CH−1

CHARGING (1GR−FE) − CHARGING SYSTEM

CHARGING SYSTEM CH0N5−01

ON−VEHICLE INSPECTION
CAUTION:

Check that the battery cables are connected to the
correct terminals.

Disconnect the battery cables when the battery is giv-
en a quick charge.

Do not perform tests with a high voltage insulation re-
sistance tester.

Never disconnect the battery while the engine is run-
ning.
1. CHECK BATTERY ELECTROLYTE LEVEL
(a) Check the electrolyte quantity of each cell (Maintenance−
Free Battery).
If under the lower level, replace the battery (or add distilled wa-
ter if possible) and check the charging system.

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(b) Check the electrolyte quantity of each cell (Except Main-
tenance−Free Battery).
If under the lower level, add distilled water.
2. CHECK BATTERY SPECIFIC GRAVITY
(Except Maintenance−Free Battery)
(a) Check the specific gravity of each cell.
Standard specific gravity: 1.25 to 1.29 at 20C (68F)
HINT:
If the specific gravity is less than specification, charge the bat-
tery.

A01259

3. CHECK BATTERY VOLTAGE

(a) After having driven the vehicle and in the case that 20
minutes have not passed after having stopped the en-
gine, 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 sys-
tems.
A01260 (c) Measure the battery voltage between the negative (−)
and positive (+) terminals of the battery.
Standard voltage: 12.5 to 12.9 V at 20C (68F)
HINT:
If the voltage is less than specification, charge the battery.
CH−2
CHARGING (1GR−FE) − CHARGING SYSTEM

(d) Check the indicator as shown in the illustration.

HINT:

Blue: OK

White: Charging Necessary

Red: Insufficient Water
4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND
FUSES
(a) Check that the battery terminals are not loose or cor-
Z11580 roded.
(b) Check the fusible link, H−fuses and fuses for continuity.
5. INSPECT DRIVE BELT
(a) Visually check the belt for excessive wear, frayed cords
etc.
HINT:

If any defect has been found, replace the drive belt.

Cracks on the rib side of a belt are considered acceptable.
If the belt has chunks missing from the ribs, it should be

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replaced.
B00543

(b) Check that it fits properly in the ribbed grooves.

HINT:
Check with your hand to confirm that the belt has not slipped out
of the groove on the bottom of the pulley.
6. VISUALLY CHECK GENERATOR WIRING
(a) Check that the wiring is in good condition.
7. LISTEN FOR ABNORMAL NOISES FROM GENERA-
TOR
B00540 (a) Check that there is no abnormal noise from the generator
while the engine is running.
8. INSPECT CHARGE WARNING LIGHT CIRCUIT
(a) Turn the ignition switch ON. Check that the charge warn-
ing light comes on.
(b) Start the engine. Check that the light goes off.
HINT:
If the light does not operate as specified, troubleshoot the
charge warning light circuit.
9. INSPECT CHARGING CIRCUIT WITHOUT LOAD
(a) If a battery/generator tester is available, connect the tes-
ter to the charging circuit as per manufacturer’s instruc-
tions.
 CH−3
CHARGING (1GR−FE) − CHARGING SYSTEM

Ammeter (b) If a tester is not available, connect a voltmeter to the

Disconnect Wire charging circuit as follows.
from Terminal B (1) Disconnect to the wire from terminal B of the gener-
ator and connect it to the negative (−) lead of the
Battery ammeter.
(2) Connect the positive (+) lead of the ammeter to ter-
B
minal B of the generator.
Generator
Voltmeter
(3) Connect the positive (+) lead of the voltmeter to ter-
Z10324 minal B of the generator.
(4) Ground the negative (−) lead of the voltmeter.
(c) Check the charging circuit.
(1) With the engine running from idle to 2,000 rpm,
check the reading on the ammeter and voltmeter.
Standard amperage: 10 A or less
Standard voltage: 13.2 to 14.8 V
HINT:

If the voltmeter reading is more than standard voltage, re-

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place the voltage regulator.

If the voltmeter reading is less than the standard voltage,
check the voltage regulator and generator as follows:
10. INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn on the high
beam headlights and place the heater blower switch at
”HI”.
(b) Check the reading on the ammeter.
Standard amperage: 30 A or more
HINT:

If the ammeter reading is less than standard amperage,
repair the generator.

If the battery is fully charged, the indication will sometimes
be less than standard amperage.
CH−4
CHARGING (1GR−FE) − GENERATOR

GENERATOR
CH0N6−01

COMPONENTS

9.8 (100, 87 in.·lbf)

V−Bank Cover

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Battery Clamp

Battery Tray

Battery Tray
Engine Under Cover

x5

N·m (kgf·cm, ft·lbf) : Specified torque B17628

 CH−5
CHARGING (1GR−FE) − GENERATOR

Drive Belt

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Generator 9.8 (100, 87 in.·lbf)

43 (438, 32)

Generator Wire

Generator Connector

A/C Compressor

8.0 (82, 71 in.⋅lbf)

Wire Harness Clamp Bracket

25 (255, 18)

8.0 (82, 71 in.⋅lbf)

A/C Compressor
Connector

N·m (kgf·cm, ft·lbf) : Specified torque

B17629
CH−6
CHARGING (1GR−FE) − GENERATOR

Generator
Bearing Cover

Generator
Drive End Frame Bearing
2.6 (27, 23 in.⋅lbf)

x4 Washer

Generator
Generator Pulley Rotor Bearing

Generator Rotor Assy

Retainer Plate

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Drive End Frame Assy
110 (1,122, 81) Generator

4.6 (47, 41 in.⋅lbf)

Terminal Insulator Generator

Generator Plate Seal
Brush Holder Assy
5.8 (59, 51 in.⋅lbf)

x4

1.8 (18, 16 in.⋅lbf)

Generator
Rear End Cover
Generator
Plate Seal

Generator Coil Assy

N·m (kgf·cm, ft·lbf) : Specified torque

Non−reusable part A23182
 CH−7
CHARGING (1GR−FE) − GENERATOR
CH0N7−01

REMOVAL
1. REMOVE V−BANK COVER
2. REMOVE ENGINE UNDER COVER
Remove the 4 bolts and engine under cover.
3. REMOVE FAN AND GENERATOR V BELT
(See page EM−62)
4. REMOVE BATTERY

5. REMOVE GENERATOR
(a) Disconnect the wire harness.
(1) Remove the bolt and wire harness stay.
(2) Disconnect the connector from the generator.
(3) Remove the terminal cap and nut.
(4) Disconnect the wire harness from the terminal B.

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B17624

(b) Remove the 2 bolts and wire harness clamp bracket from
the generator assy.

B17625

(c) Remove the 2 bolts and generator.

B17626
CH−8
CHARGING (1GR−FE) − GENERATOR
CH0N8−01

SST (A) DISASSEMBLY

1. REMOVE GENERATOR PULLEY
SST (B)
SST 09820−63011
(a) Hold SST (A) with a torque wrench, and tighten SST (B)
Turn
clockwise with the specified torque.
Hold
Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf)
NOTICE:
Check that SST is secured to the rotor shaft.
B17632

(b) Mount SST 2 in a vise.

(c) Insert SST (A) and (B) into SST (C), and attach the pulley
nut to SST (C).

Insert SST (C)

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B17633

(d) To loosen the pulley nut, turn SST (A) in the direction
shown in the illustration.
NOTICE:
To prevent damage to the rotor shaft, do not loosen the
pulley nut more than one−half turn.
(e) Remove the generator from SST (C).

Turn
B17634

SST (A) (f) Turn SST (B), and remove SST (A) and (B).
(g) Remove the pulley nut and pulley.

SST (B)
Hold
Turn

B17635

2. REMOVE GENERATOR REAR END COVER

(a) Place the generator on the pulley.
(b) Remove the 3 nuts and rear end cover.
Pulley

B17636
 CH−9
CHARGING (1GR−FE) − GENERATOR

3. REMOVE TERMINAL INSULATOR

B17637

4. REMOVE GENERATOR BRUSH HOLDER ASSY

(a) Remove the plate seal.
(b) Remove the 2 nuts and brush holder.
(c) Remove the plate seal.

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B17638

5. REMOVE GENERATOR COIL ASSY

(a) Remove the 4 bolts.

B17639

(b) Using SST, remove the coil.

SST Turn
SST 09950−40011 (09951−04020, 09952−04010,
09953−04020, 09954−04010, 09955−04071,
09957−04010, 09958−04011)

Hold

B17640

6. REMOVE GENERATOR ROTOR ASSY

(a) Remove the washer and rotor.

B17641
CH−10
CHARGING (1GR−FE) − GENERATOR
CH0N9−01

Ohmmeter
INSPECTION
1. INSPECT ROTOR
(a) Check the rotor for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the slip rings.
Continuity Standard resistance: 2.3 to 2.7 Ω at 20°C (68°F)
If there is no continuity, replace the rotor.

B12264

(b) Check the rotor for ground.

Ohmmeter
Using an ohmmeter, check that there is no continuity be-
tween the slip ring and rotor.
If there is continuity, replace the rotor.
(c) Check that the slip rings are not rough or scored.
No Continuity If rough or scored, replace the rotor.

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B12265

(d) Using vernier calipers, measure the slip ring diameter.

Standard diameter: 14.2 to 14.4 mm (0.559 to 0.567 in.)
Minimum diameter: 14.0 mm (0.551 in.)
If the diameter is less than the minimum, replace the rotor.

B17642

2. INSPECT BRUSHES
Using vernier caliper, measure the exposed brush length.
Standard exposed length: 10.5 mm (0.413 in.)
Length Minimum exposed length: 4.5 mm (0.177 in.)
If the exposed length is less than the minimum, replace the
brushes and the brush holder assembly.
3. INSPECT BEARING
Check the bearing is not rough or worn.
B16374 If necessary, replace the bearing (See page CH−11).
 CH−11
CHARGING (1GR−FE) − GENERATOR
CH0NA−01

REPLACEMENT
1. INSPECT GENERATOR ROTOR BEARING
(a) Check the bearing is not rough or worn.
If necessary, replace the bearing.

B17643

2. REMOVE GENERATOR ROTOR BEARING

SST
Turn SST 09820−00021
NOTICE:
Hold Be careful not to damage the fan.
(a) Remove the bearing cover (Inside).

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B17644

3. INSTALL GENERATOR ROTOR BEARING

SST
(a) Place the rotor on the pulley.
(b) Install the bearing cover (Inside).
(c) Using SST and a press, press in a new bearing.
SST 09820−00031

Pulley B17645

(d) Using SST, push in the bearing cover (outside).

SST SST 09285−76010

B17646

4. INSPECT GENERATOR DRIVE END FRAME BEARING

(a) Check the bearing is not rough or worn.
If necessary, replace the bearing.

B17647
CH−12
CHARGING (1GR−FE) − GENERATOR

5. REMOVE GENERATOR DRIVE END FRAME BEARING

(a) Remove the 4 screws and retainer plate.

B17648

(b) Using SST, tap out the bearing.

SST 09950−60010 (09951−00250), 09950−70010
(09951−07100)

SST

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B17649

6. INSTALL GENERATOR DRIVE END FRAME BEARING

(a) Using SST and a press, press in a new bearing.
SST 09950−60010 (09951−00470), 09950−70010
SST (09951−07100)
(b) Install the retainer plate with the 4 screws.
Torque: 2.6 N⋅m (27 kgf⋅cm, 23 in.⋅lbf)

B17650
 CH−13
CHARGING (1GR−FE) − GENERATOR
CH0NB−01

REASSEMBLY
1. INSTALL GENERATOR ROTOR ASSY
(a) Place the drive end frame on the rotor.
(b) Install the rotor and washer.

B17641

2. INSTALL GENERATOR COIL ASSY

SST
(a) Using SST and a press, press in the coil carefully.
SST 09285−76010
(b) Install the 4 bolts.
Torque: 5.8 N⋅m (59 kgf⋅cm, 51 in.⋅lbf)

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B17651

3. INSTALL GENERATOR BRUSH HOLDER ASSY

Pin (a) Install the plate seal (Inside).
(b) Place the brush holder with the pin facing upward.
NOTICE:
Be careful of the brush holder installing direction.
(c) Install the 2 screws.
Torque: 1.8 N⋅m (18 kgf⋅cm, 16 in.⋅lbf)
(d) Align the pins of the brush holder with the holes of the
B17638 plate seal (outside), and install the plate seal (outside).

4. INSTALL TERMINAL INSULATOR

B17637

5. INSTALL GENERATOR REAR END COVER

(a) Install the rear end cover with the 3 nuts.
Torque: 4.6 N⋅m (47 kgf⋅cm, 41 in.⋅lbf)

B17636
CH−14
CHARGING (1GR−FE) − GENERATOR

SST (A) 6. INSTALL GENERATOR PULLEY

SST 09820−63011
SST (B) (a) Install the pulley to the rotor shaft by tightening the pulley
nut by hand.
Turn (b) Hold SST (A) with a torque wrench, and tighten SST (B)
Hold clockwise with the specified torque.
Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf)
NOTICE:
B17632 Check that SST is secured to the rotor shaft.

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

(d) Insert SST (A) and (B) into SST (C), and attach the pulley
nut to SST (C)

Insert SST (C)

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B17633

(e) Tighten the pulley nut by turning SST (A) in the direction
shown in the illustration.
Torque: 111 N⋅m (1,125 kgf⋅cm, 81 ft⋅lbf)
(f) Remove the generator from SST (C).

Turn

B17657

SST (A)
(g) Turn SST (B), and remove SST (A), (B).
(h) Turn the pulley, and check that the pulley moves smooth-
ly.

SST (B)
Hold
Turn

B17635
 CH−15
CHARGING (1GR−FE) − GENERATOR
CH0NC−01

INSTALLATION
1. INSTALL GENERATOR
(a) Install the generator with the 2 bolts.
Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf)

B17626

(b) Install the wire harness clamp bracket with the 2 bolts.
Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf)

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B17625

(c) Connect the wire harness.

(1) Connect the wire harness to the terminal B and
install the nut.
Torque: 9.8 N⋅m (100 kgf⋅cm, 7 ft⋅lbf)
(2) Connect the connector to the generator assy.
(3) Install the wire harness stay with the bolt.
Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf)
2. INSTALL BATTERY
B17624 3. INSTALL FAN AND GENERATOR V BELT
(See page EM−89)
4. INSTALL ENGINE UNDER COVER SUB−ASSY NO.1
Install the engine under cover sub−assy No. 1 with the 4 bolts.
Torque: 29 N⋅m (296 kgf⋅cm, 21 ft⋅lbf)
5. INSTALL V−BANK COVER
Install the V−bank cover with the 2 nuts.
Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf)