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    Alternator and Regulator Nippondenso

    Uploaded by

    Toua Yaj
    This document provides information on alternators and regulators for 1988 Toyota vehicles with Nippondenso parts. It describes the components, testing procedures, specifications, and troubleshooting tips. The key points are: 1) Nippondenso alternators use 3-phase rectification and an internal integrated circuit voltage regulator to control charging system voltage. 2) Testing procedures are outlined for no-load testing, full-field testing, load testing, and checking control relays according to vehicle model. 3) Specification tables provide the expected voltage and current outputs at 2,000 RPM for various Toyota models.

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    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd

    Alternator and Regulator Nippondenso

    Uploaded by

    Toua Yaj
    331 views16 pages
    This document provides information on alternators and regulators for 1988 Toyota vehicles with Nippondenso parts. It describes the components, testing procedures, specifications, and troubleshooting tips. The key points are: 1) Nippondenso alternators use 3-phase rectification and an internal integrated circuit voltage regulator to control charging system voltage. 2) Testing procedures are outlined for no-load testing, full-field testing, load testing, and checking control relays according to vehicle model. 3) Specification tables provide the expected voltage and current outputs at 2,000 RPM for various Toyota models.

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    This document provides information on alternators and regulators for 1988 Toyota vehicles with Nippondenso parts. It describes the components, testing procedures, specifications, and troubleshooting tips. The key points are: 1) Nippondenso alternators use 3-phase rectification and an internal integrated circuit voltage regulator to control charging system voltage. 2) Testing procedures are outlined for no-load testing, full-field testing, load testing, and checking control relays according to vehicle model. 3) Specification tables provide the expected voltage and current outputs at 2,000 RPM for various Toyota models.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    331 views16 pages

    Alternator and Regulator Nippondenso

    Uploaded by

    Toua Yaj
    This document provides information on alternators and regulators for 1988 Toyota vehicles with Nippondenso parts. It describes the components, testing procedures, specifications, and troubleshooting tips. The key points are: 1) Nippondenso alternators use 3-phase rectification and an internal integrated circuit voltage regulator to control charging system voltage. 2) Testing procedures are outlined for no-load testing, full-field testing, load testing, and checking control relays according to vehicle model. 3) Specification tables provide the expected voltage and current outputs at 2,000 RPM for various Toyota models.

    Copyright:

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    of 16

    ALTERNATOR & REGULATOR - NIPPONDENSO

    1988 Toyota Celica

    1988 ELECTRICAL
    Alternators & Regulators - Nippondenso

    Camry, Celica, Corolla, Cressida, Land Cruiser, MR2, Pickup,


    Supra, Tercel, Van, 4Runner

    DESCRIPTION
    Nippondenso 3-phase alternators utilize 3 positive and 3
    negative diodes to rectify current. Charging system voltage is
    controlled by an internal Integrated Circuit (IC) voltage regulator.
    Some models use engine, ignition, and charging light relays.

    TROUBLE SHOOTING
    See TROUBLE SHOOTING - BASIC PROCEDURES article in GENERAL
    TROUBLE SHOOTING.

    ADJUSTMENTS

    BELT TENSION
    See appropriate BELT ADJUSTMENT table.

    4-CYLINDER BELT ADJUSTMENT (1)


    
    Application New Belt Used Belt

    Camry & Celica


    Alternator (Without A/C) . 125 (57) .................... 95 (43)
    Alternator (With A/C) .... 175 (79) ................... 130 (59)
    Power Steering ........... 125 (57) .................... 80 (36)
    Corolla
    A/C ...................... 160 (73) ................... 100 (45)
    Alternator ............... 160 (73) ................... 125 (57)
    Power Steering ........... 125 (57) .................... 80 (36)
    MR2
    Alternator ............... 175 (79) ................... 115 (52)
    A/C ...................... 160 (73) ................... 105 (48)
    Pickup & 4Runner
    "V" Ribbed (With A/C) .... 160 (73) ................... 100 (45)
    "V" Ribbed (Without A/C) . 105 (48) .................... 85 (39)
    Conventional ............. 125 (57) .................... 80 (36)
    Tercel
    Alternator ............... 160 (73) ................... 100 (45)
    A/C ...................... 165 (75) ................... 110 (50)
    Power Steering ........... 175 (79) ................... 115 (52)
    Van
    "V" Ribbed ............... 175 (79) ................... 115 (52)
    Conventional ............. 125 (57) .................... 80 (36)

    (1) - Tension in Lbs. (Kg) Using Burroughs Tension Gauge.


    
    6-CYLINDER BELT ADJUSTMENT (1)
    
    Application New Belt Used Belt
    Cressida
    Alternator ............... 175 (79) ................... 115 (52)
    A/C ...................... 160 (73) ................... 105 (48)
    P/S ...................... 160 (73) ................... 100 (45)
    Land Cruiser
    A/C Belt ................. 125 (57) .................... 80 (36)
    All Others ............... 145 (66) ................... 100 (45)
    Supra
    Alternator ............... 175 (79) ................... 115 (52)
    A/C & P/S ................ 160 (73) ................... 105 (48)

    (1) - Tension in Lbs. (Kg) Using Burroughs Tension Gauge.


    
    V6 BELT ADJUSTMENT TABLE (1)
    
    Application New Belt Used Belt

    Camry
    Alternator ............... 175 (79) ................... 115 (52)
    Power Steering ........... 125 (57) .................... 80 (36)
    Pickup & 4Runner
    Alternator ............... 160 (73) ................... 100 (45)
    All Others ............... 125 (57) .................... 80 (36)

    (1) - Tension in Lbs. (Kg) Using Burroughs Tension Gauge.


    

    TESTING (ON VEHICLE)

    NO LOAD TEST
    1) Disconnect alternator terminal "B" wire. Using an ammeter
    and voltmeter, connect negative ammeter lead to disconnected
    alternator terminal "B" wire and positive lead to alternator terminal
    "B". Connect voltmeter positive lead to alternator terminal "B" and
    negative lead to ground. See Fig. 1.

    Fig. 1: Charging Circuit Testing


    Courtesy of Toyota Motor Sales, U.S.A., Inc.

    2) Start engine and increase engine speed to 2000 RPM.


    Voltmeter and ammeter should read according to specification. See
    ALTERNATOR OUTPUT SPECIFICATIONS table.
    3) If voltage is more than specified, replace IC regulator.
    If voltage is less than specified, ground "F" (full field) terminal.
    See Fig. 2, 3 or 4.
    4) If voltage now climbs above specified range, replace IC
    regulator. If voltage remains below specified range, repair or replace
    alternator.

    ALTERNATOR OUTPUT SPECIFICATIONS (1)


    
    Application Amps Volts

    Cressida ...................... 10 ..................... 14.0-15.0


    Land Cruiser .................. 10 ..................... 13.8-14.4
    All Others .................... 10 ..................... 13.9-15.1
     
    (1) - At 2000 RPM with temperature at 77 F (25 C).
    

    Fig. 2: Alt Full Field Output Test (Camry, Celica, Corolla 4A-GE,
    Cressida, MR2, Supra)
    Courtesy of Toyota Motor Sales, U.S.A., Inc.

    Fig. 3: Alt Full Field Output Test (Corolla 4A-F 4A-FE, Land Cruiser,
    Pickup, 4Runner)
    Courtesy of Toyota Motor Sales, U.S.A., Inc.
    Fig. 4: Tercel Alternator Full Field Output Test
    Courtesy of Toyota Motor Sales, U.S.A., Inc.

    LOAD TEST
    NOTE: During load test procedure, if voltage reading is low due to
    a fully charged battery, it may be necessary to disable
    ignition system and crank engine for about 15 seconds to
    partially discharge battery.

    1) Connect an ammeter as described in NO LOAD TEST step 1).


    Start engine. Turn on high beam headlights and place heater control on
    "HI".
    2) Increase engine speed to 2000 RPM and check ammeter
    reading. Ammeter should read more than 30 amps. If amperage is less
    than specified, repair or replace alternator.

    CONTROL RELAYS
    NOTE: Charge light relay is located above right kick panel.

    CHARGE LIGHT RELAY


    Land Cruiser
    1) Using an ohmmeter, connect ohmmeter positive lead to
    charge light relay terminal No. 4 and negative lead to terminal No. 3.
    See Fig. 5 "STEP 1".
    2) Ohmmeter should indicate continuity. Reverse ohmmeter
    leads. Ohmmeter should now indicate no continuity.
    3) Connect ohmmeter between terminals No. 1 and 2. Ohmmeter
    should indicate no continuity. If charge light relay does not test as
    indicated, replace relay.
    4) Check charge light relay operation. Connect positive side
    of battery to terminal No. 3. Connect negative side of battery to
    terminal No. 4. See Fig. 5 "STEP 2". Check for continuity between
    charge light relay terminals No. 1 and 2. If relay does not test as
    indicated, replace relay.

    Fig. 5: Testing Charge Light Relay (Land Cruiser)


    Courtesy of Toyota Motor Sales, U.S.A., Inc.

    ENGINE MAIN RELAY


    Camry, Celica, Corolla, MR2 & Tercel
    1) Using an ohmmeter, check for continuity between engine
    main relay terminals No. 3 and 5 and between terminals No. 1 and 2.
    Check that continuity does not exist between terminals No. 3 and 4.
    See Fig. 6 "STEP 1". If engine main relay does not test as indicated,
    replace relay.

    NOTE: For location of engine main relay, see ENGINE MAIN RELAY
    LOCATION table.

    2) Check engine main relay operation. Apply battery voltage


    between terminals No. 1 and 2. Using an ohmmeter, check that
    continuity exists between terminals No. 3 and 4. Check that continuity
    does not exist between terminals No. 3 and 5. See Fig. 6 "STEP 2". If
    main relay does not test as indicated, replace relay.

    ENGINE MAIN RELAY LOCATION


    
    Application Location

    Camry (2VZ-FE) .............................. Left Rear Fender Panel


    MR2 ........................ Engine Compartment No. 2 Junction Block
    All Others ............................ Engine Compartment Relay Box
    

    Fig. 6: Testing Engine Main Relay


    Courtesy of Toyota Motor Sales, U.S.A., Inc.

    IGNITION RELAY
    Land Cruiser & Van
    1) Using an ohmmeter, check for continuity between ignition
    relay terminals No. 1 and 3. Check that continuity does not exist
    between terminals No. 2 and 4. See Fig. 7 "STEP 1".
    2) On Land Cruiser, also check that continuity does not
    exists between terminals No. 3 and 4. If ignition relay does not test
    as indicated, replace relay.

    NOTE: On Van, ignition relay is located under instrument panel, in


    relay box. On Land Cruiser, ignition relay is located in
    relay box, above left kick panel.

    3) Check ignition relay operation. Apply battery voltage


    across terminals No. 1 and 3. Using an ohmmeter, check that continuity
    exists between terminals No. 2 and 4. See Fig. 7 "STEP 2".
    4) On Land Cruiser, also check that continuity does not
    exists between terminals No. 3 and 4. If ignition relay does not test
    as indicated, replace relay.

    Fig. 7: Testing Ignition Relay


    Courtesy of Toyota Motor Sales, U.S.A., Inc.

    BENCH TESTING
    BRUSHES
    1) Check for cracks and minimum brush length of .18-.22" (4.
    5-5.5 mm). Replace brushes if damaged or worn. Brushes should slide
    smoothly in holders. Install new springs when replacing brushes.
    Solder brush wire.
    2) New brush exposed length should be .413" (10.5 mm). Old
    brush minimum exposed length not be less than .059" (1.5 mm).

    ROTOR
    1) Check rotor for open field windings by using an ohmmeter
    across slip rings. Rotor resistance should be 2.8-3.0 ohms.
    2) Check rotor for shorts to ground by connecting ohmmeter
    between slip ring and rotor shaft. Ohmmeter should indicate no
    continuity. Check slip rings for wear or pitting.
    3) Turn slip rings on lathe if necessary. Minimum slip ring
    diameter should not be less than .504" (12.8 mm). Check bearing and
    replace if necessary.

    STATOR
    Connect ohmmeter between 2 stator leads. Continuity should
    exist between all stator leads. Connect ohmmeter between each stator
    lead and metal core. Continuity should not exist. If stator does not
    test as indicated, replace stator.

    DIODES
    1) With diode 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 for all diodes.
    2) All diodes should show a low reading in one direction and
    NO reading in opposite direction. If any diode is defective, replace
    diode assembly.

    OVERHAUL

    Fig. 8: Exploded View of Camry, Celica, Cressida & Supra (7M-GE) Alt
    Courtesy of Toyota Motor Sales, U.S.A., Inc.
    Fig. 9: Exploded View of Corolla Alternator
    Courtesy of Toyota Motor Sales, U.S.A., Inc.
    Fig. 10: Exploded View of Land Cruiser Alternator
    Courtesy of Toyota Motor Sales, U.S.A., Inc.
    Fig. 11: Exploded View of Pickup & 4Runner Alternator
    Courtesy of Toyota Motor Sales, U.S.A., Inc.
    Fig. 12: Exploded View of Pickup (3VZ-E) & 4Runner (3VZ-E) Alternator
    Courtesy of Toyota Motor Sales, U.S.A., Inc.
    Fig. 13: Exploded View of Tercel (50-Amp) Alternator
    Courtesy of Toyota Motor Sales, U.S.A., Inc.
    Fig. 14: Exploded View of Tercel (55-Amp) & Van Alternator
    Courtesy of Toyota Motor Sales, U.S.A., Inc.
    Fig. 15: Exploded View of MR2 (4A-GE) Alternator
    Courtesy of Toyota Motor Sales, U.S.A., Inc.
    Fig. 16: Exploded View of Supra (7M-GTE) Alternator
    Courtesy of Toyota Motor Sales, U.S.A., Inc.

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