ALTERNATOR & REGULATOR - NIPPONDENSO Article Text

1986 Toyota MR2 For RSe 7 HotRod Lane C'Ville VA 22901

Copyright 1997 Mitchell International Sunday, May 19, 2002 11:49PM

ARTICLE BEGINNING

1986 Alternators & Regulators NIPPONDENSO ALTERNATORS Toyota: Camry, Celica, Corolla, Cressida, Land Cruiser, MR2, Pickup, Supra, Tercel, Van, 4 Runner
DESCRIPTION

Nippondenso alternators are conventional 3-phase alternators utilizing 3 positive and 3 negative diodes to rectify current. Charging system voltage is controlled by an internal Integrated Circuit (IC) voltage regulator, or external voltage regulators. Some Toyota models use engine, ignition, and charging light relays. NIPPONDENSO ALTERNATOR APPLICATION TABLE

Model Toyota Camry Diesel .............. Gas ................. Celica ............... Corolla (FWD) ........ Corolla (RWD) Carb. ............... Fuel Inj. ........... Cressida ............. Land Cruiser ......... MR2 .................. Pickup ............... Supra ................ Tercel ............... Van .................. 4Runner ..............

Amps.

(1) Part No.

55 55 55 55 55 55 65 55 60 55 65 50 60 55

.............. .............. .............. .............. .............. .............. .............. .............. .............. .............. .............. .............. .............. ..............

27020-64080 27020-63020 27060-35060 27060-16030 27060-63030 27060-16030 27060-43060 27020-35060 27060-16050 27020-35060 27060-43060 27020-15120 27060-72060 27060-35060

(1) - Vehicle manufacturer's part number.

TESTING ON-VEHICLE

Preliminary Inspection Check alternator wire harness connections and drive belt

tension. Check "ENGINE", "CHARGE", "IGN" and alternator fusible link for continuity. Battery must be fully charged prior to beginning test. No Load Test 1) Connect battery/alternator tester according to manufacturer's instructions. Check amperage and voltage with engine running at 2000 RPM. On all models, alternator output should be less than 10 amps. 2) Voltage should be 13.8-14.8 volts on Camry Diesel, Corolla, and Tercel (without IC regulator). Voltage reading on all other models should be 13.5-15.1 volts. 3) If voltage reading is above specified range, replace IC regulator. If voltage reading is less than specified, ground "F" (full field) terminal. See Fig. 3. 4) If voltage now climbs above specified range, replace IC regulator. If reading remains below specified range, repair or replace alternator.

Fig. 1:

Toyota Alternator Output Test

Load Test Start engine. Turn on high beam headlights and place heater control on "HI". Run engine at 2000 RPM and check amperage. Ammeter should read more than 30 amps. If reading is less, repair or replace alternator. NOTE: If reading is low due to a fully charged battery, it may be necessary to crank engine with coil disconnected for about 15 seconds to partially discharge battery.

CONTROL RELAYS

Charging Light Relay (Camry Diesel, RWD Corolla) 1) Connect ohmmeter positive lead to terminal No. 2 and ohmmeter negative lead to terminal No. 1 on charging light relay located under hood. Ohmmeter should indicate continuity. See Fig. 4. 2) Reverse ohmmeter leads. Ohmmeter should now indicate no & REG continuity. Ensure there is no continuity between terminals No. 3ALTERNATOR and

4. If relay does not test as indicated, replace relay. 3) Connect positive side of battery to terminal No. 1. Connect negative side of battery to terminal No. 2. Check for continuity between terminals No. 3 and 4. If relay does not test as indicated, replace relay.

Fig. 2:

Testing Toyota Charging Light Relay

Engine Main Relay (Camry, Corolla & MR2) 1) Using an ohmmeter, check for continuity between terminals No. 1 and 3, and between terminals No. 2 and 4. on engine main relay located under hood. See Fig. 5. Ensure there is no continuity between terminals No. 4 and 5. If relay does not test as indicated, replace. 2) Apply battery voltage across terminals No. 1 and 3. Using an ohmmeter, check for continuity between terminals No. 4 and 5. Ensure there is no continuity between terminals No. 2 and 4. If relay does not test as indicated, replace.

ALTERNATOR &

Fig. 3:

Testing Toyota Engine Main Relay

Ignition Relay (Tercel & Van) 1) Using an ohmmeter, check for continuity between terminals No. 1 and 3. on ignition relay located under hood. Check that there is no continuity between terminals No. 2 and 4. See Fig. 6. If relay does not test as indicated, replace relay. 2) Apply battery voltage across terminals No. 1 and 3. Using an ohmmeter, check for continuity between terminals No. 2 and 4. Check for no continuity between terminals No. 3 and 5. If relay does not test as indicated, replace.

ALTERNATOR & REGULATOR - NIPPONDENSOArticle Text (p. 4)1986 Toyota MR2For RSe 7 HotRod Lane C'Vill

Fig. 4: Testing Toyota Ignition Relay Tercel ignition relay is square and Van relay is round.

OVERHAUL DISASSEMBLY

Toyota Diesel Engine Equipped Models 1) Remove vacuum pump and "O" ring (if equipped). Remove nuts, insulator, rubber washer, and cover. See Fig. 7. Remove screw to brush holder and disconnect Blue wire. Pull out brush holder with IC regulator. Remove screw and disconnect White wire. 2) Remove screws and separate IC regulator from brush holder. Remove 3 through bolts. Pull drive housing and rotor away from stator. Remove pulley nut, washer, pulley, fan and spacer. Press rotor out of drive housing. Remove bearing retainer and front bearing. 3) Remove 2 rubber caps, 4 nuts, condenser, and 2 insulators. Remove rectifier and stator from end housing. Remove 4 insulators from rectifier studs. Unsolder stator leads from rectifier.

Fig. 5:

Testing IC Voltage Regulator

Corolla, Prelude & Tercel (Without IC (p. Regulator) ALTERNATOR & REGULATOR - NIPPONDENSOArticle Text 5)1986 Toyota MR2For RSe 7 HotRod Lane C'Vill

1) Remove 3 alternator through bolts. Pull drive housing and rotor away from stator. Remove pulley nut, washer, pulley, fan and spacer. Press rotor out of drive housing. Remove bearing retainer screws and front bearing. 2) Remove condenser, clip and terminal insulators from end housing. Remove stator/rectifier assembly from end housing. Remove insulators from rectifier studs. Unsolder stator leads from rectifier. On Corolla alternator, unsolder IC regulator leads from rectifier.

Fig. 6: Exploded View of Camry Alternator FWD Corolla and Pickup alternators are similar. All Other Models 1) Remove nut and terminal insulator. Remove nuts and end cover. Remove 4 stator lead screws from rectifier assembly. Remove brush holder, IC regulator, rectifier assembly, and insulators. 2) Remove 4 nuts and end housing. Remove pulley nut (if equipped) and pulley. Remove stator through bolts and stator. Press rotor out of drive housing. Remove bearing retainer and front bearing.
BENCH TESTING

NOTE:

Also see CHARGING SYSTEM TROUBLE SHOOTING in the TROUBLE SHOOTING - BASIC PROCEDURES article. Rotor

ALTERNATOR & REGULATOR

1) Check rotor for open field windings by using an ohmmeter across slip rings. Rotor resistance should be 4.0-4.2 ohms for Tercel alternator without IC regulator and 2.8-3.0 ohms for all other models. 2) Check rotor for shorts to ground by connecting ohmmeter between slip ring and rotor shaft. Ohmmeter should show no continuity. Check slip rings for wear or pitting. Turn rotor on lathe if necessary. Check bearing and replace if necessary. Stator Connect ohmmeter between 2 stator leads. Ensure there is continuity between all stator leads. Connect ohmmeter between each stator lead and metal core. Ohmmeter should show no continuity. If continuity is indicated, stator must be replaced. Rectifier Diodes 1) With rectifier assembly on bench, contact diode plate with one probe and each of the 3 diode leads with other probe. Note ohmmeter reading. Reverse probes and repeat test. Check all diodes in this manner. 2) All diodes should show a low reading in one direction and NO reading in opposite direction. If any rectifier diode is defective, replace rectifier assembly. 3) On all models, set ohmmeter to x100 ohm scale. Check for continuity between terminals "B" and "F". There should be continuity in one direction only.

Fig. 7: Exploded View of Spectrum & Sprint Alternators Toyota alternators are similar.

ALTERNATOR & REGULATOR - NIPPONDENSOArticle Text (p. 7)1986 Toyota MR2For RSe

COMPONENT REPLACEMENT

Brushes 1) Check for cracks and minimum length of .18-.22" (4.5-5.5 mm). If damaged or worn, replace brushes. Brushes should slide smoothly in holders. Install new springs when replacing brushes. Solder brush wire. 2) New brush protrusion should be .49" (12.5 mm) for Tercel, .79" (20. mm) for diesel engine equipped models, .41" (10.5 mm) for all other models.
REASSEMBLY

1) To assemble, reverse disassembly procedure. Press brushes into holder against spring tension. To prevent brushes from falling, insert a wire through hole in rectifier, end housing and brush holder. 2) Press rear bearing onto rotor shaft. Pack drive end bearing with grease, and install. Install felt ring, cover, and bearing retainer (if equipped). Tighten body screws and remove brush retaining wire. Ensure stator terminal insulators are in place, otherwise alternator may short to ground.
END OF ARTICLE

ALTERNATOR & REGULATOR - NIPPONDENSOArticle Text (p. 8)