2GR-FE CHARGING CHARGING SYSTEM

CH1
CH
CHARGING SYSTEM
PRECAUTION
1. Check that the battery cables are connected to the
correct terminals.
2. Disconnect the battery cables when the battery is
given a quick charge.
3. Do not perform tests with a high voltage insulation
resistance tester.
4. Never disconnect the battery while the engine is
running.
5. Check that the charging cable nut is tightened on
terminal B of the generator and the engine room R/B.
CH2
2GR-FE CHARGING CHARGING SYSTEM
CH
PARTS LOCATION
INSTRUMENT PANEL J/B
-GAUGE NO. 1 FUSE
-GAUGE NO. 2 FUSE
-ALT-S FUSE
-ALT FUSE
ENGINE ROOM R/B
COMBINATION METER
-CHARGE WARNING LIGHT
GENERATOR
A135521E01
2GR-FE CHARGING CHARGING SYSTEM
CH3
CH
SYSTEM DIAGRAM
From Battery
From IG1 Relay
From IG2 Relay
ALT-S
GAUGE No. 1
GAUGE No. 2
F1
13
IG+ IG+
Charge
CHG-
F1
23
Combination Meter
IC
Regulator
C18
C18
C18
4
2
1
S
IG
L
Generator
C19
1
B
ALT
FL MAIN
Battery
A138773E01
CH4
2GR-FE CHARGING CHARGING SYSTEM
CH
PROBLEM SYMPTOMS TABLE
Result
Symptom Suspected area See page
Charge Warning Light Comes ON while Driving
1. Clutch pulley
CH-7
2. Generator assembly
Noise Occurs from Generator while Engine is Running
1. V-ribbed belt
CH-8 2. Clutch pulley
3. Generator assembly
2GR-FE CHARGING CHARGING SYSTEM
CH5
CH
ON-VEHICLE INSPECTION
1. CHECK BATTERY ELECTROLYTE LEVEL
(a) Check the electrolyte level.
(1) If the electrolyte level is low, replace the battery
(or add distilled water) and check the charging
system.
2. CHECK BATTERY SPECIFIC GRAVITY
(a) Check the color of the indicator.
Result
3. CHECK BATTERY VOLTAGE
(a) If it has not been 20 minutes since you drove the
vehicle or since the engine was stopped, turn the
ignition switch on (IG) and turn on the electrical
systems (headlight, blower motor, rear defogger,
etc.) for 60 seconds. This will remove the surface
charge from the battery.
(b) Turn off the ignition switch and the electrical
systems.
(c) Measure the battery voltage between the negative (-
) and positive (+) terminals of the battery.
Standard voltage:
12.5 to 12.9 V at 20C (68F)
HINT:
If the voltage is below the specification, charge the
battery.
4. CHECK BATTERY TERMINAL
(a) Check that the battery terminals are not loose or
corroded.
If the terminals are corroded, clean them.
5. CHECK FUSES
(a) Measure the resistance of the ALT fuse, ALT-S fuse,
GAUGE No. 1 fuse and GAUGE No. 2 fuse.
Standard resistance:
Below 1
If the result is not as specified, replace the fuses as
necessary.
6. CHECK V-RIBBED BELT
(a) Check the belt for wear, cracks or other signs of
damage.
If any of the following defects is found, replace the
V-ribbed belt.
The belt is worn out, cracked, or the cords are
exposed.
The cracks reach the cords in more than one
place.
The belt has chunks missing from the ribs.
Green Dark Clear or Light Yellow
A115815E01
Indicator color Condition
Green Good
Dark Charging necessary
Clear or light yellow Replacement necessary
A081052E01
B000543
CH6
2GR-FE CHARGING CHARGING SYSTEM
CH
(b) Check that the belt fits properly in the ribbed
grooves.
HINT:
Check with your hand to confirm that the belt has
not slipped out of the groove on the bottom of the
pulley.
If it has slipped out, replace the V-ribbed belt. Install
a new V-ribbed belt correctly.
7. VISUALLY CHECK GENERATOR WIRING
(a) Check that the generator wiring is in good condition.
If the condition is not good, repair or replace the
generator wire.
8. LISTEN FOR ABNORMAL NOISES FROM
GENERATOR
(a) Check that there is no abnormal noise from the
generator while the engine is running.
If there is abnormal noise, replace the pulley or
generator.
9. CHECK CHARGE WARNING LIGHT CIRCUIT
(a) Turn the ignition switch on (IG). Check that the
charge warning light comes on.
(b) Start the engine and check that the light goes off.
If the light does not operate as specified,
troubleshoot the charge warning light circuit.
10. CHECK CHARGING CIRCUIT WITHOUT LOAD
(a) According to the following procedure, connect an
ammeter and voltmeter as shown in the illustration.
(1) Disconnect the wire from terminal B of the
generator and connect it to the negative (-) lead
of the ammeter.
(2) Connect the positive (+) lead of the ammeter to
terminal B of the generator.
(3) Connect the positive (+) lead of the voltmeter to
positive (+) terminal of the battery.
(4) Ground the negative (-) lead of the voltmeter.
(b) Check the charging circuit.
(1) While keeping the engine speed at 2,000 rpm,
check the readings on the ammeter and
voltmeter.
Standard amperage:
10 A or less
Standard voltage:
13.2 to 14.8 V
If the results are not as specified, replace the
generator assembly.
HINT:
If the battery is not fully charged, the
ammeter reading may be more than the
standard amperage. In this case, increase
electrical load by operating devices such as
the wiper motor and rear window defogger.
Then, recheck the reading on the ammeter.
CORRECT INCORRECT
B000540E03

V

A
Disconnect
Wire from
Terminal B
Ammeter
Battery
Battery
Generator
Voltmeter
A110265E04
2GR-FE CHARGING CHARGING SYSTEM
CH7
CH
11. CHECK CHARGING CIRCUIT WITH LOAD
(a) Keep the engine speed at 2,000 rpm, turn on the
high beam headlights, and turn the heater blower
switch to the "HI" position.
(b) Check the reading on the ammeter.
Standard amperage:
30 A or more
If the ammeter reading is less than the standard
amperage, replace the generator assembly.
HINT:
If the battery is fully charged, the ammeter
reading may be less than the standard
amperage. In this case, increase electrical load
by operating devices such as the wiper motor
and rear window defogger. Then, recheck the
reading on the ammeter.
CH8
2GR-FE CHARGING CHARGING SYSTEM
CH
INSPECTION PROCEDURE
(a) Check the lock function with the pulley installed in the
vehicle.
(1) Visually check that the rotor in the generator
operates with the engine started.
(b) Check the lock function with the pulley removed from the
vehicle.
(1) Remove the generator pulley cap. Using SST, hold
the generator rotor.
(2) Turn the clutch pulley clockwise and check that the
outer ring locks.
OK:
The outer ring locks.
SST 09820-63020
NG
OK
(a) Start the engine and visually check looseness of the
clutch pulley.
OK:
The clutch pulley is not loose.
NG
OK
Charge Warning Light Comes ON while Driving
1 CHECK LOCK FUNCTION OF CLUTCH PULLEY
Free Lock
A128078E01
REPLACE CLUTCH PULLEY
2 CHECK LOCK OF CLUTCH PULLEY
TIGHTEN CLUTCH PULLEY TO THE
SPECIFIED TORQUE
REPLACE GENERATOR ASSEMBLY
2GR-FE CHARGING CHARGING SYSTEM
CH9
CH
INSPECTION PROCEDURE
(a) Check the tension of the belt by pushing it down with a
finger.
OK:
The tension of the belt is enough.
NG
OK
(a) Check the V-ribbed belt for wear.
OK:
The V-ribbed belt is not worn.
NG
OK
(a) Check the clutch pulley groove for wear or other defects.
OK:
The clutch pulley groove is not damaged.
NG
OK
(a) Perform a driving test and check if noise occurs when
decelerating.
OK:
Noise does not occur.
NG
OK
Noise Occurs from Generator while Engine is Running
1 CHECK LOOSENESS OF V-RIBBED BELT
REPLACE V-RIBBED BELT TENSIONER
ASSEMBLY
2 CHECK V-RIBBED BELT FOR WEAR
REPLACE V-RIBBED BELT
3 CHECK CLUTCH PULLEY FOR WEAR
REPLACE CLUTCH PULLEY
4 CHECK FOR NOISE WHILE CLUTCH PULLEY IS OPERATING
REPLACE CLUTCH PULLEY
REPLACE GENERATOR ASSEMBLY
2GR-FE CHARGING GENERATOR
CH9
CH
ENGINE 2GR-FE CHARGING
GENERATOR
COMPONENTS
NO. 1 AIR CLEANER INLET
COOL AIR INTAKE DUCT SEAL
V-BANK COVER SUB-ASSEMBLY
5.0 (51, 44 in.*lbf)
5.0 (51, 44 in.*lbf)
N*m (kgf*cm, ft.*lbf) : Specified torque
x2
AIR CLEANER FILTER ELEMENT
AIR CLEANER CAP SUB-ASSEMBLY
AIR CLEANER INLET ASSEMBLY
A134975E01
CH10
2GR-FE CHARGING GENERATOR
CH
RADIATOR SUPPORT UPPER
RADIATOR GRILLE
PROTECTOR
N*m (kgf*cm, ft.*lbf) : Specified torque
7.0 (71, 62 in.*lbf)
7.5 (77, 66 in.*lbf)
7.5 (77, 66 in.*lbf)
7.0 (71, 62 in.*lbf)
x2
x4
x2
x2
x2
x9
ENGINE UNDER COVER LH
ENGINE UNDER COVER RH
FRONT WHEEL OPENING
EXTENSION PAD RH
FRONT WHEEL OPENING
EXTENSION PAD LH
FRONT BUMPER ASSEMBLY
FRONT BUMPER
ENERGY ABSORBER
HOOD LOCK ASSEMBLY
HORN CONNECTOR
A133359E05
2GR-FE CHARGING GENERATOR
CH11
CH
N*m (kgf*cm, ft.*lbf) : Specified torque
8.4 (86, 74 in.*lbf)
20 (204, 15)
20 (204, 15)
43 (438, 32)
43 (438, 32)
9.8 (100, 87 in.*lbf)
GENERATOR BRACKET
FAN SHROUD
RADIATOR ASSEMBLY
RADIATOR INLET HOSE
RADIATOR OUTLET HOSE
5.0 (51, 44 in.*lbf)
V-RIBBED BELT
FAN MOTOR
CONNECTOR
WIRE HARNESS
CLAMP STAY
x4
FRONT FENDER APRON SEAL RH
GENERATOR ASSEMBLY
A133878E01
CH12
2GR-FE CHARGING GENERATOR
CH
GENERATOR BRUSH
HOLDER ASSEMBLY
GENERATOR
CLUTCH PULLEY
GENERATOR COIL ASSEMBLY
GENERATOR DRIVE END
FRAME BEARING
GENERATOR REAR END COVER
GENERATOR
ROTOR ASSEMBLY
GENERATOR TERMINAL INSULATOR
N*m (kgf*cm, ft.*lbf) : Specified torque
Non-reusable part
4.6 (47, 41 in.*lbf)
x3
x4
5.8 (59, 51 in.*lbf)
x2
1.8 (18, 16 in.*lbf)
GENERATOR
WASHER
GENERATOR
PULLEY CAP
111 (1,125, 81)
GENERATOR DRIVE END FRAME
BEARING RETAINER
2.3 (23, 20 in.*lbf)
x4
A135482E01
2GR-FE CHARGING GENERATOR
CH13
CH
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2. REMOVE FRONT WHEEL RH
3. REMOVE FRONT FENDER APRON SEAL RH
4. REMOVE FRONT WHEEL OPENING EXTENSION
PAD RH
5. REMOVE FRONT WHEEL OPENING EXTENSION
PAD LH
6. REMOVE ENGINE UNDER COVER RH
7. REMOVE ENGINE UNDER COVER LH
8. DRAIN ENGINE COOLANT (See page CO-5)
9. REMOVE V-BANK COVER SUB-ASSEMBLY (See
page EM-23)
10. REMOVE COOL AIR INTAKE DUCT SEAL (See page
EM-23)
11. REMOVE AIR CLEANER INLET ASSEMBLY (See
page EM-24)
12. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See
page ES-503)
13. REMOVE NO. 1 AIR CLEANER INLET (See page EM-
24)
14. REMOVE FRONT BUMPER ASSEMBLY (w/o Fog
Light) (See page ET-5)
15. REMOVE FRONT BUMPER ASSEMBLY (w/ Fog
Light) (See page ET-6)
16. REMOVE FRONT BUMPER ENERGY ABSORBER
(See page ET-9)
17. SEPARATE RADIATOR RESERVE TANK HOSE (See
page CO-24)
18. SEPARATE RADIATOR INLET HOSE (See page CO-
24)
19. SEPARATE RADIATOR OUTLET HOSE (See page
CO-24)
20. SEPARATE NO. 1 OIL COOLER INLET HOSE (See
page CO-25)
21. SEPARATE NO. 1 OIL COOLER OUTLET HOSE (See
page CO-25)
22. REMOVE RADIATOR SUPPORT UPPER (See page
CO-25)
23. REMOVE FAN SHROUD (See page CO-26)
24. REMOVE RADIATOR ASSEMBLY (See page CO-26)
25. REMOVE V-RIBBED BELT (See page EM-6)
CH14
2GR-FE CHARGING GENERATOR
CH
26. REMOVE GENERATOR ASSEMBLY
(a) Remove the terminal cap.
(b) Remove the nut and disconnect the wire harness
from terminal B.
(c) Disconnect the generator connector from the
generator assembly.
(d) Disconnect the connector from the compressor and
magnetic clutch.
(e) Disconnect the 2 wire harness clamps.
(f) Remove the 2 bolts.
(g) Remove the bolt from the cylinder block.
(h) Disconnect the wire harness clamp and remove the
generator assembly.
(i) Remove the bolt and wire harness clamp stay.
(j) Remove the bolt and bracket.
A133865
A133866
A133867
A128066
A135391
2GR-FE CHARGING GENERATOR
CH15
CH
DISASSEMBLY
1. REMOVE GENERATOR CLUTCH PULLEY
(a) Using a screwdriver, remove the generator pulley
cap.
(b) Set SST (A) and (B).
SST 09820-63020
(c) Clamp SST (A) in a vise.
(d) Place the rotor shaft end into SST (A).
(e) Fit SST (B) to the clutch pulley.
(f) Loosen the pulley by turning SST (B) in the direction
shown in the illustration.
(g) Remove the generator assembly from the SST.
(h) Remove the clutch pulley from the rotor shaft.
A128068E01
SST (A)
SST (B)
A128069E01
SST (B) SST (A)
Rotor Shaft
A135194E01
SST (B)
Clutch Pulley
SST (B)
A135195E01
SST (B)
A135196E01
CH16
2GR-FE CHARGING GENERATOR
CH
2. REMOVE GENERATOR REAR END COVER
(a) Place the generator assembly on the clutch pulley.
(b) Remove the 3 nuts and generator rear end cover.
3. REMOVE GENERATOR TERMINAL INSULATOR
(a) Remove the terminal insulator from the generator
coil.
4. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
(a) Remove the 2 screws and brush holder from the
generator coil.
5. REMOVE GENERATOR COIL ASSEMBLY
(a) Remove the 4 bolts.
A135197
A128071
A128072
A128073
A128074
2GR-FE CHARGING GENERATOR
CH17
CH
(b) Using SST, remove the generator coil assembly.
SST 09950-40011 (09951-04020, 09952-04010,
09953-04020, 09954-04010, 09955-04071,
09957-04010, 09958-04011)
6. REMOVE GENERATOR ROTOR ASSEMBLY
(a) Remove the generator washer.
(b) Remove the generator rotor assembly.
7. REMOVE GENERATOR DRIVE END FRAME
BEARING
(a) Remove the 4 screws and retainer plate from the
drive end frame.
(b) Using SST and a hammer, tap out the drive end
frame bearing from the drive end frame.
SST 09950-60010 (09951-00250), 09950-70010
(09951-07100)
SST
Turn
SST
Hold
A118275E01
A118365E01
A118367E01
A128076
SST
A128077E01
CH18
2GR-FE CHARGING GENERATOR
CH
INSPECTION
1. INSPECT GENERATOR CLUTCH PULLEY
(a) Hold the center of the pulley, and confirm that the
outer ring turns counterclockwise and does not turn
clockwise.
If the result is not as specified, replace the clutch
pulley.
2. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY
(a) Using vernier calipers, measure the length of the
exposed brushes.
Standard exposed length:
9.5 to 11.5 mm (0.374 to 0.453 in.)
Minimum exposed length:
4.5 mm (0.177 in.)
If the exposed length is less than the minimum,
replace the brush holder assembly.
3. INSPECT GENERATOR ROTOR ASSEMBLY
(a) Check that the generator rotor bearing is not rough
or worn.
If necessary, replace the generator rotor assembly.
(b) Check the generator rotor for an open circuit.
(1) Using an ohmmeter, measure the resistance
between the slip rings.
Standard resistance
If the result is not as specified, replace the
generator rotor assembly.
(c) Check the rotor for a short to ground.
(1) Using an ohmmeter, measure the resistance
between the slip ring and rotor.
Standard resistance
If the result is not as specified, replace the
generator rotor assembly.
Free Lock
A128078E01
Length
A128079E01
A079306E02
Ohmmeter
Slip Rings
B012264E08
Condition Specified condition
Approx. 20C (68F) 2.3 to 2.7
Ohmmeter
Slip Ring
Rotor
B012265E01
Tester condition Specified condition
Slip ring - Rotor 1 M or higher
2GR-FE CHARGING GENERATOR
CH19
CH
(d) 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 the minimum, replace the
generator rotor assembly.
4. INSPECT GENERATOR DRIVE END FRAME
BEARING
(a) Check that the drive end frame bearing is not rough
or worn.
If necessary, replace the drive end frame bearing.
REASSEMBLY
1. INSTALL GENERATOR DRIVE END FRAME
BEARING
(a) Using SST and a press, press in a new generator
drive end frame bearing.
SST 09950-60010 (09951-00470), 09950-70010
(09951-07100)
(b) Fit the tabs on the retainer plate into the cutouts on
the drive end frame to install the retainer plate.
(c) Install the 4 screws.
Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf)
2. INSTALL GENERATOR ROTOR ASSEMBLY
(a) Place the drive end frame on the clutch pulley.
(b) Install the generator rotor assembly to the drive end
frame.
Diameter
A124106E01
A128080
SST
A128081E01
Tab
Cutout
A137712E01
A118367E01
CH20
2GR-FE CHARGING GENERATOR
CH
(c) Place a new generator washer on the generator
rotor.
3. INSTALL GENERATOR COIL ASSEMBLY
(a) Using a deep socket wrench (21 mm) and a press,
slowly press in the generator coil assembly.
(b) Install the 4 bolts.
Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf)
4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
(a) While pushing the 2 brushes into the generator
brush holder assembly, insert a 1.0 mm (0.039 in.)
pin into the brush holder hole.
(b) Install the brush holder assembly to the generator
coil with the 2 screws.
Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf)
(c) Pull out the pin from the generator brush holder.
A118365E01
Deep socket
wrench (21 mm)
A128082E01
A128074
Pin
A079315E04
Pin
A079316E02
2GR-FE CHARGING GENERATOR
CH21
CH
5. INSTALL GENERATOR TERMINAL INSULATOR
(a) Install the terminal insulator to the generator coil.
NOTICE:
Pay attention to installation direction of the
terminal insulator.
6. INSTALL GENERATOR REAR END COVER
(a) Install the generator rear end cover to the generator
coil with the 3 nuts.
Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)
7. REMOVE GENERATOR CLUTCH PULLEY
(a) Temporarily install the clutch pulley onto the rotor
shaft.
(b) Set SST (A) and (B).
SST 09820-63020
(c) Clamp SST (A) in a vise.
(d) Place the rotor shaft end into SST (A).
(e) Fit SST (B) to the clutch pulley.
A128083E01
A128071
SST (A)
SST (B)
A128084E01
SST (B) SST (A)
Rotor Shaft
A135194E01
SST (B)
Clutch Pulley
SST (B)
A135195E01
CH22
2GR-FE CHARGING GENERATOR
CH
(f) Tighten the pulley by turning SST (B) in the direction
shown in the illustration.
Torque: 111 N*m (1,125 kgf*cm, 81 ft.*lbf)
NOTICE:
The torque shown above should be used for
tightening without using the SST. When the SST
is used for tightening, the torque should be
calculated based on the length of the SST (See
page IN-6).
(g) Remove the generator assembly from the SST.
(h) Check that the clutch pulley rotates smoothly.
(i) Install a new clutch pulley cap to the clutch pulley.
INSTALLATION
1. INSTALL GENERATOR ASSEMBLY
(a) Install the bracket with the bolt.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
(b) Install the wire harness clamp stay.
Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
(c) Connect the wire harness clamp.
(d) Install the generator assembly to the cylinder block
with the bolt.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
100 mm (3.937 in.)
SST (B)
A135208E01
A135391
A128066
A133867
2GR-FE CHARGING GENERATOR
CH23
CH
(e) Install the 2 bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
(f) Connect the generator connector to the generator
assembly.
(g) Install the generator wire with the nut.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
(h) Install the terminal cap.
(i) Connect the 2 wire harness clamps.
(j) Connect the magnetic clutch connector to the
compressor and magnetic clutch.
2. INSTALL V-RIBBED BELT (See page EM-7)
3. INSTALL RADIATOR ASSEMBLY (See page CO-31)
4. INSTALL FAN SHROUD (See page CO-32)
5. INSTALL RADIATOR SUPPORT UPPER (See page
CO-32)
6. CONNECT NO. 1 OIL COOLER OUTLET TUBE (See
page CO-33)
7. CONNECT NO. 1 OIL COOLER INLET TUBE (See
page CO-33)
8. CONNECT RADIATOR OUTLET HOSE (See page CO-
33)
9. CONNECT RADIATOR INLET HOSE (See page CO-
33)
10. CONNECT RADIATOR RESERVE TANK HOSE (See
page CO-34)
11. INSTALL FRONT BUMPER ENERGY ABSORBER
(See page ET-10)
12. INSTALL FRONT BUMPER ASSEMBLY (w/o Fog
Light) (See page ET-13)
13. INSTALL FRONT BUMPER ASSEMBLY (w/ Fog Light)
(See page ET-14)
14. INSTALL NO. 1 AIR CLEANER INLET (See page EM-
49)
15. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See
page ES-506)
16. INSTALL AIR CLEANER INLET ASSEMBLY (See page
EM-50)
A133866
A133865
CH24
2GR-FE CHARGING GENERATOR
CH
17. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL (See page EM-51)
18. ADD ENGINE COOLANT (See page CO-6)
19. CHECK FOR ENGINE COOLANT LEAKS (See page
CO-1)
20. INSTALL V-BANK COVER SUB-ASSEMBLY (See
page EM-52)
21. INSTALL COOL AIR INTAKE DUCT SEAL (See page
EM-52)
22. INSTALL FRONT FENDER APRON SEAL RH
23. INSTALL ENGINE UNDER COVER RH
24. INSTALL ENGINE UNDER COVER LH
25. INSTALL FRONT WHEEL OPENING EXTENSION PAD
RH
26. REMOVE FRONT WHEEL OPENING EXTENSION
PAD LH
27. INSTALL FRONT WHEEL RH (See page EM-7)