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1GR FE Charging
1GR FE Charging
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.
1. CHECK BATTERY ELECTROLYTE LEVEL
(a) 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.
(b) Check the electrolyte quantity of each cell (Except Main-
tenance-Free Battery).
If under the lower level, add distilled water.
2. CHECK BATTERY SPECIFIC GRAVITY
(Except Maintenance-Free Battery)
(a) Check the specific gravity of each cell.
Standard specific gravity: 1.25 to 1.29 at 20C (68F)
HINT:
If the specific gravity is less than specification, charge the bat-
tery.
A01259
GENERATOR
CH0N6-01
COMPONENTS
V-Bank Cover
Battery Clamp
Battery Tray
Battery Tray
Engine Under Cover
x5
Drive Belt
43 (438, 32)
Generator Wire
Generator Connector
A/C Compressor
A/C Compressor
Connector
Generator
Bearing Cover
Generator
Drive End Frame Bearing
2.6 (27, 23 in.⋅lbf)
x4 Washer
Generator
Generator Pulley Rotor Bearing
Retainer Plate
x4
B17633
(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 turn.
(e) Remove the generator from SST (C).
Turn
B17634
SST (A) (f) Turn SST (B), and remove SST (A) and (B).
(g) Remove the pulley nut and pulley.
SST (B)
Hold
Turn
B17635
B17636
B17637
B17638
B17639
Hold
B17640
B17641
Ohmmeter
INSPECTION
1. INSPECT ROTOR
(a) Check the rotor for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the slip rings.
Continuity Standard resistance: 2.3 to 2.7 Ω at 20°C (68°F)
If there is no continuity, replace the rotor.
B12264
B12265
B17642
2. INSPECT BRUSHES
Using vernier caliper, measure the exposed brush length.
Standard exposed length: 10.5 mm (0.413 in.)
Length Minimum exposed length: 4.5 mm (0.177 in.)
If the exposed length is less than the minimum, replace the
brushes and the brush holder assembly.
3. INSPECT BEARING
Check the bearing is not rough or worn.
B16374 If necessary, replace the bearing (See page CH-1 1).
INSTALLATION
1. INSTALL GENERATOR
(a) Install the generator with the 2 bolts.
Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf)
B17626
(b) Install the wire harness clamp bracket with the 2 bolts.
Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf)
B17625
REASSEMBLY
1. INSTALL GENERATOR ROTOR ASSY
(a) Place the drive end frame on the rotor.
(b) Install the rotor and washer.
B17641
B17651
B17637
B17636
B17633
(e) Tighten the pulley nut by turning SST (A) in the direction
shown in the illustration.
Torque: 111 N⋅m (1,125 kgf⋅cm, 81 ft⋅lbf)
(f) Remove the generator from SST (C).
Turn
B17657
SST (A)
(g) Turn SST (B), and remove SST (A), (B).
(h) Turn the pulley, and check that the pulley moves smooth-
ly.
SST (B)
Hold
Turn
B17635
REMOVAL
1. REMOVE V-BANK COVER
2. REMOVE ENGINE UNDER COVER
Remove the 4 bolts and engine under cover.
3. REMOVE FAN AND GENERATOR V BELT
(See page EM-62 )
4. REMOVE BATTERY
5. REMOVE GENERATOR
(a) Disconnect the wire harness.
(1) Remove the bolt and wire harness stay.
(2) Disconnect the connector from the generator.
(3) Remove the terminal cap and nut.
(4) Disconnect the wire harness from the terminal B.
B17624
(b) Remove the 2 bolts and wire harness clamp bracket from
the generator assy.
B17625
B17626
REPLACEMENT
1. INSPECT GENERATOR ROTOR BEARING
(a) Check the bearing is not rough or worn.
If necessary, replace the bearing.
B17643
B17644
Pulley B17645
B17646
B17647
B17648
SST
B17649
B17650