Starting System & Charging System: Other Toyota Highlander I рестайлинг

PRECAUTION

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1. CHECK BATTERY ELECTROLYTE LEVEL Check the electrolyte quantity of each cell. Maintenance-free battery: If it is under the lower level, replace the battery. Except Maintenance-free battery: If it is under the lower level, add distilled water.
2. Except Maintenance-free battery: CHECK BATTERY SPECIFIC GRAVITY Check the specific gravity of each cell. Standard specific gravity: 1.25 to 1.29 at 20° C (68° F) If the specific gravity is less than the specification, charge the battery.
3. Maintenance-free battery: CHECK BATTERY VOLTAGE After the vehicle has run for 20 minutes, stop the engine. Turn the ignition switch ON, and operate the headlight, blower fan and defogger for 1 minute. Turn the ignition switch OFF. Measure the battery voltage. Standard voltage: 12.5 to 12.9 V at 20° C (68° F) If the voltage is less than specification, charge the battery.
4. 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 and fuses for resistance of below 1 ohm.
5. INSPECT DRIVE BELT Check the belt for wear, cracks and other signs of damage. If any defect is found, replace the drive belt. HINT: Replace the drive belt if the following defects are found: If the belt has worn out until the wire can be seen. If the cracks reach the wire more than one place. If the belt has chunks missing from the ribs. Check that the belt fits properly in the ribbed grooves. HINT: With your hand, confirm that the belt has not slipped out of the groove on the bottom of the pulley.
6. VISUALLY CHECK GENERATOR WIRING Check that the wiring is in good condition.
7. LISTEN FOR ABNORMAL NOISES FROM GENERATOR Check that there is no abnormal noise from the generator while the engine is running.
8. INSPECT CHARGE WARNING LAMP CIRCUIT Turn the ignition switch ON. Check that the charge warning lamp turns on. Start the engine and check that the lamp turns off. If the lamp does not operate as specified, troubleshoot the charge warning lamp circuit.
9. INSPECT CHARGING CIRCUIT WITHOUT LOAD HINT: If a battery/generator tester is available, connect the tester to the charging circuit according to the manufacturer's instructions. If a tester is not available, connect an ammeter and voltmeter to the charging circuit as follows. Disconnect the wire from terminal B of the generator and connect it to the negative (-) lead of the ammeter. Connect the ammeter's positive (+) lead to terminal B of the generator. Connect the voltmeter's positive (+) lead to terminal B of the generator. Ground the voltmeter's negative (-) lead. Check the charging circuit. Keep the engine speed at 2,000 RPM, check the reading on the ammeter and voltmeter. Standard amperage: 10 A or less Standard voltage: 13.2 to 14.8 V If the result is not as specified, replace the generator.
10. INSPECT CHARGING CIRCUIT WITH LOAD With the engine running at 2,000 RPM, turn on the high-beam headlamps and turn the heater blower switch to the HI position. Check the reading on the ammeter. Standard amperage: 30 A or more HINT: If the ammeter reading is less than the standard amperage, repair the generator. If the battery is fully charged, the indication will sometimes be less than the standard amperage.

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1. REMOVE V BELT (See «FAN AND GENERATOR V BELT (2AZ-FE)»(ref-226410-S35764191172006032800000) )
2. REMOVE GENERATOR ASSY Remove the bolt, and disconnect the wire clip on the wire connectors from the generator. Disconnect the wire clamp from the wire clip. Remove the cap and nut, and disconnect the generator wire. Disconnect the generator connector. Remove the 2 bolts and generator.
3. INSTALL GENERATOR ASSY Install the generator. Torque: 52 N.m (530 kgf.m cm, 38 ft.lbf) for bolt A 21 N.m (214 kgf. cm, 15 ft. Ibf) for bolt B NOTE: Be careful not to put the wire harness between the engine and the generator when install the generator. Connect the generator connector. Connect the generator wire with the nut, and install the cap. Torque: 9.8 N.m (100 kgf. cm, 7.0 ft.Ibf) Install the wire clamp to the wire clip. Install the wire clip on the wire connectors to the generator.
4. INSTALL V BELT (See «FAN AND GENERATOR V BELT (2AZ-FE)»(ref-226410-S35764191172006032800000) )

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1. REMOVE GENERATOR PULLEY SST 09820-63010 (09820-06010, 09820-06020) HINT: SST REFERENCE SST(1-A, B) 09820-06010 SST (2) 09820-06020 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 turn. Remove the generator from SST (2). Turn SST (1 -B) and remove SST (1 -A, B). Remove the pulley nut and pulley.
2. REMOVE GENERATOR REAR END COVER Place the generator on the pulley. Remove the 3 nuts and rear end cover.
3. REMOVE TERMINAL INSULATOR Remove the terminal insulator from the rectifier end frame.
4. REMOVE GENERATOR BRUSH HOLDER ASSY 100 A: Remove the 2 screws and brush holder. 130 A: Remove the brush holder. Remove the plate seal. Remove the 2 screws and brush holder. Remove the plate seal.
5. REMOVE GENERATOR COIL ASSY Remove the 4 bolts. Using SST, remove the rectifier end frame. SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011)
6. REMOVE GENERATOR ROTOR ASSY Remove the washer and rotor. INSPECT GENERATOR BRUSH HOLDER ASSY 100 A: Using a vernier caliper, measure the exposed brush length. Standard exposed brush length: 10.5 mm (0.413 in.) Minimum exposed brush length: 4.5 mm (0.177 in.) If the exposed brush length is less than the minimum, replace the brush holder assy. 130 A: Using a vernier caliper, measure the exposed brush length. Standard exposed brush length: 10.5 mm (0.413 in.) Minimum exposed brush length: 4.5 mm (0.177 in.) If the exposed brush length is less than the minimum, replace the brush holder assy.
7. INSPECT GENERATOR ROTOR ASSY Check that the bearing is not rough or worn. 100 A: If necessary, replace the rotor assy. 130 A: If necessary, replace the rotor bearing. Check if the rotor has open circuit. Measure the resistance between the slip ring. Resistance: 2.3to2.7 ohm at 20° C (68° F) If the resistance is not as specified, replace the rotor assy. Check the rotor for ground. Measure the resistance between the slip ring and rotor core. Standard: 1 M ohm or higher If the resistance is not as specified, replace the rotor assy. Check that the slip rings are not rough or scored. If rough or scored, replace the rotor assy. 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 rotor assy. 130 A: REMOVE GENERATOR ROTOR BEARING Using SST, remove the bearing cover (outside) and bearing. SST 09820-00021 NOTE: Be careful not to damage the fan. Remove the bearing cover (inside). 130 A: INSTALL GENERATOR ROTOR BEARING Place the generator rotor on the generator pulley. Install the bearing cover (inside). Using SST and a press, press in a new bearing. SST 09820-00031 Using SST, push in the bearing cover (outside). SST 09285-76010
8. INSPECT GENERATOR DRIVE END FRAME BEARING Check that the bearing is not rough or worn. If necessary, replace the bearing.
9. REMOVE GENERATOR DRIVE END FRAME BEARING Remove the 4 screws and retainer plate. Using SST and a wooden block, tap out the bearing. SST 09950-60010 (09951-00250), 09950-70010 (09951-07100)
10. INSTALL GENERATOR DRIVE END FRAME BEARING Using SST and a press, press in a new bearing. SST 09950-60010 (09951-00470), 09950-70010 (09951-07100) Install the retainer plate with the 4 screws. Torque: 2.3 N.m (23 kgf.cm, 20 In.lbf)
11. INSTALL GENERATOR ROTOR ASSY Place the generator drive end frame on the pulley. Install the rotor and washer.
12. INSTALL GENERATOR RECTIFIER END FRAME 100 A: Using deep socket wrench 21 and a press, press in the coil carefully. 130 A: Using deep socket wrench 20 and a press, press in the coil carefully. Tighten the 4 bolts. Torque: 5.8 N. m (59 kgf.cm, 51 in.lbf)
13. INSTALL GENERATOR BRUSH HOLDER ASSY 100 A: Install the brush holder. While pushing the 2 brushes to inside the brush holder, insert a pin (phi 1.0 mm (0.039 in.)) into the brush holder hole. Install the brush holder with the 2 screws. Torque: 1.8 N.m (18 kgf.cm, 16 In..Ibf) Pull out the pin (phi 1.0 mm (0.039 in.)) from the brush holder. 130 A: Install the brush holder Install the plate seal (inside). Place the brush holder with the pin facing upward. NOTE: Be careful of the generator brush holder installing direction. Tighten the 2 screws. Torque: 1.8 N.m (18 kgf.cm, 16 In..Ibf) Align the pins of the brush holder with the holes of the plate seal (outside), and install the plate seal (outside).
14. INSTALL TERMINAL INSULATOR Install the terminal insulator. NOTE: pay attention to the mounting direction of the terminal insulator.
15. INSTALL GENERATOR REAR END COVER Install the rear end cover with the 3 nuts. Torque: 4.6 N.m (47 kgf.cm, 41 in.Ibf)
16. INSTALL GENERATOR PULLEY SST 09820-63010 (09820-06010, 09820-06020) HINT: SST REFERENCE SST 1-A and B 09820-06010 SST 2 09820-06020 Install the pulley to the rotor shaft by tightening the generator pulley nut by hand. Hold SST (1-A) with a torque wrench, and tighten SST (1 -B) clockwise with 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) and (B) into SST (2), and attach the generator pulley nut to SST (2) Tighten the pulley nut by turning SST (1-A) in the direction shown in the illustration. Torque: 111 N.m (1,125 kgf.cm, 81 ft.lbf) Remove the generator from 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. INSPECT STARTER ASSY NOTE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil. Do the pull-in test. Disconnect the lead wire from terminal C. Connect the battery to the magnetic switch as shown in the illustration on the left. Check that the clutch pinion gear extends. If the clutch pinion gear does not move, replace the magnetic switch assy. Do the hold-in test. Maintain the battery connections in step (a), but disconnect the negative (-) lead from terminal C. Check that the pinion gear remains extended. If the clutch pinion gear returns inward, replace the magnetic switch assy. Check the clutch pinion gear return. Disconnect the negative (-) lead from the switch body. Check that the clutch pinion gear returns. If the clutch pinion gear does not return, replace the magnetic switch assy. Do the no-load performance test. Connect the lead wire to terminal C. Make sure that the lead is not grounded. Torque: 10 N.m (102 kgf.cm, 7ft.lbf) Clamp the starter in a vise. Connect the battery and an ammeter to the starter as shown in the illustration. Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. Check that the ammeter reads the specified current. Specified current: 90 A or less at 11.5 V
2. INSPECT RELAY (Marking: STARTER) Check the resistance of the STARTER relay. Standard: TESTER CONNECTION SPECIFIED CONDITION Tester Connection Specified Condition 3-5 10 kohm or higher 3-5 Below 1ohm (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay.

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1. CHECK BATTERY ELECTROLYTE LEVEL Check the electrolyte quantity of each cell. Maintenance-free battery: If it is under the lower level, replace the battery. Except Maintenance-free battery: If it is under the lower level, add distilled water.
2. Except Maintenance-free battery: CHECK BATTERY SPECIFIC GRAVITY Check the specific gravity of each cell. Standard specific gravity: 1.25 to 1.29 at 20°C (68°F) If the specific gravity is less than the specification, charge the battery.
3. Maintenance-free battery: CHECK BATTERY VOLTAGE After the vehicle has run for 20 minutes, stop the engine. Turn the ignition switch ON, and operate the headlight, blower fan and defogger for 1 minute. Turn the ignition switch OFF. Measure the battery voltage. Standard voltage: 12.5 to 12.9 V at 20°C (68°F) If the voltage is less than specification, charge the battery.
4. 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 and fuses for resistance of below 1 ohm.
5. INSPECT DRIVE BELT Check the belt for wear, cracks and other signs of damage. If any defect is found, replace the drive belt. HINT: Replace the drive belt if the following defects are found: If the belt has worn out until the wire can be seen. If the cracks reach the wire more than one place. If the belt has chunks missing from the ribs. Check that the belt fits properly in the ribbed grooves. HINT: With your hand, confirm that the belt has not slipped out of the groove on the bottom of the pulley.
6. VISUALLY CHECK GENERATOR WIRING Check that the wiring is in good condition.
7. LISTEN FOR ABNORMAL NOISES FROM GENERATOR Check that there is no abnormal noise from the generator while the engine is running.
8. INSPECT CHARGE WARNING LAMP CIRCUIT Turn the ignition switch ON. Check that the charge warning lamp turns on. Start the engine and check that the lamp turns off. If the lamp does not operate as specified, troubleshoot the charge warning lamp circuit.
9. INSPECT CHARGING CIRCUIT WITHOUT LOAD HINT: If a battery/generator tester is available, connect the tester to the charging circuit according to the manufacturer's instructions. If a tester is not available, connect an ammeter and voltmeter to the charging circuit as follows. Disconnect the wire from terminal B of the generator and connect it to the negative (-) lead of the ammeter. Connect the ammeter's positive (+) lead to terminal B of the generator. Connect the voltmeter's positive (+) lead to terminal B of the generator. Ground the voltmeter's negative (-) lead. Check the charging circuit. Keep the engine speed at 2,000 RPM, check the reading on the ammeter and voltmeter. Standard amperage: 10 A or less Standard voltage: 13.2 to 14.8 V If the result is not as specified, replace the generator.
10. INSPECT CHARGING CIRCUIT WITH LOAD With the engine running at 2,000 RPM, turn on the high-beam headlamps and turn the heater blower switch to the HI position. Check the reading on the ammeter. Standard amperage: 30 A or more HINT: If the ammeter reading is less than the standard amperage, repair the generator. If the battery is fully charged, the indication will sometimes be less than the standard amperage.

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1. REMOVE GENERATOR ASSY Remove the wire harness clamp. Disconnect the generator connector. Open the terminal cap, remove the nut and disconnect the generator wire. Loosen bolts A and B. Loosen bolt C to lessen the tension of the V belt. Remove bolts A and B, and the generator.
2. INSTALL GENERATOR ASSY Temporarily install the generator with bolts A and B. Adjust the V belt tension by tightening bolt C (see «DRIVE BELT (3MZ-FE)»(ref-226410-S41883703282006032800000) ). Tighten bolts A and B. Torque: 58 N.m (592 kgf.cm, 43 ft.lbf) for bolt A 18 N.m (184 kgf.cm, 13 ft.lbf) for bolt B Install the generator wire with the nut. Torque: 9.8 N.m (100 kgf.cm, 7.0 ft.lbf) Connect the generator connector. Install the wire harness clamp.
3. INSPECT V BELT (See «ENGINE (3MZ-FE)»(ref-226410-S17749095692006032800000) )

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1. REMOVE GENERATOR PULLEY SST 09820-63010 (09820-06010, 09820-06020) HINT: SST REFERENCE SST (1-A, B) 09820-06010 SST (2) 09820-06020 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 turn. Remove the generator from SST (2). Turn SST (1-B) and remove SST (1-A, B). Remove the pulley nut and pulley.
2. REMOVE GENERATOR REAR END COVER Place the generator on the pulley. Remove the 3 nuts and rear end cover.
3. REMOVE TERMINAL INSULATOR Remove the terminal insulator from the rectifier end frame.
4. REMOVE GENERATOR BRUSH HOLDER ASSY 100 A: Remove the 2 screws and brush holder. 130 A: Remove the brush holder. Remove the plate seal. Remove the 2 screws and brush holder. Remove the plate seal.
5. REMOVE GENERATOR RECTIFIER END FRAME Remove the 4 bolts. Using SST, remove the rectifier end frame. SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011)
6. REMOVE GENERATOR ROTOR ASSY Remove the washer and rotor.
7. INSPECT GENERATOR BRUSH HOLDER ASSY 100 A: Using a vernier caliper, measure the exposed brush length. Standard exposed brush length: 10.5 mm (0.413 in.) Minimum exposed brush length: 4.5 mm (0.177 in.) If the exposed brush length is less than the minimum, replace the brush holder assy. 130 A: Using a vernier caliper, measure the exposed brush length. Standard exposed brush length: 10.5 mm (0.413 in.) Minimum exposed brush length: 4.5 mm (0.177 in.) If the exposed brush length is less than the minimum, replace the brush holder assy.
8. INSPECT GENERATOR ROTOR ASSY Check that the bearing is not rough or worn. 100 A: If necessary, replace the rotor assy. 130 A: If necessary, replace the rotor bearing. Check if the rotor has open circuit. Measure the resistance between the slip ring. Resistance: 2.3 to 2.7 ohm at 20°C (68°F) If the resistance is not as specified, replace the generator rotor. Check the rotor for ground. Measure the resistance between the slip ring and rotor core. Standard: 1 Mohm or higher If the resistance is not as specified, replace the rotor assy. Check that the slip rings are not rough or scored. If rough or scored, replace the rotor assy. 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 rotor assy.
9. 130 A: REMOVE GENERATOR ROTOR BEARING Using SST, remove the bearing cover (outside) and bearing. SST 09820-00021 NOTE: Be careful not to damage the fan. Remove the bearing cover (inside).
10. 130 A: INSTALL GENERATOR ROTOR BEARING Place the generator rotor on the generator pulley. Install the bearing cover (inside). Using SST and a press, press in a new bearing. SST 09820-00031 Using SST, push in the bearing cover (outside). SST 09285-76010
11. INSPECT GENERATOR DRIVE END FRAME BEARING Check that the bearing is not rough or worn. If necessary, replace the bearing.
12. REMOVE GENERATOR DRIVE END FRAME BEARING Remove the 4 screws and retainer plate. Using SST and a wooden block, tap out the bearing. SST 09950-60010 (09951-00250), 09950-70010 (09951-07100)
13. INSTALL GENERATOR DRIVE END FRAME BEARING Using SST and a press, press in a new bearing. SST 09950-60010 (09951-00470), 09950-70010 (09951-07100) Install the retainer plate with the 4 screws. Torque: 2.3 N.m (23 kgf.cm, 20 in..lbf)
14. INSTALL GENERATOR ROTOR ASSY Place the drive end frame on the pulley. Install the rotor and washer.
15. INSTALL GENERATOR RECTIFIER END FRAME 100 A: Using deep socket wrench 21 and a press, press in the coil carefully. 130 A: Using deep socket wrench 20 and a press, press in the coil carefully. Tighten the 4 bolts. Torque: 5.8 N.m (59 kgf.cm, 51 in..lbf)
16. INSTALL GENERATOR BRUSH HOLDER ASSY 100 A: Install the brush holder. While pushing the 2 brushes to inside the brush holder, insert a pin (phi1.0 mm (0.039 in.)) into the brush holder hole. Install the generator brush holder with the 2 screws. Torque: 1.8 N.m (18 kgf.cm, 16 in..lbf) Pull out the pin (phi1.0 mm (0.039 in.)) from the generator brush holder. 130 A: Install the brush holders. Install the plate seal (inside). Place the brush holder with the pin facing upward. NOTE: Be careful of the generator brush holder installing direction. Tighten the 2 screws. Torque: 1.8 N.m (18 kgf.cm, 16 in..lbf) Align the pins of the brush holder with the holes of the plate seal (outside), and install the plate seal (outside).
17. INSTALL TERMINAL INSULATOR Install the terminal insulator. NOTE: pay attention to the mounting direction of the terminal insulator.
18. INSTALL GENERATOR REAR END COVER Install the rear end cover with the 3 nuts. Torque: 4.6 N.m (47 kgf.cm, 41 in..lbf)
19. INSTALL GENERATOR PULLEY SST 09820-63010 (09820-06010, 09820-06020) HINT: SST REFERENCE SST 1-A and B 09820-06010 SST 2 09820-06020 Install the pulley to the rotor shaft by tightening the generator pulley nut by hand. Hold SST (1-A) with a torque wrench, and tighten SST (1-B) clockwise with 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) and (B) into SST (2), and attach the generator pulley nut to SST (2). Tighten the pulley nut by turning SST (1-A) in the direction shown in the illustration. Torque: 111 N.m (1,125 kgf.cm, 81 ft.lbf) Remove the generator from SST (2). Turn SST (1-B), and remove SST (1-A), (B). Turn the pulley, and check that the pulley moves smoothly.