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CHARGING (5VZ-FE)

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CHARGING SYSTEM

CH-1

CHARGING SYSTEM

CH0IW-01

ON-VEHICLE INSPECTION

CAUTION:

Check that the battery cables are connected to the

correct terminals. Disconnect the battery cables when the battery is giv-

en a quick charge. Do not perform tests with a high voltage insulation re-

sistance tester. Never disconnect the battery while the engine is run- ning.

Z18925
Z18925
  • 1. CHECK BATTERY ELECTROLYTE LEVEL

Check the electrolyte quantity of each cell. (Maintenance-Free Battery) If under the lower level, replace the battery (or add distilled wa- ter if possible) and check the charging system. (Except Maintenance-Free Battery) If under the lower level, add distilled water.

Except Maintenance-Free Battery

Except Maintenance-Free Battery S05376

S05376

  • 2. (Except Maintenance-Battery) CHECK BATTERY SPECIFIC GRAVITY

Check the specific gravity of each cell. Standard specific gravity: At 20°C (68°F): 1.25 - 1.29 If the specific gravity is less than specification, charge the bat-

tery.

2002 4RUNNER

(RM887U)

Author :

Date :

1060

CH-2

CHARGING (5VZ-FE)

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CHARGING SYSTEM

Maintenance-Free Battery Voltmeter Z18827
Maintenance-Free Battery
Voltmeter
Z18827
  • 3. (Maintenance-Free Battery) CHECK BATTERY VOLTAGE

Measure the battery voltage between the negative (-) and posi-

tive (+) terminals of the battery. Standard voltage: At 20°C (68°F): 12.7 - 12.9 V

HINT:

Before measuring the voltage, turn the ignition switch OFF and turn off the electrical systems (headlight, blower

motor, rear defogger etc.) for 60 secondsto remove the

surface charge. When measuring the voltage, however, turn the ignition switch OFF and turn off the electrical systems. If the voltage is less than the specification, charge the battery.

Maintenance-Free Battery Blue White Red OK Charging Insufficient Necessary Water Z11580
Maintenance-Free Battery
Blue
White
Red
OK
Charging
Insufficient
Necessary
Water
Z11580

HINT:

Check the indicator as shown in the illustration.

P15119
P15119
  • 4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES

    • (a) Check that the battery terminals are not loose or cor- roded.

    • (b) Check the fusible link and fuses for continuity.

P06717 2002 4RUNNER (RM887U)
P06717
2002 4RUNNER
(RM887U)
  • 5. INSPECT DRIVE BELT

    • (a) Visually check the belt for excessive wear, frayed cords etc.

HINT:

Cracks on the ribbed side of the belt are considered acceptable. If the belt has chunks missing from the ribs, it should be re- placed.

Author :

Date :

1061

CHARGING (5VZ-FE)

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CHARGING SYSTEM

CH-3

Nippondenso Borroughs Z00038
Nippondenso
Borroughs
Z00038
  • (b) Using a belt tension gauge, check the drive belt tension. Belt tension gauge: Nippondenso BTG 20 (95506-00020) or Borroughs No. BT-33-73F Drive belt tension:

New belt: 160 ± 20 lbf Used belt: 100 ± 20 lbf If necessary, adjust the drive belt tension.

CORRECT WRONG WRONG P06723
CORRECT
WRONG
WRONG
P06723
Ammeter Disconnect Wire from Terminal B Battery B Generator Voltmeter Z10324
Ammeter
Disconnect Wire
from Terminal B
Battery
B
Generator
Voltmeter
Z10324

HINT:

”New belt” refers to a belt which has been used less than

of the crank pulley.

5 minutes on a running engine. ”Used belt” refers to a belt which has been used on a run-

ning engine for 5 minutes or more. After installing the drive 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

After installing a new belt, run the engine for approx. 5 minutes and then recheck the tension.

6.

INSPECT FUSES FOR CONTINUITY

ENGINE 10A

CHARGE 7.5A

IGN 7.5A

7.

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 generator while the engine is running.

8.

CHECK CHARGING CIRCUIT WITHOUT LOAD

HINT:

If a battery/generator tester is available, connect the tester to the charging circuit according to the manufactuer’s instructions.

  • (a) If a tester is not available, connect a voltmeter and amme- ter to the charging circuit as follows:

Disconnect the wire from terminal B of the generator

and connect the wire to the negative (-) terminal of the ammeter. Connect the test lead from the positive (+) terminal

of the ammeter to terminal B of the generator. Connect the positive (+) lead of the voltmeter to ter-

minal B of the generator. Ground the negative (-) lead of the voltmeter.

2002 4RUNNER

(RM887U)

Author :

Date :

1062

CH-4

CHARGING (5VZ-FE)

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CHARGING SYSTEM

  • (b) Check the charging circuit as follows: With the engine running from idling to 2,000 rpm, check the reading on the ammeter and voltmeter. Standard amperage: 10 A or less Standard voltage:

At 25 °C (77 °F): 13.7 - 14.7 V At 115 °C (239 °F): 13.2 - 14.0 V If the voltage reading is greater than the standard voltage, check the voltage regulator (See page CH-9 ).

  • 9. INSPECT CHARGING CIRCUIT WITH LOAD

    • (a) With the engine running at 2,000 rpm, turn on the high beam headlights and place the heater fan control switch to HI.

    • (b) Check the reading on the ammeter. Standard amperage: 30 A or more

If the ammeter reading is less than 30 A, repair the generator.

HINT:

If the battery is fully charged, the indication will sometimes be less than 30 A.

2002 4RUNNER

(RM887U)

Author :

Date :

1063

CHARGING (5VZ-FE)

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GENERATOR

CH-5

GENERATOR

CH00F-03

COMPONENTS Generator Connector Generator Wire Adjusting Bolt Pivot Bolt Lock Nut Drive Belt Generator S02091
COMPONENTS
Generator Connector
Generator Wire
Adjusting
Bolt
Pivot Bolt
Lock Nut
Drive Belt
Generator
S02091
Rear Bearing Retainer Drive End Frame (Starter) Bearing Cover Pulley Bearing (outside) Cover (inside) Rotor Front
Rear Bearing
Retainer
Drive End Frame (Starter)
Bearing
Cover
Pulley
Bearing
(outside)
Cover
(inside)
Rotor
Front Bearing
Rear End Cover
Brush
Voltage Regulator
Rubber Insulator x4
Spring
Brush Holder Cover
Brush Holder
Rectifier Holder
Generator Washer
Rectifier End Frame
Terminal Insulator
S05685
2002 4RUNNER
(RM887U)
Author :
Date :
1064

CH-6

CHARGING (5VZ-FE)

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GENERATOR

Pivot Bolt Adjusting Bolt Lock Nut P20342
Pivot Bolt
Adjusting Bolt
Lock Nut
P20342

REMOVAL

CH00G-03

  • 1. DISCONNECT WIRING FROM GENERATOR

    • (a) Disconnect the connector from the generator.

    • (b) Remove the nut and disconnect the wire from the genera- tor.

      • 2. REMOVE GENERATOR DRIVE BELT

Loosen the adjust lock nut, adjusting bolt and pivot bolt, and re-

move the drive belt.

Pivot Bolt Lock Nut P20343
Pivot Bolt
Lock Nut
P20343
  • 3. REMOVE GENERATOR

    • (a) Remove the pivot bolt and adjusting lock nut.

    • (b) Remove the generator. Torque: Pivot bolt: 51 N·m (520kgf·cm, 38 ft·lbf) Lock Nut: 18.5 N·m (189kgf·cm, 25 ft·lbf)

2002 4RUNNER

(RM887U)

Author :

Date :

1065

CHARGING (5VZ-FE)

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GENERATOR

CH-7

P13397
P13397

CH00H-03

DISASSEMBLY

  • 1. REMOVE REAR END COVER

    • (a) Remove the nut and terminal insulator.

    • (b) Remove the 3 nuts and end cover.

P13398
P13398
  • 2. REMOVE BRUSH HOLDER

    • (a) Remove the 2 screws, brush holder and cover.

P13623
P13623
  • (b) Remove the brush holder cover from the brush holder.

P13396
P13396
  • 3. REMOVE VOLTAGE REGULATOR

Remove the 3 screws and voltage regulator.

P20344 2002 4RUNNER (RM887U)
P20344
2002 4RUNNER
(RM887U)
  • 4. REMOVE RECTIFIER HOLDER

    • (a) Remove the 4 screws and rectifier holder.

Author :

Date :

1066

CH-8

CHARGING (5VZ-FE)

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GENERATOR

P20346
P20346
  • (b) Remove the 4 rubber insulators.

SST (A) SST (B) CH0213
SST (A)
SST (B)
CH0213
  • 5. REMOVE PULLEY

    • (a) Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST

09820-6301 1

Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

  • (b) Check that SST (A) is secured to the rotor shaft.

SST (C) Z00040
SST (C)
Z00040
P20347
P20347
  • (c) As shown in the illustration, mount SST (C) in a vise, and install the generator with SST (A) and (B) to SST (C).

  • (d) 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.

  • (e) Remove the generator with SST (A) and (B) from SST (C).

  • (f) Turn SST (B) and remove SST (A) and (B).

  • (g) Remove the pulley nut and pulley.

    • 6. REMOVE RECTIFIER END FRAME

      • (a) Remove the 4 nuts.

SST CH0335 2002 4RUNNER (RM887U)
SST
CH0335
2002 4RUNNER
(RM887U)
  • (b) Using SST, remove the rectifier end frame. SST 09286-4601 1

  • (c) Using snap ring pliers, remove the generator washer from the rectifier end frame.

    • 7. REMOVE ROTOR FROM DRIVE END FRAME

Author :

Date :

1067

CH-9

CHARGING (5VZ-FE) - GENERATOR INSPECTION 1. INSPECT VOLTAGE REGULATOR Ohmmeter (a) Using an ohmmeter, check the
CHARGING (5VZ-FE)
-
GENERATOR
INSPECTION
1.
INSPECT VOLTAGE REGULATOR
Ohmmeter
(a)
Using an ohmmeter, check the continuity between termi-
nals F and B.
Standard:
F
B
When the positive and negative poles between termi-
nals F and B are exchanged, there is continuity in one
way but no continuity in another way.
B12989
If the continuity is not as specified, replace the voltage regula-
tor.
E Ohmmeter F B12990
E
Ohmmeter
F
B12990

CH0IX-02

  • (b) Using an ohmmeter, check the continuity between termi- nals F and E. Standard: When the positive and negative poles between termi- nals F and E are exchanged, there is continuity in one way but no continuity in another way.

If the continuity is not as specified, replace the voltage regula- tor.

Ohmmeter Continuity
Ohmmeter
Continuity

CH0784

  • 2. INSPECT ROTOR FOR OPEN CIRCUIT

Using an ohmmeter, check that there is continuity between the

slip rings. Standard resistance: At 20°C (68°F): 2.1 - 2.5 If there is no continuity, replace the rotor.

CH-9 CHARGING (5VZ-FE) - GENERATOR INSPECTION 1. INSPECT VOLTAGE REGULATOR Ohmmeter (a) Using an ohmmeter, check
CH0783
CH0783
Ohmmeter No Continuity 2002 4RUNNER (RM887U)
Ohmmeter
No Continuity
2002 4RUNNER
(RM887U)
  • 3. INSPECT ROTOR FOR GROUND

Using an ohmmeter, check that there is no continuity between the slip ring and rotor. If there is continuity, replace the rotor.

Author :

Date :

1068

CH-10

CHARGING (5VZ-FE)

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GENERATOR

CH0192
CH0192
  • 4. INSPECT SLIP RINGS

    • (a) Check that the slip rings are not rough or scored.

If rough or scored, replace the rotor.

  • (b) Using vernier calipers, measure the slip ring diameters. 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 the minimum, replace the rotor.

Continuity Ohmmeter CH0806
Continuity
Ohmmeter
CH0806
  • 5. INSPECT STATOR FOR OPEN CIRCUIT

Using an ohmmeter, check that there is continuity between the coil leads. If there is no continuity, replace the drive end frame assembly.

No Continuity Ohmmeter CH0803
No Continuity
Ohmmeter
CH0803
  • 6. INSPECT STATOR FOR GROUND

Using an ohmmeter, check that there is no continuity between the coil leads and drive end frame. If there is continuity, replace the drive end frame assembly.

P13395
P13395
  • 7. INSPECT EXPOSED BRUSH LENGTH

Using a scale, measure the exposed brush length.

Standard exposed length:

9.5 - 11.5 mm (0.374 - 0.452 in.) Minimum exposed length: 1.5 mm (0.059 in.)

If the exposed length is less than the minimum, replace the

brushes.

CH0248 2002 4RUNNER (RM887U)
CH0248
2002 4RUNNER
(RM887U)
  • 8. IF NECESSARY, REPLACE BRUSHES

    • (a) Unsolder and remove the brush and spring.

    • (b) Run the wire of the brush through the hole in the brush holder, and insert the spring and brush into the brush holder.

Author :

Date :

1069

CHARGING (5VZ-FE)

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GENERATOR

CH-1 1

9.5 - 11.5 mm (0.374 - 0.452 in.) Z19065
9.5 - 11.5 mm (0.374 - 0.452 in.)
Z19065
  • (c) Solder the brush wire to the brush holder at the exposed length. Exposed length: 9.5 - 11.5 mm (0.374 - 0.452 in.)

  • (d) Check that the brush moves smoothly in the brush holder.

  • (e) Cut off the excess wire.

  • (f) Apply insulation paint to the soldered point.

S02207 Ohmmeter Positive (+) Terminal Rectifer Terminal
S02207
Ohmmeter
Positive (+)
Terminal
Rectifer
Terminal
  • 9. INSPECT POSITIVE RECTIFIER

    • (a) Using an ohmmeter, connect one tester probe to the posi- tive (+) terminal and the other to each rectifier terminal.

    • (b) Reverse the polarity of the tester probes and repeat step (a).

    • (c) Check that one shows continuity and the other shows no

continuity. If continuity is not as specified, replace the rectifier holder.

10. INSPECT NEGATIVE RECTIFIER Ohmmeter (a) Using an ohmmeter, connect one tester probe to each negative
10.
INSPECT NEGATIVE RECTIFIER
Ohmmeter
(a)
Using an ohmmeter, connect one tester probe to each
negative (-) terminal and the other to each rectifier termi-
nal.
Negative (-)
(b)
Reverse the polarity of the tester probes and repeat step
Terminal
(a).
(c)
Check that one shows continuity and the other shows no
continuity.
If continuity is not as specified, replace the rectifier holder.
S02206
Socket Wrench B00544
Socket Wrench
B00544
  • 11. INSPECT FRONT BEARING

Check that the bearing is not rough or worn.

  • 12. IF NECESSARY, REPLACE FRONT BEARING

    • (a) Remove the 4 screws and bearing retainer.

    • (b) Using a press and socket wrench, press out the front bearing.

SST P22369 2002 4RUNNER (RM887U)
SST
P22369
2002 4RUNNER
(RM887U)
  • (c) Using SST and a press, press the front bearing into the drive end frame. SST 09950-60010 (09951-00500)

  • (d) Install the bearing retainer with the 4 screws.

Author :

Date :

1070

CH-12

CHARGING (5VZ-FE)

-

GENERATOR

SST
SST

N00581

  • 13. INSPECT REAR BEARING

Check that the bearing is not rough or worn.

  • 14. IF NECESSARY, REPLACE REAR BEARING

    • (a) Using SST, remove the bearing cover and bearing. SST 09820-00021

    • (b) Remove the bearing cover (inside).

P13567

P13567

  • (c) Place the bearing cover (inside) on the rotor.

SST
SST

N00578

  • (d) Using SST and a press, press in a new bearing and the bearing cover. SST 09820-00031

SST P00074

SST

P00074

  • (e) Using SST, push in the bearing cover (outside). SST 09285-76010

S05684 2002 4RUNNER (RM887U)
S05684
2002 4RUNNER
(RM887U)
  • (f) Place the generator washer on the rotor.

Author :

Date :

1071

CHARGING (5VZ-FE)

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GENERATOR

CH-13

P04218
P04218

REASSEMBLY

CH00J-03

  • 1. PLACE RECTIFIER END FRAME ON PULLEY

  • 2. INSTALL ROTOR TO DRIVE END FRAME

29 mm Socket Wrench P13695
29 mm
Socket
Wrench
P13695
  • 3. INSTALL RECTIFIER END FRAME

    • (a) Install the generator washer to the rectifier end frame.

NOTICE:

Be careful of the generator washer installation direction.

  • (b) Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.

  • (c) Install the 4 nuts. Torque: 4.5 N·m (45 kgf·cm, 39 in.·lbf)

SST (A) SST (B) CH0213
SST (A)
SST (B)
CH0213
  • 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 09820-6301 1 Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

    • (c) Check that SST (A) is secured to the pulley shaft.

SST (C) Z00045
SST (C)
Z00045
  • (d) As shown in the illustration, mount SST (C) in a vise, and install the generator with SST (A) and (B) to SST (C).

  • (e) To torque the pulley nut, turn SST (A) in the direction shown in the illustration. Torque: 110 N·m (1,125 kgf·cm, 81 ft·lbf)

  • (f) Remove the generator with SST (A) and (B) from SST (C).

  • (g) Turn SST (B) and remove SST (A) and (B).

    • 5. INSTALL RECTIFIER HOLDER

      • (a) Install the 4 rubber insulators on the lead wires.

      • (b) Install the rectifier with the 4 screws. Torque: 2.0 N·m (20 kgf·cm, 18 in.·lbf)

2002 4RUNNER

(RM887U)

Author :

Date :

1072

CH-14

CHARGING (5VZ-FE)

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GENERATOR

P14035
P14035
  • 6. INSTALL BRUSH HOLDER AND VOLTAGE REGULA- TOR

    • (a) Place the brush holder cover to the brush holder.

    • (b) Install the voltage regulator and brush holder to the rear end frame horizontally as shown in the illustration.

HINT:

Check that the brush holder’s cover doesn’t slip to one side dur- ing installation.

1 mm P13394
1 mm
P13394
  • (c) Tighten the 5 screws until there is a clearance of at least 1 mm (0.04 in.) between the brush holder cover and con- nector.

    • 7. INSTALL REAR END COVER

      • (a) Install the end cover with the 3 nuts. Torque: 4.5 N·m (45 kgf·cm, 39 in.·lbf)

      • (b) Install the terminal insulator with the nut. Torque: 4.1 N·m (42 kgf·cm, 36 in.·lbf)

        • 8. MAKE SURE ROTOR ROTATES SMOOTHLY

2002 4RUNNER

(RM887U)

Author :

Date :

1073

 

CH-15

 

CHARGING (5VZ-FE)

-

GENERATOR

 

CH00K-02

INSTALLATION

 

Installation is in the reverse order of removal (See page CH-6 ).

 

2002 4RUNNER

(RM887U)

 

Author :

Date :

1074