1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine CH02H−02
− CHARGING (3RZ−FE)GENERATOR
CH−17
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page CH−7).

Downloaded from www.Manualslib.com manuals search engine CH – CHARGING (5VZ-FE)

CHARGING SYSTEM CH-1
GENERATOR CH-5

Downloaded from www.Manualslib.com manuals search engine CH02P−03
S05376
Except Maintenance−Free Battery
Z18827
Voltmeter Maintenance−Free Battery
− CHARGING (5VZ−FE)CHARGING SYSTEM
CH−1
1220 Author: Date:
1996 TOYOTA T100 (RM449U)
CHARGING SYSTEM
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
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.
Except Maintenance−Free Battery:
If under the lower level, add distilled water.
2. Except Maintenance−Battery:
CHECK BATTERY SPECIFIC GRAVITY
Check the specific gravity of each cell.
Standard specific gravity: At 20°C (68°F): 1.25 − 1.29
If the specific gravity is less than specification, charge the bat-
tery.
3. Maintenance−Free Battery:
CHECK BATTERY VOLTAGE
Measure the battery voltage between the negative (−) and posi-
tive (+) terminals of the battery.
Standard voltage: At 20°C (68°F): 12.7 − 12.9 V
HINT:
Before measuring the voltage, turn the ignition switch
OFF and turn off the electrical systems (headlight, blower
motor, rear defogger etc.) for 60 seconds to remove the
surface charge.

Downloaded from www.Manualslib.com manuals search engine P15119
P06717
Z00038
Nippondenso Borroughs CH−2
− CHARGING (5VZ−FE)CHARGING SYSTEM
1221 Author: Date:
1996 TOYOTA T100 (RM449U)
When measuring the voltage, however, turn the ignition
switch OFF and turn off the electrical systems.
If the voltage is less than the specification, charge the battery.
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.
(b) Check the fusible link and fuses for continuity.
5. INSPECT DRIVE BELT
(a) Visually check the belt for excessive wear, frayed cords
etc.
HINT:
Cracks on the ribbed side of the belt are considered acceptable.
If the belt has chunks missing from the ribs, it should be re-
placed.
(b) Using a belt tension gauge, check the drive belt tension.
Belt tension gauge:
Nippondenso BTG 20 (95506−00020) or
Borroughs No. BT−33−73F
Drive belt tension:
New belt: 160 ± 20 lbf
Used belt: 100 ± 20 lbf
If necessary, adjust the drive belt tension.

Downloaded from www.Manualslib.com manuals search engine P06723
CORRECT WRONG WRONG
− CHARGING (5VZ−FE)CHARGING SYSTEM
CH−3
1222 Author: Date:
1996 TOYOTA T100 (RM449U)
HINT:
”New belt” refers to a belt which has been used less than
5 minutes on a running engine.
”Used belt” refers to a belt which has been used on a run-
ning engine for 5 minutes or more.
After installing the drive 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 crank pulley.
After installing a new belt, run the engine for approx. 5
minutes and then recheck the tension.
6. INSPECT FUSES FOR CONTINUITY
ENGINE 10A
CHARGE 7.5A
IGN 7.5A
7. VISUALLY CHECK GENERATOR WIRING AND LIS-
TEN 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.
8. CHECK CHARGING CIRCUIT WITHOUT LOAD
HINT:
If a battery/generator tester is available, connect the tester to
the charging circuit according to the manufactuer’s instructions.
(a) If a tester is not available, connect a voltmeter and amme-
ter to the charging circuit as follows:
Disconnect the wire from terminal B of the generator
and connect the wire to the negative (−) terminal of
the ammeter.
Connect the test lead from the positive (+) terminal
of the ammeter to terminal B of the generator.
Connect the positive (+) lead of the voltmeter to ter-
minal B of the generator.
Ground the negative (−) lead 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:
At 25 °C (77 °F): 14.0 − 15.0 V
At 115 °C (239 °F): 13.5 − 14.3 V
If the voltage reading is greater than the standard voltage, re-
place the voltage regulator.

Downloaded from www.Manualslib.com manuals search engine P20582
Terminal F
CH−4
− CHARGING (5VZ−FE)CHARGING SYSTEM
1223 Author: Date:
1996 TOYOTA T100 (RM449U)
If the voltage reading is less than the standard voltage, check
the voltage regulator and generator as follows:
With terminal F grounded, start the engine and
check the voltage reading of terminal B.
If the voltage reading is higher than the standard
voltage, replace the voltage regulator.
If the voltage reading is less than the standard volt-
age, repair 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 fan control switch
to HI.
(b) Check the reading on the ammeter.
Standard amperage: 30 A or more
If the ammeter reading is less than standard amperage, repair
the generator.
HINT:
If the battery is fully charged, the indication will sometimes be
less than standard amperage.

Downloaded from www.Manualslib.com manuals search engine CH02J−05
P20588
S05685
Generator WasherPulley
Drive End Frame (Starter)
Retainer
Front Bearing
Rotor
Rear Bearing
Bearing
Cover
(inside)
Bearing
Cover
(outside)
Rear End Cover
Brush Holder Cover
Brush
Brush Holder
Spring
Voltage Regulator
Terminal Insulator
Rectifier Holder
Rubber Insulator x4
Rectifier End Frame
− CHARGING (5VZ−FE)GENERATOR
CH−5
1224 Author: Date:
1996 TOYOTA T100 (RM449U)
GENERATOR
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine CH0HY−01
P20342
Pivot Bolt
Adjusting Bolt
Lock Nut
P20342
Pivot Bolt
Lock Nut
CH−6
− CHARGING (5VZ−FE)GENERATOR
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DISCONNECT WIRING FROM GENERATOR
(a) Disconnect the connector from the generator.
(b) Remove the nut and disconnect the wire from the genera-
tor.
2. REMOVE GENERATOR DRIVE BELT
(a) Loosen the adjust lock nut, adjusting bolt and pivot bolt.
(b) Remove the drive belt.
3. REMOVE GENERATOR
(a) Remove the pivot bolt and adjusting lock nut.
(b) Remove the generator.
Torque:
Pivot bolt: 51.0 N·m (520kgf·cm, 38 ft·lbf)
Lock Nut: 18.5 N·m (185kgf·cm, 14 ft·lbf)