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CHARGING SYSTEM
CHARGING SYSTEM
CH2
CHARGING SYSTEM
(5SFE)
(5SFE)
DESCRIPTION
The generator is a small, high speed, high performance type with an voltage regulator incorporat
ed. The voltage regulator uses integrated circuits and controls the voltage produced by the
generator.
PRECAUTION
1.
2.
3.
4.
Check that the battery cables are connected to the correct terminals.
Disconnect the battery cables when the battery is given a quick charge.
Do not perform tests with a high voltage insulation resistance tester.
Never disconnect the battery while the engine is running.
CH3
CHARGING SYSTEM
(5SFE)
SYSTEM CIRCUIT
OPERATION
EH00N0a
When the ignition switch is turned ON, current from the battery flows from terminal L of the
generator through the voltage regulator to terminal E, causing the discharge warning light to light
up.
Then when the engine is started, the voltage output increases as the generator rpm increases.
When the voltage output becomes greater than the battery voltage, current for recharging flows
from terminal B. Simultaneously, voltage at terminal L increases and the potential difference
between battery and terminal L disappears, causing the discharge warning light to go off. When
the voltage output exceeds the regulator adjustment voltage, the transistor inside the voltage
regulator regulates the voltage so that the voltage from the generator remains constant.
CH4
CHARGING SYSTEM
(5SFE)
PREPARATION
SST (SPECIAL SERVICE TOOLS)
0928576010 Injection Pump Camshaft Bearing
Cone Replacer
(0960800030) Replacer
RECOMMENDED TOOLS
0908200050 TOYOTA Electrical Tester Set
EQUIPMENT
Ammeter(A)
Battery specific gravity gauge
Belt tension gauge
Torque wrench
Vernier calipers
CH5
CHARGING SYSTEM
(5SFE)
ONVEHICLE INSPECTION
1. Except Delco Battery:
CHECK BATTERY ELECTROLYTE LEVEL
Check the electrolyte quantity of each cell.
A. Maintenance Free Battery
If under the lower level, replace the battery (or add
distilled water if possible). Check the charging system.
6. Except Maintenance Free Battery
If under the LOWER or MIN line, add distilled
water.
HINT:
Before measuring the voltage, turn the ignition
switch to LOCK and turn off the electrical sys
tems (headlight, blower motor, rear defogger etc.)
for 60 seconds to remove the surface charge.
If the vehicle has been running, wait 5 minutes or
more after the vehicle stops before measuring
the battery voltage.
If the voltage is less than specification, charge the
battery.
HINT: Check the indicator as shown in the illustration.
CH6
CHARGING SYSTEM
(5SFE)
3. Delco Battery:
CHECK HYDROMETER
Green Dot visible:
Battery is adequately charged
Dark (Green Dot not visible):
Battery must be charged
Clear or Light Yellow:
Replace battery
CH7
CHARGING SYSTEM
(5SFE)
HINT:
New belt refers to a belt which has been used
less than 5 minutes on a running engine.
Used belt refers to a belt which has been used
on a running engine for 5 minutes or more.
After installing a belt, check that it fits properly in
the ribbed grooves.
Check with your hand to confirm that the belt has
not slipped out of the groove on the bottom of
the pulley.
After installing a new belt, run the engine for
about 5 minutes 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 gener
ator while the engine is running.
CH8
CHARGING SYSTEM
(5SFE)
CH9
CHARGING SYSTEM
(5SFE)
CH10
CHARGING SYSTEM
(5SFE)
GENERATOR
COMPONENTS FOR REMOVAL AND
INSTALLATION
GENERATOR REMOVAL
(See Components for Removal and installation)
1. DISCONNECT NEGATIVE () TERMINAL CABLE
FROM BATTERY
CAUTION: Work must be started after 90 seconds from
the time the ignition switch is turned to the LOCK
position and the negative () terminal cable is discon
nected from the battery.
2. REMOVE GENERATOR
(a) Disconnect the wire clamp from the wire clip on the
rectifier end frame.
(b) Disconnect the generator connector.
(c) Remove the rubber cap and nut, and disconnect the
generator wire.
CH11
CHARGING SYSTEM
(5S FE)
CH12
CHARGING SYSTEM
(5SFE)
GENERATOR DISASSEMBLY
(See Components for Disassembly and Assembly)
1. REMOVE REAR END COVER
(a) Remove the nut and terminal insulator.
CH13
CHARGING SYSTEM
(5SFE)
(b) Remove the brush holder cover from the brush holder.
4. REMOVE PULLEY
(a) Hold SST
(A) with a torque wrench, and tighten SST
(B) clockwise to the specified torque.
SST 0982063010
Torque: 39 Nm (400 kgfcm. 29 ftlbf)
CH14
CHARGING SYSTEM
(5SFE)
CH15
CHARGING SYSTEM
(5SFE)
CH16
CHARGING SYSTEM
(5SFE)
Brushes
1. INSPECT EXPOSED BRUSH LENGTH
Using vernier calipers, measure the exposed brush
length.
Standard exposed length:
10.5 mm (0.413 In.)
Minimum exposed length:
1.5 mm (0.059 in.)
CH17
CHARGING SYSTEM
(5SFE)
CH18
CHARGING SYSTEM
(5SFE)
Bearings
1. INSPECT FRONT BEARING
Check that the bearing is not rough or worn.
(b) Using a socket wrench and press, press out the bear
ing.
CH19
CHARGING SYSTEM
(5SFE)
CH20
CHARGING SYSTEM
(5SFE)
GENERATOR ASSEMBLY
(See Components for Disassembly and Assembly)
1. PLACE RECTIFIER END FRAME ON PULLEY
CH21
CHARGING SYSTEM
(5SFE)
4. 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 Nm (400 kgfcm, 29 ftlbf)
(f) To torque the pulley nut, turn SST (A) in the direction
shown in the illustration.
Torque: 110 Nm (1,125 kgfcm, 81 ftlbf)
CH22
CHARGING SYSTEM
(5SFE)
CH23
CHARGING SYSTEM
(5SFE)
CH24
CHARGING SYSTEM
(5SFE)
GENERATOR INSTALLATION
(See Components for Removal and Installation)
1. INSTALL GENERATOR
(a) Temporarily install the generator with the pivot bolt
and adjusting lock bolt (w/ A/C) or adjusting bolt
(w/o A/C).
CH25
CHARGING SYSTEM
SERVICE SPECIFICATIONS
SERVICE DATA
Battery
(Except
Delco Battery)
Drive belt
Tension
Generator
Rated output
Rotor coil resistance
Slip ring diameter
Regulating voltage
TORQUE SPECIFICATIONS
Part tightened
Bearing cover x Drive end frame
Rectifier end frame x Drive end frame
Generator pulley x Rotor
Rectifier holder x Coil lead on rectifier end frame
Rear end cover x Rectifier holder
Terminal insulator x Rectifier holder
Generator x Generator bracket
Generator x Adjusting bar
(5SFE)
CH26
CHARGING SYSTEM
(1MZFE)
(1MZFE)
DESCRIPTION
The generator is a small, highspeed, highperformance type with a voltage regulator incorpo
rated. The voltage regulator uses integrated circuits and controls the voltage produced by the
generator.
PRECAUTION
1.
2.
3.
4.
Check that the battery cables are connected to the correct terminals.
Disconnect the battery cables when the battery is given a quick charge.
Do not perform tests with a high voltage insulation resistance tester.
Never disconnect the battery while the engine is running.
CH27
CHARGING SYSTEM
(1MZFE)
SYSTEM CIRCUIT
OPERATION
When the ignition switch is turned ON, current from the battery flows from terminal L of the
generator through the voltage regulator to terminal E, causing the discharge warning light to light
up. Then when the engine is started, the voltage output increases as the generator speed
increases. When the voltage output becomes greater than the battery voltage, current for
recharging flows from terminal B. Simultaneously, voltage at terminal L increases and the
potential difference between battery and terminal L disappears, causing the discharge warning
light to go off. When the voltage output exceeds the regulator adjustment voltage, the transistor
inside the voltage regulator regulates the voltage so that the voltage from the generator remains
constant.
CH28
CHARGING SYSTEM
(1MZFE)
PREPARATION
SST (SPECIAL SERVICE TOOLS)
0928576010 Injection Pump Camshaft Bearing
Cone Replacer
(0960800030) Replacer
RECOMMENDED TOOLS
0908200050 TOYOTA Electrical Tester Set
EQUIPMENT
Ammeter(A)
Battery specific gravity gauge
CH29
CHARGING SYSTEM
(1MZFE)
ONVEHICLE INSPECTION
1. Except Delco Battery:
CHECK BATTERY ELECTROLYTE LEVEL
Check the electrolyte quantity of each cell.
A. Maintenance Free Battery
If under the lower level, replace the battery (or add
distilled water if possible). Check the charging system.
HINT:
CH30
CHARGING SYSTEM
(1MZFE)
3. Delco Battery:
CHECK HYDROMETER
Green Dot visible:
Battery I: adequately charged
Dark (Green Dot not visible):
Battery must be charged
Clear or Light Yellow:
Replace battery
CH31
CHARGING SYSTEM
(1MZFE)
Check with your hand to confirm that the belt has not
slip out of the groove on the bottom of the pulley.
CH32
CHARGING SYSTEM
(1MZFE)
CH33
CHARGING SYSTEM
(1MZFE)
CH34
CHARGING SYSTEM
(1MZFE)
GENERATOR
COMPONENTS FOR REMOVAL AND
INSTALLATION
GENERATOR REMOVAL
(See Components for Removal and Installation)
1. DISCONNECT NEGATIVE () TERMINAL CABLE
FROM BATTERY
CAUTION: Work must be started after 90 seconds from
the time the ignition switch is turned to the LOCK
position and the negative () terminal cable is discon
nected from the battery.
CH35
CHARGING SYSTEM
(1MZFE)
3. 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.
CH36
CHARGING SYSTEM
(1MZFE)
GENERATOR DISASSEMBLY
(See Components for Disassembly and Assembly)
1. REMOVE REAR END COVER
(a) Remove the nut and terminal insulator.
CH37
CHARGING SYSTEM
(1MZFE)
4. REMOVE PULLEY
(a) Hold SST (A) with a torque wrench, and tighten SST
(B) clockwise to the specified torque.
SST 0982063010
Torque: 39 Nm (400 kgfcm, 29 ftlbf)
(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 onehalf of a turn.
CH38
CHARGING SYSTEM
(1MZFE)
CH39
CHARGING SYSTEM
(1MZFE)
CH40
CHARGING SYSTEM
(1MZFE)
Brushes
1. INSPECT EXPOSED BRUSH LENGTH
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.)
CH41
CHARGING SYSTEM
(1MZFE)
Bearings
1. INSPECT FRONT BEARING
Check that the bearing is not rough or worn.
(b) Using a socket wrench and press, press out the bear
ing.
CH42
CHARGING SYSTEM
(1MZFE)
CH43
CHARGING SYSTEM
(1MZFE)
GENERATOR ASSEMBLY
(See Components for Disassembly and Assembly)
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.
CH44
CHARGING SYSTEM
(1MZFE)
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 Nm (400 kgfcm, 29 ftlbf)
(f) To torque the pulley nut, turn SST (A) in the direction
shown in the illustration.
Torque: 110 Nm (1,125 kgfcm, 81 ftlbf)
CH45
CHARGING SYSTEM
(1MZFE)
CH46
CHARGING SYSTEM
(1MZFE)
CH47
CHARGING SYSTEM
(1MZFE)
GENERATOR INSTALLATION
(See Components for Removal and Installation)
1. INSTALL GENERATOR
(a) Mount generator on the generator bracket with the
pivot bolt and adjusting lock bolt. Do not tighten the
bolts yet.
(b) Connect the generator connector.
(c) Connect the generator wire with the nut.
2. INSTALL DRIVE BELT
(a) Install the drive belt with the adjusting bolt.
(b) Using a belt tension gauge, measure the drive belt
tension.
Belt tension gauge:
Nippondenso BTG20 (9550600020)
Borroughs No. BT3373F
Drive belt tension:
New belt
175 5 lbf
Used belt
115 20 lbf
HINT:
CH48
CHARGING SYSTEM
SERVICE SPECIFICATIONS
SERVICE DATA
Battery
(Except
Delco Battery)
Drive belt
Tension
New belt
Used belt
Generator
Rated output
Rotor coil resistance
Slip ring diameter
Regulating voltage
TORQUE SPECIFICATIONS
Part tightened
Rectifier end frame x Drive end frame
Cord clamp x Rectifier end frame
Generator pulley x Rotor
Rectifier holder x Coil lead on rectifier end frame
Rear end cover x Rectifier holder
Plate terminal x Rectifier holder
Terminal insulator x Rectifier holder
Generator x Generator bracket
Generator x Adjusting bar
(1MZFE)