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Wiring Diagram — CHARGE — /WITH GASOLINE ENGINEEKS00317
TKWA1513E
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CHARGING SYSTEM
Wiring Diagram — CHARGE — /WITH DIESEL ENGINEEKS00EAF
TKWA1514E
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Trouble DiagnosesEKS00319
Before performing an alternator test, make sure that the battery is fully charged. A 30-volt voltmeter and suit-
able 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
NOTE:
If the inspection result is OK even though the charging system is malfunctioning, check the B terminal
connection. (Check the tightening torque and voltage drop.)
Check condition of rotor coil, rotor slip ring, brush and stator coil. 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.
PKIA3570E
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CHARGING SYSTEM
Removal and Installation EKS0031A
REMOVAL (QR ENGINE MODELS)
1. Disconnect the battery cable from the negative terminal.
2. Remove alternator drive belt. Refer to EM-13, "
Checking Drive Belts" in EM section.
3. Remove alternator harness mounting bolt, ground mounting
bolt, alternator connector and B terminal mounting nut.
4. Remove alternator mounting bolts.
5. Remove alternator assembly upward.
REMOVAL (YD ENGINE MODELS)
1. Disconnect the battery cable from the negative terminal.
2. Remove alternator harness mounting bolt, alternator connector
and B terminal mounting nut.
3. Remove drive belt. Refer to EM-131, "
Checking Drive Belts" in
EM section.
4. Remove alternator bracket mounting bolts and alternator
bracket.
5. Remove alternator mounting bolts.
6. Remove alternator assembly upward.
INSTALLATION
Note the following, and install in the reverse order of removal.
Install alternator, and check tension of belt. Refer to EM-13, "Tension Adjustment" (QR engine models) or
EM-131, "
Tension Adjustment" (YD engine models) in “ENGINE MECHANICAL (EM)” section.
CAUTION:
Be sure to tighten B terminal mounting nut carefully.
QR engine models
YD engine models
PKIA2496E
MEL948N
B terminal nut:
: 7.9 - 11.0 N·m (0.8 - 1.11 kg-m, 6.0 - 8.0 ft-lb)
Ground bolt:
: 2.3 - 2.6 N·m (0.23 - 0.27 kg-m, 20 - 23 in-lb)
Alternator mounting bolt:
: 59 - 69 N·m (6.1 - 7.1 kg-m, 45 - 51 ft-lb)
B terminal nut:
: 7.9 - 11.0 N·m (0.8 - 1.11 kg-m, 6.0 -8.0 ft-lb)
Ground bolt:
: 2.3 - 2.6 N·m (0.23 - 0.27 kg-m, 20 - 23 in-lb)
Alternator mounting bolt (upper side):
: 16 - 20 N·m (1.6 - 2.1 kg-m, 12 - 15 ft-lb)
Alternator mounting bolt (lower side):
: 38 - 50 N·m (3.8 - 5.1 kg-m, 28 - 36 ft-lb)
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Disassembly and AssemblyEKS0031B
QR ENGINE MODELS
1. Stator 2. Rear bearing 3. Rotor
4. Retainer 5. Front bearing 6. Front cover
7. Pulley 8. Fan guide 9. Labyrinth seal
10. IC voltage regulator assembly 11. Diode assembly 12. Rear cover
13. Terminal assembly 14. Through-bolt
PKIA4856E
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YD ENGINE MODELS
DisassemblyEKS0031C
REAR COVER
CAUTION:
Rear cover may be hard to remove because a ring is used to lock outer race of rear bearing. To facili-
tate removal of rear cover, heat just 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.
1. Rear bearing 2. Rotor 3. Retainer
4. Front bearing 5. Through bolt 6. Front cover
7. Pulley 8. Pulley nut 9. Stator
10. IC voltage regulator assembly 11. Diode assembly 12. Rear cover
13. B terminal
PKIA4857E
SEL032Z
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InspectionEKS0031D
ROTOR CHECK
1. Resistance test
Not within the specified values... Replace rotor.
2. Insulator test
Continuity exists... Replace rotor.
3. Check slip ring for wear.
Not within the specified values... Replace rotor.
BRUSH CHECK
1. Check smooth movement of brush.
Not smooth... Check brush holder and clean.
2. Check brush for wear.
Replace brush if it is worn down to the limit line.
PULLEY CHECK (WITH CLUTCH TYPE)
1. Check for locking (Outer ring is turned counterclockwise when
viewed from the rear).
If it rotates in both directions... Replace pulley.
2. Check for dragging (Outer ring is turned clockwise when viewed
from the rear).
If it locks or unusual resistance is felt... Replace pulley.
STATOR CHECK
1. Continuity test
No continuity... Replace stator.Resistance : Refer to SDS. SC-34, "
Alternator" .
Slip ring minimum
outer diameter: Refer to SDS. SC-34, "
Alternator" .
SKIB0463E
SEL631DA
PKIA0458E
SKIB0464E
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CHARGING SYSTEM
2. Ground test
Continuity exists... Replace stator.
AssemblyEKS0031E
RING FITTING IN REAR BEARING
Fix ring into groove in rear bearing so that it is as close to the
adjacent area as possible.
CAUTION:
Do not reuse rear bearing after removal.
REAR COVER INSTALLATION
1. Fit brush assembly, diode assembly, regulator assembly and
stator.
2. Push brushes up with fingers and install them to rotor.
Take care not to damage slip ring sliding surface.
SKIB0465E
SEL044Z
SEL048Z
SEL049Z