CH–4

CHARGING (2RZ–FE, 3RZ–FE) – GENERATOR

GENERATOR
CH00O–02

COMPONENTS

Generator Wire

Generator Connector
Adjusting Lock Bolt

Adjusting Bolt Generator

Pivot Bolt

Drive Belt
B00775

Bearing Cover
Rotor

Retainer
Drive End Frame (Stator) Alternator Washer

Pulley
Rear Bearing

Front Bearing Brush Holder Cover

Brush Holder
Terminal Insulator

Rectifier End Frame Spring

Brush Rear End Cover
Voltage Regulator

Rectifier Holder

Non–reusable part B00776

TOYOTA TACOMA (RM1002U)

Author: Date: 1564

CH–6
CHARGING (2RZ–FE, 3RZ–FE) – GENERATOR
CH00Q–03

DISASSEMBLY
1. REMOVE REAR END COVER
(a) Remove the nut and terminal insulator.

B00761

(b) Remove the 3 nuts, and end cover.

B00762

2. REMOVE BRUSH HOLDER AND VOLTAGE REGULA-

TOR
Remove the 5 screws, bush holder and voltage regulator.

B00763

3. REMOVE RECTIFIER HOLDER

Remove the bolt, 4 screws and rectifier holder.

B00764

SST (A) 4. REMOVE PULLEY

SST (B) (a) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
SST 09820–63010
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Check that SST (A) is secured to the rotor shaft.

B00765

TOYOTA TACOMA (RM1002U)

Author: Date: 1566

CH–8
CHARGING (2RZ–FE, 3RZ–FE) – GENERATOR

INSPECTION
1. INSPECT VOLTEGE REGULATOR
Ohmmeter (a) Using an ohmmeter, check the continuity between termi-
nals F and B.
F Standard:
B When the positive and negative poles between termi-
nals F and B are exchanged, there is continuity in one
way but no continuity in another way.
B15877
If the continuity is not as specified, replace the regulator.
CH0L2–01

(b) Using an ohmmeter, check the continuity between termi-

E nals F and E.
Standard:
Ohmmeter
When the positive and negative poles between termi-
nals F and E are exchanged, there is continuity in one
way but no continuity in another way.
If the continuity is not as specified, replace the regulator.
F
B15878

Ohmmeter 2. INSPECT ROTOR

(a) Check the rotor for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the slip rings.
Standard resistance: 2.1 – 2.5 Ω at 20°C (68°F)
If there is no continuity, replace the rotor.

Continuity
CH0784

(b) Check the rotor for ground.

Using an ohmmeter, check that there is no continuity be-
tween the slip ring and rotor.
If there is continuity, replace the rotor.
Ohmmeter

No Continuity
B02105

(c) Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor.
(d) Using vernier calipers, measure the slip ring diameter.
Standard diameter: 14.2 – 14.4 mm (0.559 – 0.567 in.)
Minimum diameter: 12.8 mm (0.504 in.)
If the diameter is less than minimum, replace the rotor.

CH1023

TOYOTA TACOMA (RM1002U)

Author: Date: 1568

 CH–9
CHARGING (2RZ–FE, 3RZ–FE) – GENERATOR

3. INSPECT STATOR (DRIVE END FRAME)

Ohmmeter
(a) Check the stator for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the coil leads.
If there is no continuity, replace the drive end frame assembly.

Continuity P14468

Ohmmeter (b) Check the stator for ground.

Using an ohmmeter, check that there is no continuity be-
tween the coil lead and drive end frame.
If there is continuity, replace the drive end frame assembly.

No Continuity
P14469

4. INSPECT BRUSHES
Using a scale, measure the exposed brush length.
Standard exposed length:
9.5 – 11.5 mm (0.374 – 0.453 in.)
Minimum exposed length: 1.5 mm (0.059 in.)
If the exposed length is less than minimum, replace the brushes
(See page CH–11).

P13395

5. INSPECT RECTIFIERS (RECTIFIRE HOLDER)

Ohmmeter (a) Check the positive (+) rectifire.
Positive (+)
(1) Using an ohmmeter, connect one tester probe to the
Terminal
positive (+) terminal and the other to each rectifier
Rectifier
terminal.
Terminal
(2) Reverse the polarity of the tester probes and repeat
step (a).
(3) Check that one shows continuity and the other
B00769 shows no continuity.
If continuity is not as specified, replace the rectifier holder.
Ohmmeter (b) Check the negative (–) rectifire.
Negative (–) (1) Using an ohmmeter, connect one tester probe to
Terminal each negative (–) terminal and the other to each
rectifier terminal.
(2) Reverse the polarity of the tester probes and repeat
step (a).
(3) Check that one shows continuity and the other
shows no continuity.
B00770 If continuity is not as specified, replace the rectifier holder.

TOYOTA TACOMA (RM1002U)

Author: Date: 1569

CH–10
CHARGING (2RZ–FE, 3RZ–FE) – GENERATOR

6. INSPECT BEARING
Check the bearing is not rough or worn.
If necessary, replace the bearing (See page CH–11).

TOYOTA TACOMA (RM1002U)

Author: Date: 1570

 CH–13
CHARGING (2RZ–FE, 3RZ–FE) – GENERATOR
CH0CP–02

REASSEMBLY
1. PLACE DRIVE END FRAME ON PULLEY
2. INSTALL ROTOR TO DRIVE END FRAME
3. INSTALL RECTIFIER END FRAME
(a) Place the generator washer on the rotor.

P25981

29 mm (b) Using a 29 mm socket wrench and press, slowly press in

Socket the rectifier end frame.
Wrench
(c) Install the 4 nuts.
Torque: 4.5 N·m (46 kgf·cm, 40 in.·lbf)

B00774

4. INSTALL PULLEY
SST (A)
SST (B) (a) Install the pulley to the rotor shaft by tightening the pulley
nut by hand.
(b) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
Turn SST 09820–63010
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(c) Check that SST (A) is secured to the pulley shaft.
B00765

(d) Mount SST (C) in a vise.

(e) Install the generator to SST (C).

SST (C)

P04210

(f) To torque the pulley nut, turn SST (A) in the direction
shown in the illustration.
SST (C) Torque: 110 N·m (1,125 kgf·cm, 81 ft·lbf)
(g) Remove the generator from SST (C).

Turn SST (A)

P04395

TOYOTA TACOMA (RM1002U)

Author: Date: 1573

CH–14
CHARGING (2RZ–FE, 3RZ–FE) – GENERATOR

SST (A) (h) Turn SST (B), and remove SST (A and B).
SST (B)

Turn

B00766

5. INSTALL RECTIFIER HOLDER

Install the rectifier holder with the bolt and 4 screws.
Torque:
1.96 N·m (20 kgf·cm, 17.4 in.·lbf) for screw
3.9 N·m (40 kgf·cm, 34.7 in.·lbf) for bolt

B00764

6. INSTALL VOLTAGE REGULATOR AND BRUSH HOLD-

Upward
ER
(a) Install the brush holder cover to the brush holder.
NOTICE:
Be careful of the holder installation direction.
(b) Place the voltage regulator together with the brush holder
horizontally on the rectifier end frame.
Protrusion
Z10167

(c) Install the 5 screws until there is a clearance of approx. 1

mm (0.04 in.) between the brush holder and connector.
1 mm Torque: 1.96 N·m (20 kgf·cm, 17.4 in.·lbf)

B00773

7. INSTALL REAR END COVER

(a) Install the end cover with the 3 nuts.
Torque: 4.5 N·m (46 kgf·cm, 40 in.·lbf)
(b) Install the terminal insulator with the nut.
Torque: 4.1 N·m (42 kgf·cm, 36 in.·lbf)
8. CHECK THAT ROTOR ROTATES SMOOTHLY

B00762

TOYOTA TACOMA (RM1002U)

Author: Date: 1574

 CH–5
CHARGING (2RZ–FE, 3RZ–FE) – GENERATOR
CH0CM–01

REMOVAL
1. DISCONNECT GENERATOR CONNECTOR AND WIRE
(a) Disconnect the generator connector.
(b) Remove the nut, and disconnect the generator wire.
Torque: 9.8 N·m (100 kgf·cm, 7.2 ft·lbf)
(c) Disconnect the wire harness with the clip.

2. REMOVE GENERATOR DRIVE BELT

Adjust Bolt (a) Loosen the adjusting lock bolt and pivot bolt.
(b) Loosen the adjusting bolt, and remove the drive belt.
3. REMOVE GENERATOR
(a) Remove the pivot bolt and adjusting lock bolt.
Torque:
59 N·m (600 kgf·cm, 43 ft·lbf) for pivot bolt
Lock Bolt 29 N·m (300 kgf·cm, 21 ft·lbf) for adjusting lock bolt
Pivot Bolt B00759 (b) Remove the generator.

TOYOTA TACOMA (RM1002U)

Author: Date: 1565