Charging System - Generators & Regulators - 2AZ-FE: Other Toyota Highlander I

PRECAUTION

1. PRECAUTION Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge. Do not perform tests with a high voltage insulation resistance tester. Never disconnect the battery while the engine is running. Check that the charging cable is tightened on terminal B of the alternator and the fuse box.

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1. CHECK BATTERY ELECTROLYTE LEVEL Check the electrolyte quantity of each cell. If under the lower level, replace the battery (or add distilled water if possible) and check the charging system.
2. CHECK BATTERY VOLTAGE After having driven the vehicle and in the case that 20 minutes have not passed after having stopped the engine, turn the ignition switch ON and turn on the electrical system (headlight, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge. Turn the ignition switch OFF and turn off the electrical systems. Measure the battery voltage between the negative (-) and positive (+) terminals of the battery. Standard voltage: 12.5 - 12.9 V at 20°C (68°F) If the voltage is less than specification, charge the battery. Check the indicator as shown in the illustration. NOTE: Blue: OK White: Charging Necessary Red: Insufficient Water
3. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES Check that the battery terminals are not loose or corroded. If the terminals are corroded, clean the terminals. Check the fusible link, H-fuses and fuses for continuity.
4. INSPECT DRIVE BELT Visually check the belt for excessive wear, frayed cords etc. If any defect has been found, replace the drive belt. NOTE: Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced. Check that it fits properly in the ribbed grooves. NOTE: Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley.
5. VISUALLY CHECK ALTERNATOR WIRING Check that the wiring is in good condition.
6. LISTEN FOR ABNORMAL NOISES FROM ALTERNATOR Check that there is no abnormal noise from the alternator while the engine is running.
7. CHECK DISCHARGE WARNING LIGHT CIRCUIT Warm up engine and then turn it off. Switch off all accessories. Turn the ignition switch ON. Check that the discharge warning light is lit. Start the engine. Check that the light goes off. If the light does not go off as specified, troubleshoot the charge warning light circuit.
8. INSPECT CHARGING CIRCUIT WITHOUT LOAD NOTE: If a battery/alternator tester is available, connect the tester to the charging circuit as per manufacturer's instructions. If a tester is not available, connect a voltmeter to the charging circuit as follows. Disconnect the wire from terminal B of the alternator, and connect it to the negative (-) tester probe of the ammeter. Connect the positive (+) tester probe of the ammeter to terminal B of the alternator. Connect the positive (+) tester probe of the voltmeter to terminal B of the alternator. Ground the negative (-) tester probe of the voltmeter. 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: 13.2 - 14.8 V
9. INSPECT CHARGING CIRCUIT WITH LOAD With the engine running at 2,000 rpm, turn on the high beam headlights and place the heater blower switch at "HI". Check the reading on the ammeter. Standard amperage: 30 A or more If the ammeter reading is less than standard amperage, repair the alternator. NOTE: If the battery is fully charged, the indication will sometimes be less than standard amperage.

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1. REMOVE FAN AND GENERATOR V BELT See REMOVE FAN AND GENERATOR V BELT . SST 09249-63010
2. REMOVE GENERATOR ASSEMBLY Disconnect the engine wire as shown. Remove 3 bolts and alternator assembly.
3. INSTALL GENERATOR ASSEMBLY Confirm the wire harness of the crank position sensor is placed as shown in the illustration. Install the alternator assembly. Torque: M8 21 N.m (214 kgf.cm, 15 ft.lbf) M10 52 N.m (530 kgf.cm, 38 ft.lbf) Wiring harness clamp 8.4 N.m (85 kgf.cm, 74 in.lbf) Alternator wire 9.8 N.m (100 kgf.cm, 7 ft.lbf) NOTE: Be careful not to pinch the wire harness when installing the alternator.
4. INSTALL FAN AND GENERATOR V BELT See REMOVE FAN AND GENERATOR V BELT . SST 09249-63010

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1. REMOVE GENERATOR PULLEY SST 09820-63010 (09820-06010, 09820-06020) NOTE: Hold SST 1 - A with a torque wrench, and tighten SST 1 - B clockwise to the specified torque. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) NOTE: Check that SST is secured to the rotor shaft. Mount SST 2 in a vise. Insert SST 1 - A, B into SST 2, and attach the pulley nut to SST 2. To loosen the pulley nut, turn SST 1 - A in the direction shown in the illustration. NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a turn. Remove the alternator form SST 2. Turn SST 1 - B, and remove SST 1 - A, B. Remove the pulley nut and pulley.
2. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY Remove the nut and terminal insulator. Remove the bolt, 3 nuts, plate terminal and end cover. Remove the brush cover. Remove the 2 screws and brush holder.
3. REMOVE GENERATOR REGULATOR ASSEMBLY Remove the 3 screws and voltage regulator.
4. REMOVE GENERATOR HOLDER W/RECTIFIER Remove the 4 screws and rectifier holder.
5. REMOVE ALTERNATOR RECTIFIER END FRAME Remove the rubber insulator. Remove the seal plate. Remove the 4 nuts and cord clip. Using bearing puller set, remove the rectifier end frame.
6. REMOVE GENERATOR ROTOR ASSEMBLY Remove the alternator washer from the rotor. Remove the rotor from drive end frame. NOTE: Do not drop the rotor.
7. INSPECT GENERATOR REGULATOR ASSEMBLY Using an ohmmeter, check the continuity between terminals F and B. Standard: When the positive and negative poles between terminals F and B are exchanged, there is continuity in one direction but not the other. If the continuity is not as specified, replace the voltage regulator. Using an ohmmeter, check the continuity between terminals F and E. Standard: When the positive and negative poles between terminals F and E are exchanged, there is continuity in one direction but not the other. If the continuity is not as specified, replace the voltage regulator.
8. INSPECT GENERATOR ROTOR ASSEMBLY Inspect rotor for open circuit. Using an ohmmeter, check that there is continuity between the slip rings. Standard resistance: 2.1 - 2.5 Ohms at 20°C (68°F) If there is no continuity, replace the rotor. 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. Inspect slip rings. Using vernier calipers, measure the slip ring diameter. 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 minimum, replace the rotor.
9. INSPECT BRUSH Using vernier calipers, measure the exposed brush length. Standard exposed length: 9.5 - 11.5 mm (0.374 - 0.453 in.) Minimum exposed length: 1.5 mm (0.059 in.) If the exposed length is less than minimum, replace the brush holder assembly.
10. INSTALL GENERATOR ROTOR ASSEMBLY Install the generator rotor. Install the alternator washer to the rotor.
11. INSTALL ALTERNATOR RECTIFIER END FRAME Using a 17 mm socket wrench and press, slowly press in the rectifier end frame. Install the cord clip and 4 nuts. Torque: Nut A 4.5 N.m (46 kgf.cm, 39 in.lbf) Nut B 5.4 N.m (55 kgf.cm, 47 in.lbf) Install the seal plate on the rectifier end frame. Install the 4 rubber insulators on the lead wires. NOTE: Be careful of the rubber insulators installation direction.
12. INSTALL GENERATOR HOLDER W/RECTIFIER Install the rectifier holder while pushing it with the 4 screws. Torque: 2.9 N.m (30 kgf.cm, 26 in.lbf)
13. INSTALL GENERATOR REGULATOR ASSEMBLY Install the 3 screws and voltage regulator. Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)
14. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY Install the 2 screws and brush holder. Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf) NOTE: Be careful of the holder installation direction. Install the brush cover. Install the end cover and plate terminal with the bolt and 3 nuts. Torque: Nut 4.4 N.m (45 kgf.cm, 39 in.lbf) Bolt 3.9 N.m (39 kgf.cm, 35 in.lbf) Install the terminal insulator with the nut. Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf)
15. INSTALL GENERATOR PULLEY SST 09820-63010 (09820-06010, 09820-06020) NOTE: Install the pulley to the rotor shaft by tightening the pulley nut by hand. Hold SST 1 - A with a torque wrench, and tighten SST 1 - B clockwise to the specified to torque. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) NOTE: Check that SST is secured to the pulley shaft. Mount SST 2 in a vise. Insert SST 1 - A, B into SST 2, and attach the pulley nut to SST 2. Tighten the pulley nut, turn SST 1 - A in the direction shown. Torque: 111 N.m (1,125 kgf.cm, 81 ft.lbf) Remove the alternator form SST 2. Turn SST 1 - B, and remove SST 1 - A, B. Turn the pulley, and check that the pulley moves smoothly.

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1. REMOVE GENERATOR PULLEY SST 09820-63010 (09820-06010, 09820-06020) NOTE: Hold SST 1 - A with a torque wrench, and tighten SST 1 - B clockwise to the specified torque. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) NOTE: Check that SST is secured to the rotor shaft. Mount SST 2 in a vise. Insert SST 1 - A, B into SST 2, and attach the pulley nut to SST 2. To loosen the pulley nut, turn SST 1 - A in the direction shown in the illustration. NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a turn. Remove the alternator from SST 2. Turn SST 1 - B, and remove SST 1 - A, B. Remove the pulley nut and pulley.
2. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY Remove the 3 nuts and end cover. Remove the rear seal plate. Remove the 2 screws and brush holder. Remove the front seal plate.
3. REMOVE COIL ASSEMBLY ALTERNATOR Remove the 4 bolts. Using SST, remove the coil assembly. SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955- 04071, 09958-04011)
4. REMOVE GENERATOR ROTOR ASSEMBLY Remove the alternator washer from the rotor. Remove the rotor from drive end frame. NOTE: Do not drop the rotor.
5. INSPECT GENERATOR ROTOR ASSEMBLY Inspect rotor for open circuit Using an ohmmeter, check that there is continuity between the slip rings. Standard resistance: 2.3 - 2.7 Ohms at 20°C (68°F) If there is no continuity, replace the rotor. . 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. . Inspect slip rings. Using vernier calipers, measure the slip ring diameter. Standard diameter: 14.2 - 14.4 mm (0.559 - 0.567 in.) Minimum diameter: 14.0 mm (0.551 in.) If the diameter is less than minimum, replace the rotor.
6. INSPECT BRUSH Using vernier calipers, measure the exposed brush length. Standard exposed length: 9.5 - 11.5 mm (0.374 - 0.453 in.) Minimum exposed length: 4.5 mm (0.177 in.) If the exposed length is less than minimum, replace the brush holder assembly.
7. INSTALL GENERATOR ROTOR ASSEMBLY Install the generator rotor. Install the alternator washer to the rotor.
8. INSTALL COIL ASSEMBLY ALTERNATOR Using a 17 mm socket wrench and press, slowly press in the coil assembly. Install the coil assembly with the 4 bolts. Torque: 5.8 N.m (59 kgf.cm, 51 in.lbf)
9. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY Place the front seal plate to the coil assembly. Install the 2 screws and brush holder. Torque: 1.8 N.m (18 kgf.cm, 16 in.lbf) NOTE: Be careful of the holder installation direction. Place the rear seal plate on the brush holder. Install the 3 nuts and end cover. Torque: 4.6 N.m (47 kgf.cm, 41 in.lbf)
10. INSTALL GENERATOR PULLEY SST 09820-63010 (09820-06010, 09820-06020) Install the pulley to the rotor shaft by tightening the pulley nut by hand. Hold SST 1 - A with a torque wrench, and tighten SST 1 - B clockwise to the specified to torque. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) NOTE: Check that SST is secured to the pulley shaft. Mount SST 2 in a vise. Insert SST 1 - A, B into SST 2, and attach the pulley nut to SST 2. Tighten the pulley nut, turn SST 1 - A in the direction shown. Torque: 111 N.m (1,125 kgf.cm, 81 ft.lbf) Remove the alternator form SST 2. Turn SST 1 - B, and remove SST 1 - A, B. Turn the pulley, and check that the pulley moves smoothly.