1996 TOYOTA T100 check engine

Downloaded from www.Manualslib.com manuals search engine P20582
Terminal F
− CHARGING (3RZ−FE)CHARGING SYSTEM
CH−5
1996 TOYOTA T100 (RM449U)
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 standard voltage, replace
the voltage regulator.
If the voltage reading is less than 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 standard volt-
age, replace the voltage regulator.
If the voltage reading is less than standard voltage,
repair the generator.
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 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 CH0ES−02
P13397
P13398
P13396
P20344
CH0213
SST (B)SST (A)
CH−8
− CHARGING (3RZ−FE)GENERATOR
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 CH0HW−01
CH0784
ContinuityOhmmeter
B02105
No ContinuityOhmmeter
CH0192
P13482
ContinuityOhmmeter
P13565
No ContinuityOhmmeter CH−10
− CHARGING (3RZ−FE)GENERATOR
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 a vernier caliper, 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.
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 lead and drive end frame.
If there is continuity, replace the drive end frame assembly.

Downloaded from www.Manualslib.com manuals search engine P13534
Length
CH0248
CH0414
10.5 mm
Positive (+)
Terminal
P13568
Rectifier
Terminal
Ohmmeter
P13566
Ohmmeter
Negative (−)
Terminal
− CHARGING (3RZ−FE)GENERATOR
CH−11
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 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
N00581
SST
CH−12
− CHARGING (3RZ−FE)GENERATOR
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.
13. IF NECESSARY, REPLACE REAR BEARING
(a) Using SST, remove the bearing cover and bearing.
SST 09820−00021
(b) Remove the bearing cover (inside).

Downloaded from www.Manualslib.com manuals search engine P13486
CH0HX−01
P13762
Upward
P13487
29 mm
Socket
Wrench
P13597
SST (A)
SST (B)TurnTurn
P10834
SST (C)SST (B)
Insert CH−14
− CHARGING (3RZ−FE)GENERATOR
1996 TOYOTA T100 (RM449U)
REASSEMBLY
1. PLACE RECTIFIER END FRAME ON PULLEY
2. INSTALL ROTOR TO DRIVE END FRAME
3. INSTALL RECTIFIER END FRAME
Install the generator washer to the rectifier end frame.
NOTICE:
Be careful of the generator washer installation directon.
4. INSTALL RECTIFIER END FRAME
(a) Using a 29 mm socket wrench and press, slowly press in
the rectifier end frame.
(b) Install the 4 nuts.
Torque: 4.5 N·m (46 kgf·cm, 39 in.·lbf)
5. 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 CH−16
− CHARGING (3RZ−FE)GENERATOR
1996 TOYOTA T100 (RM449U)
9. CHECK THAT ROTOR ROTATES SMOOTHLY

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.