Page 2313 of 4770

Z03473
BatteryAmmeter
VoltmeterDisconnect Wire
from Terminal B
Generator
± CHARGING (1MZ±FE)CHARGING SYSTEM
CH±3
1766 Author: Date:
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 DISCHARGE WARNING LIGHT CIRCUIT
(a) Warm up the engine and then turn it off.
(b) Turn off all accessories.
(c) Turn the ignition switch ºONº. Check that the discharge
warning light is lit.
(d) Start the engine. Check that the light goes off.
If the light does not go off as specified, troubleshoot the dis-
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:
Disconnect the wire from terminal B of the genera-
tor, and connect it to the negative (±) tester probe
of the ammeter.
Connect the positive (+) tester probe of the amme-
ter to terminal B of the generator.
Connect the positive (+) tester probe of the voltme-
ter to terminal B of the generator.
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.
Page 2314 of 4770
P14228
Terminal F CH±4
± CHARGING (1MZ±FE)CHARGING SYSTEM
1767 Author: Date:
If the voltmeter reading is less than standard voltage, check the
voltage regulator and generator as follows:
With terminal F grounded, start the engine and
check the voltmeter reading of terminal B.
If the voltmeter reading is more than standard volt-
age, replace the voltage regulator.
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
ºHIº.
(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.
Page 2315 of 4770
CH01E±01
S05218
Pivot BoltPlate Washer
Adjusting Lock BoltAdjusting Bolt
GeneratorGenerator Wire
Generator Connector
Drive Belt
S05077
PulleyDrive End Flame (Stator) Front Bearing
Retainer
RotorBearing Cover
Rear Bearing Bearing Cover
Generator Washer
Rectifire End Flame
Cord ClipSeal Plate
Robber Insulator x 4Rectifire Holder Terminal Insulator
Voltage RegulatorBrush HolderBrush Holder CoverRear End CoverPlate Terminal
Non±reusable part
± CHARGING (1MZ±FE)GENERATOR
CH±5
1768 Author: Date:
GENERATOR
COMPONENTS
Page 2316 of 4770
CH01F±01
P14226
Pivot Bolt
Adjusting
Lock BoltAdjusting Bolt
P14227
CH±6
± CHARGING (1MZ±FE)GENERATOR
1769 Author: Date:
REMOVAL
1. REMOVE DRIVE BELT
Loosen the pivot bolt, adjusting lock bolt, and adjusting bolt,
and remove the drive belt.
Torque:
Pivot bolt: 56 N´m (570 kgf´cm, 41 ft´lbf)
Lock bolt: 18 N´m (180 kgf´cm, 13 ft´lbf)
2. REMOVE GENERATOR
(a) Disconnect the generator connector.
(b) Remove the nut, and disconnect the generator wire.
(c) Disconnect the wire harness from the clip.
(d) Remove the pivot bolt, plate washer, adjusting lock bolt
and generator.
Page 2317 of 4770
CH01G±01
P14233
Plate Terminal
P14234
S05072
P10835
SST (B)SST (A) Turn
P10834
SST (C)SST (B)
Insert
± CHARGING (1MZ±FE)GENERATOR
CH±7
1770 Author: Date:
DISASSEMBLY
1. REMOVE REAR END COVER
(a) Remove the nut and terminal insulator.
(b) Remove the screw, 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.
3. REMOVE RECTIFIER HOLDER
(a) Remove the 4 screws and rectifier holder.
(b) Remove the 4 rubber insulators.
(c) Remove the seal plate.
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).
Page 2318 of 4770
P10827
SST (C)
SST (A)
Turn
P10836
Turn
SST (A)
SST (B)
S05073
P01762
SST CH±8
± CHARGING (1MZ±FE)GENERATOR
1771 Author: Date:
(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 cord clip.
(b) Using SST, remove the rectifier end frame.
SST 09286±46011
(c) Remove the generator washer.
6. REMOVE ROTOR FROM DRIVE END FRAME
Page 2319 of 4770

CH01H±01
CH0784
Ohmmeter
Continuity
CH0783
Ohmmeter
No Continuity
CH0192
P00484
OhmmeterContinuity
P00482
OhmmeterContinuity
± CHARGING (1MZ±FE)GENERATOR
CH±9
1772 Author: Date:
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: 2.1 ± 2.5 W 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.
Page 2320 of 4770

P13535
Length
P00480
OhmmeterPositive (+)
Terminal
Rectifire
Terminal
P00481
OhmmeterNegative (±)
Treminal CH±10
± CHARGING (1MZ±FE)GENERATOR
1773 Author: Date:
3. INSPECT BRUSHES
Using a vernier caliper, 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
and 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)