1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine CH0HZ−01
P13397
P13398
P13396
P20344
CH0213
SST (A)SST (B)
− CHARGING (5VZ−FE)GENERATOR
CH−7
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE REAR END COVER
(a) Remove the nut and terminal insulator.
(b) Remove the 3 nuts and end cover.
2. REMOVE BRUSH HOLDER
(a) Remove the 2 screws, brush holder and cover.
(b) Remove the brush holder cover from the brush holder.
3. REMOVE VOLTAGE REGULATOR
Remove the 3 screws and voltage regulator.
4. REMOVE RECTIFIER HOLDER
(a) Remove the 4 screws and rectifier holder.
(b) Remove the 4 rubber insulators.
5. 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.

Downloaded from www.Manualslib.com manuals search engine P10834
SST (C)SST (B)
Insert
P10827
SST (A) SST (C)
Turn
P20347
CH0335
SST
CH−8
− CHARGING (5VZ−FE)GENERATOR
1996 TOYOTA T100 (RM449U)
(c) Mount SST (C) in a vise.
(d) Insert SST (B) into SST (C), and attach the pulley nut to
SST (C).
(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.
6. REMOVE RECTIFIER END FRAME
(a) Remove the 4 nuts.
(b) Using SST, remove the rectifier end frame.
SST 09286−46011
(c) Using snap ring pliers, the generator washer from the rec-
tifier end continuity.
7. REMOVE ROTOR FROM DRIVE END FRAME

Downloaded from www.Manualslib.com manuals search engine CH0I0−01
CH0784
Ohmmeter
Continuity
CH0783
Ohmmeter
No Continuity
CH0192
P13482
Ohmmeter
Continuity
P13565
Ohmmeter
No Continuity
− CHARGING (5VZ−FE)GENERATOR
CH−9
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT ROTOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
slip rings.
Standard resistance:
2.8 − 3.0 Ω at 20°C (68°F)
If there is no continuity, replace the rotor.
2. INSPECT ROTOR FOR GROUND
Using an ohmmeter, check that there is no continuity between
the slip ring and rotor.
If there is continuity, replace the rotor.
3. INSPECT SLIP RINGS
(a) Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor.
(b) Using vernier calipers, measure the slip ring diameters.
Standard diameter:
14.2 − 14.4 mm (0.559 − 0.567 in.)
Minimum diameter:
12.8 mm (0.504 in.)
4. INSPECT STATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
coil leads.
If there is no continuity, replace the drive end frame assembly.
5. INSPECT STATOR FOR GROUND
Using an ohmmeter, check that there is no continuity between
the coil leads and drive end frame.
If there is continuity, replace the drive end frame assembly.

Downloaded from www.Manualslib.com manuals search engine P13534
Length
P13729
CH0414
10.5 mm
P13568
Terminal Positive (+)
Ohmmeter
Terminal Rectifer
P13566
Ohmmeter
Terminal Negative (−)
CH−10
− CHARGING (5VZ−FE)GENERATOR
1996 TOYOTA T100 (RM449U)
6. INSPECT EXPOSED BRUSH LENGTH
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
brushes.
7. IF NECESSARY, REPLACE BRUSHES
(a) Unsolder and remove the brush and spring.
(b) Run the wire of the brush through the hole in the brush
holder, and insert the spring and brush into the brush
holder.
(c) Solder the brush wire to the brush holder at the exposed
length.
Exposed length:
10.5 mm (0.413 in.)
(d) Check that the brush moves smoothly in the brush holder.
(e) Cut off the excess wire.
(f) Apply insulation paint to the soldered point.
8. INSPECT POSITIVE RECTIFIER
(a) Using an ohmmeter, connect one tester probe to the posi-
tive (+) terminal and the other to each rectifier terminal.
(b) Reverse the polarity of the tester probes and repeat step
(a).
(c) Check that one shows continuity and the other shows no
continuity.
If continuity is not as specified, replace the rectifier holder.
9. INSPECT NEGATIVE RECTIFIER
(a) Using an ohmmeter, connect one tester probe to each
negative (−) terminal and the other to each rectifier termi-
nal.
(b) Reverse the polarity of the tester probes and repeat step
(a).
(c) Check that one shows continuity and the other shows no
continuity.
If continuity is not as specified, replace the rectifier holder.

Downloaded from www.Manualslib.com manuals search engine CH0827
P22368
SST
P22369
SST
CH1026
− CHARGING (5VZ−FE)GENERATOR
CH−11
1996 TOYOTA T100 (RM449U)
10. INSPECT FRONT BEARING
Check that the bearing is not rough or worn.
11. IF NECESSARY, REPLACE FRONT BEARING
(a) Remove the 4 screws and bearing retainer.
(b) Using SST and a press, press out the bearing.
SST 09950−60010 (09951−00260, 09952−06010)
(c) Using SST and a press, press in a new bearing.
SST 09950−60010 (09951−00500)
(d) Install the bearing retainer with the 4 screws.
Torque:2.6 N·m (27 kgf·cm, 23 in.·lbf)
12. INSPECT REAR BEARING
Check that the bearing is not rough or worn.

Downloaded from www.Manualslib.com manuals search engine N00581
SST
P13567
N00578
SST
P00074
SST CH−12
− CHARGING (5VZ−FE)GENERATOR
1996 TOYOTA T100 (RM449U)
13. IF NECESSARY, REPLACE REAR BEARING
(a) Using SST, remove the bearing cover and bearing.
SST 09820−00021
(b) Remove the bearing cover (inside).
(c) Place the bearing cover (inside) on the rotor.
(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

Downloaded from www.Manualslib.com manuals search engine CH02N−03
P13486
P13762
Upward
P13487
Wrench Socket
29 mm
P13597
SST (B)SST (A)
P10834
SST (B)
SST (C)Insert
− CHARGING (5VZ−FE)GENERATOR
CH−13
1996 TOYOTA T100 (RM449U)
REASSEMBLY
1. PLACE RECTIFIER END FRAME ON PULLEY
2. INSTALL ROTOR TO DRIVE END FRAME
3. INSTALL RECTIFIER END FRAME
(a) Install the generator washer to the rectifier end frame.
NOTICE:
Be careful of the generator washer installation direction.
(b) Using a 29 mm socket wrench and press, slowly press in
the rectifier end frame.
(c) Install the 4 nuts.
Torque:4.5 N·m (46 kgf·cm, 39 in.·lbf)
4. INSTALL PULLEY
(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.
SST 09820−63010
Torque:39 N·m (400 kgf·cm, 29 ft·lbf)
(c) Check that SST (A) is secured to the pulley shaft.
(d) Mount SST (C) in a vise.
(e) Insert SST (B) into SST (C), and attach the pulley nut to
SST (C).

Downloaded from www.Manualslib.com manuals search engine P04395
SST (A)
SST (C)
Turn
P13569
P13541
B07119
Upward
Protrusion
P13542
CH−14
− CHARGING (5VZ−FE)GENERATOR
1996 TOYOTA T100 (RM449U)
(f) To torque the pulley nut, turn SST (A) in the direction
shown in the illustration.
Torque:110 N·m (1,125 kgf·cm, 81 ft·lbf)
(g) Remove the generator from SST (C).
(h) Turn SST (B), and remove SST (A and B).
5. INSTALL RECTIFIER HOLDER
(a) Install the 4 rubber insulators on the lead wires.
NOTICE:
Be careful of the rubber insulators installation direction.
(b) Install the rectifier with the 4 screws.
Torque: 2.0 N·m (20 kgf·cm, 18 in.·lbf)
6. INSTALL BRUSH HOLDER AND VOLTAGE
REGULATOR
(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.