2001 TOYOTA AVALON Service Repair Manual

CH03V-02
B09070
Pivot Bolt
Plate Washer
Adjusting Lock BoltAdjusting Bolt
GeneratorGenerator Wire
Generator Connector
Drive Belt
Wire Clamp
Wire Clamp
B09071
PulleyDrive End Flame (Stator)
Front BearingRetainer
RotorBearing Cover

Rear Bearing Bearing Cover
Thrust Washer
Rectifire End FlameCord ClipSeal Plate
Robber InsulatorRectifire Holder Terminal Insulator
Voltage RegulatorBrush Holder Brush Holder CoverRear End CoverPlate Terminal

Non-reusable part
x 4
x 4
- CHARGINGGENERATOR
CH-5
1278 Author
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2001 AVALON (RM808U)
GENERATOR
COMPONENTS

CH03X-01
P20102
P14233
Plate Terminal
P14234
P20103
P10835
SST (B)Turn
SST (A)
- CHARGINGGENERATOR
CH-7
1280 Author
: Date
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2001 AVALON (RM808U)
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 REGULA-
TOR
(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.

P10834
SST (C)InsertSST (B)
P10827
SST (C)
SST (A)
Turn
P10836
SST (A) Turn
SST (B)
P19942
P01762
SST CH-8
- CHARGINGGENERATOR
1281 Author
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2001 AVALON (RM808U)
(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.
5. REMOVE RECTIFIER END FRAME
(a) Remove the wire clamp.
(b) Remove the 4 nuts and cord clip.
(c) Using SST, remove the rectifier end frame.
SST 09286-4601 1
(d) Remove the thrust washer.
6. REMOVE ROTOR FROM DRIVE END FRAME

CH03Y-01
CH0784
Ohmmeter
Continuity
B02105
Ohmmeter
No Continuity
CH0192
P00484
OhmmeterContinuity
P00482
OhmmeterContinuity
- CHARGINGGENERATOR
CH-9
1282 Author
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2001 AVALON (RM808U)
INSPECTION
1. INSPECT ROTOR
(a) Inspect 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) Inspect 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 FLAME)
(a) Inspect 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) Inspect 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.

P13535
Length
P00480
OhmmeterPositive (+)
Terminal
Rectifire
Terminal
P00481
OhmmeterNegative (-)
Terminal CH-10
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1283 Author
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2001 AVALON (RM808U)
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 that bearing is not rough or worn.
If necessary, replace the bearing (See page CH-1 1).

CH041-01
CH-16
- CHARGINGGENERATOR
1289 Author
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2001 AVALON (RM808U)
INSTALLATION
Installation is in the reverse order of removal (See page CH-6).

P01364
Pulley
CH040-02
P00427
P01763
29 mm
Socket
Wrench
P19942
A
AB
A
P10835
SST (B)Turn
SST (A)
- CHARGINGGENERATOR
CH-13
1286 Author
: Date
:
2001 AVALON (RM808U)
REASSEMBLY
1. INSTALL ROTOR TO DRIVE END FRAME
(a) Place the rectifier end frame on the pulley.
(b) Install the rotor to the rectifier end frame.
2. INSTALL RECTIFIER END FRAME
(a) Place the thrust washer on the rotor.
(b) Using a 29 mm socket wrench and press, slowly press in
the rectifier end frame.
(c) NUT A:
Install the cord clip and 4 nuts.
Torque: 4.5 N´m (46 kgf´cm, 40 in.´lbf)
(d) NUT B:
Install the cord clip and 4 nuts.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
(e) Install the wire clamp.
3. 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.

P10834
SST (A)
SST (C)Insert
P10829
SST (C)
SST (A)
Turn
P10836
SST (A) Turn
SST (B)
P00428
P00645
CH-14
- CHARGINGGENERATOR
1287 Author
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:
2001 AVALON (RM808U)
(d) Mount SST (C) in a vise.
(e) Insert SST (B) into SST (C), and attach the pulley nut to
SST (C).
(f) To torque the pulley nut, turn SST (A) in the direction
shown in the illustration.
Torque: 110.5 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).
4. INSTALL RECTIFIER HOLDER
(a) Place the seal plate on the rectifier end frame.
(b) Install the 4 rubber insulators on the lead wires.