CH02U–01 Z11577 Except Maintenance–Free Battery Z11556 Maintenance–Free Battery Voltmeter –CHARGING (5S–FE) CHARGING SYSTEM CH–1 1748AuthorĂ: DateĂ: CHARGING SYSTEM 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 giv- en a quick charge. z Do not perform tests with a high voltage insulation re- sistance tester. z Never disconnect the battery while the engine is run- ning. 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 wa- ter if possible). Check the charging system. Except Maintenance–Free Battery: If under the lower level, add distilled water. 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 bat- tery. 3. 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 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. (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. Z18811 Maintenance–Free Battery Type A Type B Blue White Red OK Charging Necessary Insufficient Water GREEN EYE DARK EYE CLEAR EYE or CHARGED DISCHARGED ADD WATER LIGHT YELLOW Z00015 Z00038 DENSO Borroughs CH0086 CORRECT WRONG CH–2 –CHARGING (5S–FE) CHARGING SYSTEM 1749AuthorĂ: DateĂ: 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 cor- roded. If the terminals are corroded, clean the terminals. (b) Check the fusible link, H–fuses, M–fuse and fuses for continuity. 5. INSPECT DRIVE BELTS (a) 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. (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: w/ A/C New belt Used belt 165 ± 25 lbf 110 ± 10 lbf w/o A/C New belt Used belt 125 ± 25 lbf 95 ± 20 lbf 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 run- ning 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. Z03473 Battery Voltmeter Generator Ammeter Disconnect Wire from Terminal B B –CHARGING (5S–FE) CHARGING SYSTEM CH–3 1750AuthorĂ: DateĂ: z After installing a new belt, run the engine for about 5 min- utes 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 warn- ing 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. 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 amme- ter to the charging circuit as follows: (1) Disconnect the wire from terminal B of the genera- tor, and connect it to the negative (–) tester probe of the ammeter. (2) Connect the positive (+) tester probe of the amme- ter to terminal B of the generator. (3) Connect the positive (+) tester probe of the voltme- ter to terminal B of the generator. (4) Ground the negative (–) tester probe of the voltme- ter. (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. P14433 Terminal F CH–4 –CHARGING (5S–FE) CHARGING SYSTEM 1751AuthorĂ: DateĂ: If the voltmeter reading is less than standard voltage, check the voltage regulator and generator as follows: z With terminal F grounded, start the engine and check the voltmeter reading of terminal B. z If the voltmeter reading is more than standard volt- age, replace the voltage regulator. z If the voltmeter reading is less than standard volt- age, check the generator. 9. 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 If the ammeter reading is less than the standard amperage, re- pair the generator. HINT: If the battery is fully charged, the indication will sometimes be less than standard amperage. CH02V–03 S05342 Pivot Bolt Adjusting Lock Bolt Generator Wire Generator Connector Generator Drive Belt Rubber Cap Wire Clamp S05076 Pulley Drive End Flame (Starter) z Front Bearing Bearing Cover Rotor Generator Washer Rectifier End Flame Wire Clip Rubber Insulator Rectifier Holder Voltage Regulator Seal Plate Brush Holder Brush Holder Cover Terminal Insulator Rear End Cover Plate Terminal z Non–reusable part Bearing Cover z Rear Bearing Bearing Cover –CHARGING (5S–FE) GENERATOR CH–5 1752AuthorĂ: DateĂ: GENERATOR COMPONENTS CH02W–03 B02375 B02376 B02377 B02693 w/o A/C w/ A/C Pivot Bolt Adjusting Bolt Adjusting Lock Bolt Pivot Bolt Adjusting Lock Bolt CH–6 –CHARGING (5S–FE) GENERATOR 1753AuthorĂ: DateĂ: REMOVAL 1. DISCONNECT CONNECTOR AND WIRE FROM GENERATOR (a) Disconnect the wire clamp from the wire clip on the rectifi- er end frame. (b) Disconnect the generator connector. (c) Remove the rubber cap and nut, and disconnect the gen- erator wire. 2. REMOVE GENERATOR (a) Loosen the adjusting lock bolt (w/ A/C), adjusting bolt and pivot bolt. Torque: Pivot bolt: 52 N·m (530 kgf·cm, 38 ft·lbf) Adjusting lock bolt (w/ A/C) or adjusting bolt (w/o A/C) 18 N·m (185 kgf·cm, 13 ft·lbf) (b) Remove the drive belt. (c) Remove the adjusting lock bolt (w/ A/C) or adjusting bolt (w/o A/C) and pivot bolt. (d) Remove the generator. CH02X–01 Z18635 Z18636 B02378 P13597 SST (B) SST (A) Turn P10834 SST (B) SST (C) Insert –CHARGING (5S–FE) GENERATOR CH–7 1754AuthorĂ: DateĂ: DISASSEMBLY 1. REMOVE REAR END COVER (a) Remove the nut and terminal insulator. (b) Remove the bolt, 3 nuts, plate terminal and end cover. 2. REMOVE BRUSH HOLDER AND VOLTAGE REGULATOR (a) Remove the brush holder cover from the brush holder. (b) Remove the 5 screws, brush holder and voltage regulator. (c) Remove the seal plate from the rectifier end frame. 3. REMOVE RECTIFIER HOLDER (a) Remove the 4 screws and rectifier holder. (b) Remove the 4 rubber insulators. 4. REMOVE PULLEY (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. (c) Mount SST (C) in a vise. (d) Insert SST (B) into SST (C), and attach the pulley nut to SST (C). P10827 SST (C) SST (A) Turn P13598 SST (B) SST (A) Turn S05070 P13490 SST CH–8 –CHARGING (5S–FE) GENERATOR 1755AuthorĂ: DateĂ: (e) 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 of a turn. (f) Remove the generator from SST (C). (g) Turn SST (B), and remove SST (A and B). (h) Remove the pulley nut and pulley. 5. REMOVE RECTIFIER END FRAME (a) Remove the 4 nuts and wire clip. (b) Using SST, remove the rectifier end frame. SST 09286–46011 (c) Remove the generator washer from the rotor. 6. REMOVE ROTOR FROM DRIVE END FRAME CH02Y–01 CH0784 Ohmmeter Continuity CH0783 Ohmmeter No Continuity CH1023 P13482 Ohmmeter Continuity P13565 Ohmmeter No Continuity –CHARGING (5S–FE) GENERATOR CH–9 1756AuthorĂ: DateĂ: INSPECTION 1. INSPECT ROTOR (a) Check the rotor for open circuit. Using an ohmmeter, check that there is continuity be- tween the slip rings. Standard resistance: 2.7 – 3.1 Ω at 20°C (68°F) If there is no continuity, replace the rotor. (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. (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. 2. INSPECT STATOR (DRIVE END FRAME) (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. (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. P13535 Length P13568 Ohmmeter Positive (+) Terminal Rectifier Terminal P13566 Ohmmeter Negative (–) Terminal CH–10 –CHARGING (5S–FE) GENERATOR 1757AuthorĂ: DateĂ: 3. INSPECT BRUSHES Using vernier calipers, measure the exposed brush length. Standard exposed length: 10.5 mm (0.413 in.) Minimum exposed length: 1.5 mm (0.059 in.) If the exposed length is less than minimum, replace the brush holder assembly. 4. INSPECT RECTIFIERS (RECTIFIRE HOLDER) (a) Check the positive (+) rectifire. (1) Using an ohmmeter, connect one tester probe to the positive (+) 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. If continuity is not as specified, replace the rectifier holder. (b) Check the negative (–) rectifire. (1) Using an ohmmeter, connect one tester probe to 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. If continuity is not as specified, replace the rectifier holder. 5. INSPECT BEARING Check the bearing is not rough or worn. If necessary, replace the bearing. (See page CH–11) [...]... N·m (42 kgf·cm, 36 in.·lbf) CHECK THAT ROTOR ROTATES SMOOTHLY Z18640 Z18635 7 S05069 AuthorĂ: DateĂ: 1762 CH–16 CHARGING (5S–FE) – GENERATOR CH031–01 INSTALLATION Installation is in the reverse order of removal (See page CH–6) AuthorĂ: DateĂ: 1763 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... Ammeter Disconnect Wire from Terminal B Battery Voltmeter 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: z Disconnect the wire from terminal B of the generator,... 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 AuthorĂ: DateĂ: 1766 CH–4 CHARGING (1MZ–FE) Terminal F P14228 – CHARGING SYSTEM If the voltmeter... belt, check that it fits properly in the ribbed grooves Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley AuthorĂ: DateĂ: 1765 CH–3 CHARGING (1MZ–FE) – CHARGING SYSTEM z 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... cover (inside) Place the bearing cover (inside) on the rotor P13567 AuthorĂ: DateĂ: 1758 CH–12 CHARGING (5S–FE) – GENERATOR (d) Using SST and a press, press in a new bearing SST 09820–00030 (e) Using SST, push in the bearing cover (outside) SST 09285–76010 SST N00578 SST P00074 AuthorĂ: DateĂ: 1759 CH–13 CHARGING (5S–FE) – GENERATOR CH030–01 REASSEMBLY 1 (a) (b) 2 (a) INSTALL RECTIFIER END FRAME Place... 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 AuthorĂ: DateĂ: 1764 CH–2 CHARGING (1MZ–FE) DARK EYE CHARGED CHARGING SYSTEM 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... reading is less than standard voltage, check the generator 9 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 If the ammeter reading is less than the standard amperage, repair the generator HINT: If the battery is fully charged, the... SST N00581 (c) Place the bearing cover (inside) on the rotor P13567 AuthorĂ: DateĂ: 1774 CH–12 CHARGING (1MZ–FE) – GENERATOR (d) Using SST and a press, press in a new bearing SST 09820–00030 (e) Using SST, push in the bearing cover (outside) SST 09285–76010 SST N00578 SST P00074 AuthorĂ: DateĂ: 1775 CH–13 CHARGING (1MZ–FE) – GENERATOR CH01J–01 REASSEMBLY 1 (a) (b) 2 (a) INSTALL RECTIFIER END FRAME Place... rubber insulators installation direction Inside S05075 (b) Push Install the rectifier holder while pushing it with the 4 screws Torque: 2.9 N·m (30 kgf·cm, 26 in.·lbf) S05074 AuthorĂ: DateĂ: 1761 CH–15 CHARGING (5S–FE) 5 (a) – GENERATOR INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER Place the seal plate on the rectifier end frame Z18638 (b) Upward Place the voltage regulator and brush holder on the rectifier...CH–11 CHARGING (5S–FE) – GENERATOR CH02Z–01 REPLACEMENT 1 (a) REPLACE FRONT BEARING Remove the 4 screws, bearing retainer and bearing (b) Using a socket wrench and press, press out the bearing (c) Using SST . Maintenance–Free Battery Z11556 Maintenance–Free Battery Voltmeter CHARGING (5S–FE) CHARGING SYSTEM CH–1 1748AuthorĂ: DateĂ: CHARGING SYSTEM ON–VEHICLE INSPECTION CAUTION: z Check that the battery. Red OK Charging Necessary Insufficient Water GREEN EYE DARK EYE CLEAR EYE or CHARGED DISCHARGED ADD WATER LIGHT YELLOW Z00015 Z00038 DENSO Borroughs CH0086 CORRECT WRONG CH–2 CHARGING (5S–FE) CHARGING. Maintenance–Free Battery Z11556 Maintenance–Free Battery Voltmeter CHARGING (1MZ–FE) CHARGING SYSTEM CH–1 1764AuthorĂ: DateĂ: CHARGING SYSTEM ON–VEHICLE INSPECTION CAUTION: z Check that the battery