Charging System (1ZZ-FE): Generator: Inspection

INSPECT GENERATOR BRUSH HOLDER ASSEMBLY
1. Check the brush length.
  1. Using vernier calipers, measure the exposed brush length.
    Standard exposed brush length: 9.5 to 11.5 mm (0.374 to 0.453 in.)
    
    Minimum exposed brush length: 4.5 mm (0.177 in.)
    
    If the exposed brush length is less than minimum, replace the generator brush holder.
    
    Fig 1: Measuring Exposed Brush Length
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT GENERATOR REGULATOR ASSEMBLY
1. Check the resistance.
  1. Using an ohmmeter, measure the resistance between terminals F and B.
    
    Fig 2: Measuring Resistance Between Terminals F And B
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Standard resistance: When the positive and negative poles of terminals F and B are switched over, there is a resistance of below 1 Ω in one direction but 10 kΩ or higher in the other direction.
    
    If the result is not as specified, replace the generator regulator.
  2. Using an ohmmeter, measure the resistance between terminals E and F.
    
    Fig 3: Measuring Resistance Between Terminals E And F
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Standard resistance: When the positive and negative poles of terminals F and E are switched over, there is a resistance of below 1 Ω in one direction but 10 kΩ or higher in the other direction.
    
    If the result is not as specified, replace the generator regulator.
INSPECT GENERATOR HOLDER W/RECTIFIER
1. Check the resistance.
  1. Using an ohmmeter, measure the resistance between the positive (+) terminal and each rectifier terminal.
    Standard resistance: When the positive and negative poles of the positive (+) terminal and each rectifier terminal are switched over, there is a resistance of below 1 Ω in one direction but 10 kΩ or higher in the other direction.
    
    Fig 4: Measuring Resistance Between Positive Terminal And Each Rectifier Terminal
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    If the result is not as specified, replace the generator holder with rectifier.
  2. Using an ohmmeter, measure the resistance between the negative (-) terminal and each rectifier terminal.
    
    Fig 5: Measuring Resistance Between Negative Terminal And Each Rectifier Terminal
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Standard resistance: When the positive and negative poles of the negative (-) terminal and each rectifier terminal are switched over, there is a resistance of below 1 Ω in one direction but 10 kΩ or higher in the other direction.
    
    If the result is not as specified, replace the generator holder with rectifier.
INSPECT GENERATOR ROTOR ASSEMBLY
1. Check for roughness or wear.
  1. Check that the bearing is not rough or worn. If necessary, replace the bearing.
    
    Fig 6: Checking Bearing Roughness Or Wear
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the resistance.
  1. Using an ohmmeter, measure the resistance between the slip rings.
    Standard resistance: 2.1 to 2.5 Ω at 20°C (68°F)
    
    If the resistance is not as specified, replace the generator rotor.
    
    Fig 7: Measuring Resistance Between Slip Rings
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Using an ohmmeter, measure the resistance between the slip ring and rotor.
    Standard resistance: 1 MΩ or higher
    
    If the result is not as specified, replace the generator rotor shaft.
3. Check the appearance.
  1. Check that the slip rings are not rough or scored.
    If rough or scored, replace the generator rotor.
    
    Fig 8: Measuring Resistance Between Slip Ring And Rotor
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Inspect the slip ring diameter.
  1. Using vernier calipers, measure the slip ring diameter.
    Standard diameter: 14.2 to 14.4 mm (0.559 to 0.567 in.)
    
    Minimum diameter: 14.0 mm (0.551 in.)
    
    If the diameter is less than minimum, replace the generator rotor.
    
    Fig 9: Inspecting Slip Ring Diameter
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT GENERATOR RECTIFIER END FRAME
1. Check for roughness or wear.
  1. Check that the bearing is not rough or worn. If necessary, replace the bearing.
    
    Fig 10: Checking Bearing Roughness Or Wear
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the resistance.
  1. Using an ohmmeter, measure the resistance between the coil wires.
    Standard resistance: Below 1Ω
    
    If the result is not as specified, replace the generator drive end frame.
    
    Fig 11: Measuring Resistance Between Coil Wires
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Using an ohmmeter, measure the resistance between the coil wire and body.
    Standard resistance: 1 MΩ or higher
    
    If the result is not as specified, replace the generator drive end frame.
    
    Fig 12: Measuring Resistance Between Coil Wire And Body
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR ROTOR BEARING
1. Clamp the generator rotor in a vise.
2. Using SST, remove the generator bearing cover (outside) and bearing.
  SST 09820-00021
  
  NOTE: Be careful not to damage the fan.
3. Remove the generator bearing cover (inside) from the generator rotor.
  
  Fig 13: Removing Generator Bearing Cover (Outside) And Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR ROTOR BEARING
1. Place the generator rotor on the generator pulley.
2. Install the generator bearing cover (inside) onto the generator rotor.
3. Using SST and a press, push a new bearing in.
  SST 09820-00031
  
  Fig 14: Pushing Bearing Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, push the generator bearing cover (outside) in.
  SST 09285-76010
  
  Fig 15: Pushing Generator Bearing Cover (Outside) In
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR DRIVE END FRAME BEARING
1. Remove the 4 screws, then remove the retainer plate.
  
  Fig 16: Removing Retainer Plate Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, push the bearing out.
  SST 09950-60010 (09951-00350), 09950-70010 (09951-07100)
  
  Fig 17: Pushing Bearing Out Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR DRIVE END FRAME BEARING
1. Using SST and a press, push a new bearing in.
  SST 09950-60010 (09951-00530), 09950-70010 (09951-07100)
  
  Fig 18: Pushing Bearing In Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the retainer plate with the 4 screws.
  Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf)
  
  Fig 19: Installing Retainer Plate With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002