm that the
Free Lock outer ring turns counterclockwise and does not turn
CH clockwise.
If the result is not as specified, replace the
generator pulley with clutch.
A130538E01
2AZ-FE CHARGING GENERATOR CH15
A079305E04
A097469E01
A097476E02
A097477E02
A097471E01
REASSEMBLY
SST
1. INSTALL GENERATOR DRIVE END FRAME
BEARING
(a) Using SST and a press, press in a new generator
drive end frame bearing.
SST 09950-60010 (09951-00250), 09950-70010
(09951-07100)
A128619E01
(b) Fit the tabs on the retainer plate into the cutouts on
the drive end frame to install the retainer plate.
(c) Install the 4 screws.
Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf)
Tab
2. INSTALL GENERATOR ROTOR ASSEMBLY
(a) Place the drive end frame on the clutch pulley.
Cutout
A128620E01
A128615
CH
A118365E01
2AZ-FE CHARGING GENERATOR CH17
A128621E01
A128612
A128613
A079315E04
CH
A128622
CH18 2AZ-FE CHARGING GENERATOR
A130537E01
A128623
A128610
SST (B)
A128084E01
Rotor Shaft
SST (A)
CH
SST (B)
A128605E01
2AZ-FE CHARGING GENERATOR CH19
SST (B)
SST (B)
A128606E01
A097394E03
A A133567E01
CH
CH20 2AZ-FE CHARGING GENERATOR
CH