Charging System - Generators & Regulators: Other Toyota Sequoia I

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.

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1. Check battery electrolyte level of each cell. (Scheme 1) If under the lower level, replace the battery (or add distilled water if possible) and check the charging system.
2. Except maintenance-free battery, check battery specific gravity of each cell.. (Scheme 2) Standard specific gravity: 1.25-1.29 at 20°C (68°F) If the specific gravity is less than specification, charge the battery.
3. For maintenance-Free Battery, 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. (Scheme 3) 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. (Scheme 4)
4. Check battery terminals, fusible link and fuses: Check that the battery terminals are not loose or corroded. Check the fusible link and fuses for continuity.
5. Inspect drive belt: Visually check the drive belt for excessive wear, frayed cords etc. If necessary, replace the drive belt. NOTE: When a new belt is installed, it should lie within area B. If not, the drive belt is not correct. (Scheme 6) After installing a belt, check that it fits properly in the ribbed grooves. (Scheme 7) Check by hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley. Check the belt tensioner operation. Check that the belt tensioner moves downward when the drive belt is pressed down at the points indicated in the illustration with approx. 98 N (10 kgf, 22.0 lbf) of force. Check the alignment of the belt tensioner pulley to make sure the drive belt has not slipped off the pulley. (Scheme 8) Check that the arrow mark on the belt tensioner falls within area A of the scale. If it is outside area A, replace the drive belt. If necessary, replace the belt tensioner.
6. Remove engine under cover No. 1.
7. Visually check generator wiring and listen for abnormal noises. Check that the wiring is in good condition. Check that there is no abnormal noise from the generator while the engine is running.
8. Check charge warning light circuit: Warm up the engine and then turn it off. Switch off all accessories. Turn the ignition switch ON, and check that the charge warning light is lit. Start the engine, and check that the light goes off. If the light does not go off as specified, troubleshoot the charge light circuit.
9. Inspect charging circuit without load: If a tester is not available, connect a voltmeter and ammeter to the charging circuit as follows: Disconnect the wire from terminal B of the generator, and connect it to the negative (-) tester probe of the ammeter. (Scheme 9) Connect the positive (+) tester probe of the ammeter to terminal B of the generator. Connect the positive (+) tester probe of the voltmeter to terminal B of the generator. 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. If the voltmeter reading is more than standard voltage, replace the voltage regulator.
10. 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 the standard amperage, repair the generator.
11. Reinstall engine under cover No. 1.

COMPONENTS

For locations of generator components, see illustration. (Scheme 10)and (Scheme 11).

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1. Remove generator drive belt. Loosen the belt tension by turning the belt tensioner counterclockwise, and remove the drive belt. (Scheme 12)
2. Remove PS vane pump from engine.
3. Remove engine under cover.
4. Remove engine under cover. Remove the 2 clips and No. 2 fan shroud.
5. Remove generator: Disconnect the generator connector. Remove the cap and nut, and disconnect the generator wire. Disconnect the generator wire clamp from the cord clip on the generator. Remove the bolt, nut and generator. (Scheme 13)

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1. Remove rear end cover: Remove the nut and terminal insulator. (Scheme 14) Remove the bolt 3 nuts, plate terminal and end cover.
2. Remove brush holder: Remove the brush holder cover from the brush holder. Remove the 2 screws and brush holder. (Scheme 15) Remove the seal plate from the rectifier end frame.
3. Remove voltage regulator. Remove the 3 screws and voltage regulator. (Scheme 16)
4. Remove rectifier holder: Remove the nut and cord clip. (Scheme 17) Remove the 4 screws and rectifier holder. (Scheme 18) Remove the 4 rubber insulators.
5. Remove pulley: Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. (Scheme 19) SST 09820-63011 Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) Check that SST (A) is secured to the rotor shaft. Mount SST (C) in a vise. Insert SST (B) into SST (C), and attach the pulley nut to SST (C). (Scheme 20) NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a turn. To loosen the pulley nut, turn SST (A) in the direction shown in the illustration. (Scheme 21) Remove the generator from SST (C). Turn SST (B), and remove SST (A and B). Remove the pulley nut and pulley.
6. Remove rectifier end frame. Remove the 3 nuts. (Scheme 22) Using SST, remove the rectifier end frame. (Scheme 23) SST 09286-46011 Remove the generator washer from the rectifier end frame.
7. Remove rotor from drive end frame.

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1. Inspect voltage regulator: Using an ohmmeter, check the continuity between terminals F and B. (Scheme 24) Standard: when the positive and negative poles between terminals F and B are exchanged, there is continuity in one way but no continuity in another way. If the continuity is not as specified, replace the voltage regulator. Using an ohmmeter, check the continuity between terminals F and E. (Scheme 25) Standard: When the positive and negative poles between terminals F and E are exchanged, there is continuity in one way but no continuity in another way. If the continuity is not as specified, replace the voltage regulator.
2. Inspect rotor for open circuit. Using an ohmmeter, check that there is continuity between the slip rings. (Scheme 26) Standard resistance: 2.1 - 2.5 ohm at 20°C (68°F). If there is no continuity, replace the rotor.
3. INSPECT ROTOR FOR GROUND Using an ohmmeter, check that there is no continuity between the slip ring and rotor. (Scheme 27) If there is continuity, replace the rotor.
4. Inspect slip rings: Check that the slip rings are not rough or scored. If rough or scored, replace the rotor. Using vernier calipers, measure the slip ring diameter. (Scheme 28) For diameter, see illustration. (Scheme 29) If the diameter is less than minimum, replace the rotor.
5. Inspect stator for open circuit: Using an ohmmeter, check that there is continuity between the coil leads. (Scheme 30) If there is no continuity, replace the drive end frame assembly.
6. Inspect stator for ground: Using an ohmmeter, check that there is no continuity between the coil lead and drive end frame. (Scheme 31) If there is continuity, replace the drive end frame assembly.
7. Inspect exposed brush length: Using vernier calipers, measure the exposed brush length. (Scheme 32) For exposed length, see illustration (Scheme 33) If the exposed length is less than minimum, replace the brush holder assembly.
8. Inspect positive rectifier: Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal. (Scheme 34) Reverse the polarity of the tester probes and repeat step (a). Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder.
9. Inspect negative rectifier: Using an ohmmeter, connect one tester probe to each negative (-) terminal and the other to each rectifier terminal. Reverse the polarity of the tester probes and repeat step (a). Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder.
10. Inspect front and rear bearing: Check that the bearing is not rough or worn. If necessary, replace the bearing. See «REPLACEMENT»(ref-170107-S41968677112004123000000).

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1. Replace front bearing: Remove the 4 screws and bearing retainer. (Scheme 36) Using SST and a press, press out the bearing. (Scheme 37) SST 09950-60010 (09951-00260, 09952-06010) Using SST and a press, press in a new bearing. (Scheme 38) SST 09950-60010 (09951-00520) Install the bearing retainer with the 4 screws. Torque: 3.0 N.m (31 kgf.cm, 27 in..lbf)
2. Replace rear bearing: CAUTION: Be careful not to damage the fan. Using SST, remove the bearing cover (outside) and bearing. (Scheme 39) SST 09820-00021 Remove the bearing cover (inside). Place the bearing cover (inside) on the rotor. (Scheme 40) Using SST and a press, press in a new bearing. (Scheme 41) SST 09820-00031 Using SST, push in the bearing cover (outside). (Scheme 42) SST 09285-76010

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1. Place drive end frame on pulley. (Scheme 43)
2. Install rotor to drive end frame.
3. Install rectifier end frame: Place the generator washer on the rotor. (Scheme 44) Using a 29 mm socket wrench and press, slowly press in the rectifier end frame. (Scheme 45) Install the 3 nuts. (Scheme 46) Torque: 4.5 N.m (46 kgf.cm, 39 in..lbf).
4. Install pulley: Install the pulley to the rotor shaft by tightening the pulley nut by hand. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. (Scheme 47) SST 09820-63011 Torque: 39 N.m (400 kgf.cm, 29 ft.lbf). Check that SST (A) is secured to the pulley shaft. Mount SST (C) in a vise. (Scheme 48) Insert SST (B) into SST (C), and attach the pulley nut to SST (C). To torque the pulley nut, turn SST (A) in the direction shown in the illustration. Torque: 110.5 N.m (1,125 kgf.cm, 81 ft.lbf). Remove the generator from SST (C). Turn SST (B), and remove SST (A and B). (Scheme 49)
5. Install rectifier holder: NOTE: Be careful of the rubber insulators installation direction. (Scheme 50) Install the 4 rubber insulators on the lead wires. Install the rectifier with the 4 screws. (Scheme 51) Torque: 2.94 N.m (30 kgf.cm, 26 in..lbf). Install the cord clip with the nut. (Scheme 17) Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf). Place the seal plate on the rectifier end frame. (Scheme 52) NOTE: Be careful of the brush holder installation direction. Place the voltage regulator and brush holder on the rectifier end frame. Install the 5 screws. (Scheme 53) Torque: 1.96 N.m (20 kgf.cm, 17 in..lbf). Place the brush holder cover on the brush holder. (Scheme 54)
6. Install rear end cover: Install the end cover and plate terminal with the bolt and 3 nuts. see scheme 56 Torque: Bolt: 3.85 N.m (39 kgf.cm, 34 in..lbf). Nut: 4.4 N.m (46 kgf.cm, 39 in..lbf). Install the terminal insulator with the nut. (Scheme 55) Torque: 4.1 N.m (41.5 kgf.cm, 36 in..lbf).
7. Check that rotor rotates smoothly.

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