Page 1185 of 2267
Wiring Diagram—CHARGE—
GASOLINE ENGINE MODELS
YEL001D
CHARGING SYSTEM
EL-53
Page 1186 of 2267
DIESEL ENGINE MODELS
YEL002D
CHARGING SYSTEM
Wiring Diagram—CHARGE—(Cont’d)
EL-54
Page 1187 of 2267

Trouble Diagnoses
Before conducting an alternator test, make sure that the battery is fully charged. A 30-volt voltmeter and
suitable test probes are necessary for the test. The alternator can be checked easily by referring to the
Inspection Table.
Before starting, inspect the fusible link.
Use fully charged battery.
WITH IC REGULATOR
Check the
following:
⋅Warning
lamp bulb
⋅Fuse for
warning
lamp
Ignition
switch“ON”Warning lamp
“OFF”Disconnect connector (S, L) and
ground L harness side.Warning lamp
“OFF”
Warning lamp
“ON”Damaged IC
regulator.
Replace.
Warning lamp
“ON”
Engine start.
Engine
speed: 1,500
rpmWarning lamp
“ON”Check the following:
⋅Drive belt
⋅Fuse for S terminal
⋅Connector (S, L terminal)
connectionEngine idlingWarning lamp
“OFF”OK
Warning lamp
“ON”
Warning lamp
“OFF”OKEngine
speed:
1,500 rpm
(Measured B
terminal
voltage)More than
15.5VDamaged IC
regulator.
Replace.
No
generationField circuit is
open.
Warning lamp:“CHARGE”warning lamp in combination meter
Note:
If the inspection result is OK even though the charging system is malfunctioning, check the B
terminal connection. (Check the tightening torque.)
When field circuit is open, check condition of rotor coil, rotor slip ring and brush. If necessary,
replace faulty parts with new ones.
MALFUNCTION INDICATOR
The IC regulator warning function activates to illuminate“CHARGE”warning lamp, if any of the following
symptoms occur while alternator is operating:
Excessive voltage is produced.
No voltage is produced.
CHARGING SYSTEM
EL-55
Page 1188 of 2267
Construction
1Pulley assembly
2Front cover
3Front bearing
4Retainer
5Rotor
6Slip ring
7Stator
8IC voltage regulator assembly
9Diode assembly
10Rear cover
NEL320
SEC. 231
LR190-734E
2
1
34
3.14 - 3.9 (0.320 - 0.398, 27.8 - 34.5)
56
73.14 - 3.9 (0.320 - 0.398, 27.8 - 34.5)
7.8 - 10.8
(0.80 - 1.10, 69.4 - 95.5)
10
3.14 - 3.9
(0.320 - 0.398, 27.8 - 34.5)
63.7 - 83.3
(6.50 - 8.50, 46.99 - 61.44):N·m (kg-m, in-lb)
:N·m (kg-m, ft-lb)
9
8
CHARGING SYSTEM
EL-56
Page 1189 of 2267
1Pulley assembly
2Front cover
3Front bearing
4Bearing retainer
5Rotor
6Rear bearing
7Stator
8IC voltage regulator assembly
9Diode assembly
10Rear cover
YEL427B
3.5 - 5.3
(0.36 - 0.54, 31.0 - 46.9)
99 - 137
(10.1 - 12.9, 73 - 101)
:N·m (kg-m, in-lb)
:N·m (kg-m, ft-lb)
SEC. 231
A2TB3691
A2TB3891
2.0 - 5.3
(0.20 - 0.54, 17.7 - 46.9)
12.8 - 18.6
(1.3 - 1.9,
10 - 13)
2.0 - 5.3
(0.20 - 0.54,
17.7 - 46.9)
CHARGING SYSTEM
Construction (Cont’d)
EL-57
Page 1190 of 2267
MEL141LA
CHARGING SYSTEM
Construction (Cont’d)
EL-58
Page 1191 of 2267
1Pulley assembly
2Front cover
3Front bearing
4Bearing retainer
5Stator
6Rotor
7Special bolt
8Rear cover
9Diode assembly
10Brush holder
11Dust cover
YEL429B
8
7
1
2
34
5
6
3-4
(0.3 - 0.4, 27 - 35)
11
6-8
(0.6 - 0.8,
53 - 71)
10
9
3.5 - 5.5 (0.36 - 0.56, 31 - 49)
SEC. 231
A115I-80A
70 - 90
(7.1 - 9.2, 51.6 - 66.4)
:N·m (kg-m, ft-lb)
:N·m (kg-m, in-lb)
CHARGING SYSTEM
Construction (Cont’d)
EL-59
Page 1192 of 2267

Removal and Installation
1. Loosen lock bolt.
2. Remove RH undertray.
3. Loosen alternator mounting bolt and remove drive belt.
4. Remove lock bolt and adjust.
5. Remove harness connectors.
6. Remove alternator mounting bolt.
7. Support engine with jack, and remove front engine mounting
bolt.
8. Remove alternator.
Disassembly
REAR COVER
CAUTION:
Rear cover may be hard to remove because a ring is used
to lock outer race of rear bearing. To facilitate removal of
rear cover, heat bearing box section with a 200W soldering
iron.
Do not use a heat gun, as it can damage diode assembly.
REAR BEARING
CAUTION:
Do not reuse rear bearing after removal. Replace with a
new one.
Do not lubricate rear bearing outer race.
Inspection
ROTOR CHECK
1. Resistance test
Resistance: Refer to SDS (EL-63).
Not within the specified values ... Replace rotor.
2. Insulator test
Continuity exists ... Replace rotor.
3. Check slip ring for wear.
Slip ring minimum outer diameter:
Refer to SDS (EL-63).
Not within the specified values ... Replace rotor.
.NEL327 Loosen
Adjusting bolt
Tighten
Lock bolt
SEL910T
16 - 21
(1.6 - 2.1, 12 - 15)
37 - 50 (3.8 - 5.1, 27 - 37)
37 - 50 (3.8 - 5.1,
27 - 37)
:N·m (kg-m, ft-lb)
SEL032Z Soldering iron
(200W capacity)
Bearing box
SEL033Z Slip rings
CHARGING SYSTEM
EL-60