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CHARGING SYSTEM
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Removal and Installation EKS0031A
REMOVAL (QR ENGINE MODELS)
1. Disconnect the battery cable from the negative terminal.
2. Remove 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 assembly upward.
5. Remove alternator mounting bolts.
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 alternator and water pump belt. Refer to EM-140,
"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.
ALTERNATOR PULLEY INSPECTION (QR ENGINE MODELS)
One-Way Clutch Pulley Check
Fix rotor with inserting a suitable tool rolled with a cloth.
CAUTION:
Be careful not to damage the rotor.
1. Check for locking. (Outer ring is turned clockwise when viewed
from the front.)
If it rotates in both directions... Replace pulley.
2. Check for dragging. (Outer ring is turned counterclockwise when
viewed from the front.)
If it locks or unusual resistance is felt... Replace pulley.
PKIA2496E
MEL948N
SKIB0529E
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CHARGING SYSTEM
INSTALLATION
Installation is the reverse order of removal.
Install alternator, and check tension of belt. Refer to EM-13, "Tension Adjustment" (QR engine models) or
EM-140, "
Tension Adjustment" (YD engine models) in EM section.
CAUTION:
Be sure to tighten “B” terminal mounting nut carefully.
QR Engine Models
YD Engine Models
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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CHARGING SYSTEM
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Disassembly and AssemblyEKS0031B
QR ENGINE MODELS
PKIB7676E
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
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CHARGING SYSTEM
YD ENGINE MODELS
DISASSEMBLY
Rear Cover
1. Remove through-bolt (4).
2. Remove rear cover.
NOTE:
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 just bearing box section with a 200 W soldering iron
until the temperature increases by about 30 °C.
CAUTION:
Never use a heat gun, as it can damage diode assembly.
PKIB9810E
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
SEL032Z
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CHARGING SYSTEM
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Front Cover (For LR1110-713V)
1. Set rotor to the vise.
CAUTION:
Be careful not to damage the rotor.
Use copper plate or thick cloth for rotor in the vise.
2. Remove pulley cap, using suitable tool.
3. Remove alternator pulley, using alternator pulley adaptor [SST].
INSPECTION
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.
SKIB0531E
PKIC1124E
Resistance : Refer to SDS. SC-36,
"Alternator" .
Slip ring minimum
outer diameter: Refer to SDS. SC-36,
"Alternator" .SKIB4525E
SKIB4526E
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CHARGING SYSTEM
Stator Check
1. Continuity test
No continuity... Replace stator.
2. Ground test
Continuity exists... Replace stator.
ASSEMBLY
Assembly is the reverse order of disassembly.
CAUTION:
Note the tightening torque shown, in the figure.
Rear Bearing
CAUTION:
Never reuse rear bearing. Replace with a new one.
Never lubricate rear bearing outer race.
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.
SKIB4527E
SKIB4528E
SKIB4529E
SKIB4530E
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STARTING SYSTEM
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STARTING SYSTEM PFP:00011
System Description EKS0031F
M/T MODELS
Power is supplied at all times
through 30A fusible link (letter J, located in the fuse and fusible link box)
to ignition switch terminal 1.
With the ignition switch in the START position, power is supplied
from ignition switch terminal 5
to starter motor harness connector terminal 1.
The starter motor plunger closes and provides a closed circuit between the battery and starter motor. The
starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the
engine starts.
A/T MODELS
Power is supplied at all times
through 30A fusible link (letter J, located in the fuse and fusible link box)
to ignition switch terminal 1.
With the ignition switch in the START position, power is supplied
from ignition switch terminal 5
to park/neutral position relay terminal 5.
With the ignition switch in the ON or START position, power is supplied
through 10A fuse [No. 13, located in the fuse block (J/B)]
to park/neutral position relay terminal 1.
With the selector lever in the P or N position, ground is supplied
to park/neutral position relay terminal 2
through the park/neutral position switch terminals 1 and 2, and
through grounds F9 and F10.
Then park/neutral position relay is energized and power is supplied
from park/neutral position relay terminal 3
to starter motor harness connector terminal 1.
The starter motor plunger closes and provides a closed circuit between the battery and starter motor. The
starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the
engine starts.
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STARTING SYSTEM
Wiring Diagram — START — /M/T ModelsEKS0031G
TKWA0056E