CH-2

CHARGING - CHARGING SYSTEM

CH0JZ-02

ON-VEHICLE INSPECTION
1. CHECK BATTERY ELECTROLYTE LEVEL
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.
Except Maintenance-Free Battery:
If under the lower level, add distilled water.
B04539

Except Maintenance-Free Battery 2. Except Maintenance-Free Battery:

CHECK BATTERY SPECIFIC GRAVITY
Check the specific gravity of each cell.
Standard specific gravity:
1.25 - 1.29 at 20°C (68°F)
If the specific gravity is less than specification, charge the bat-
tery.

B04881

Maintenance-Free Battery 3. Maintenance-Free Battery:

Voltmeter CHECK BATTERY VOLTAGE
(a) After having driven the vehicle and in the case that 20
minutes have not passed after having stopped the en-
gine, 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.
(b) Turn the ignition switch OFF and turn off the electrical sys-
B04538 tems.
(c) 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.

Maintenance-Free Battery HINT:

Check the indicator as shown in the illustration.
Blue White Red
4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND
FUSES
(a) Check that the battery terminals are not loose or cor-
roded.
OK Charging Insufficient (b) Check the fusible link and fuses for continuity.
Necessary Water
Z11580

2004 LAND CRUISER (RM1071U)

Author
: Date
: 1837

 CH-3
CHARGING - CHARGING SYSTEM

5. INSPECT DRIVE BELT

HINT:
A belt tensioner is used, so checking the belt tension is not nec-
essary.

(a) Visually check the drive belt for excessive wear, frayed
cords etc.
If necessary, replace the drive belt.
HINT:

Cracks on the rib side of a drive belt are considered ac-
ceptable. If the drive belt has chunks missing from the
ribs, it should be replaced.

The drive belt tension can be released by turning the belt
Z00030 tensioner counterclockwise. The pulley bolt for the belt
tensioner has a left-hand thread.
(b) Check the belt tensioner operation.

Check that the belt tensioner moves downward
when the drive belt is pressed down at the points in-
dicated 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.
B00807 If necessary, replace the belt tensioner.

A
Check that the arrow mark on the belt tensioner falls

B within area A of the scale.
If it is outside area A, replace the drive belt.
HINT:

When a new belt is installed, it should lie within area B. If
not, the drive belt is not correct.

B00808

After installing a belt, check that it fits properly in the

ribbed grooves.

Check by hand to confirm that the belt has not slipped out
of the groove on the bottom of the pulley.
6. REMOVE ENGINE UNDER COVER NO.1
7. VISUALLY CHECK GENERATOR WIRING AND LIS-
CORRECT WRONG TEN FOR ABNORMAL NOISES
(a) Check that the wiring is in good condition.
AC2024 (b) Check that there is no abnormal noise from the generator
while the engine is running.
2004 LAND CRUISER (RM1071U)

Author
: Date
: 1838

CH-4
CHARGING - CHARGING SYSTEM

8. CHECK CHARGE WARNING LIGHT CIRCUIT

(a) Warm up the engine and then turn it off.
(b) Switch off all accessories.
(c) Turn the ignition switch ON, and check that the charge
warning light is lit.
(d) Start the engine, and check that the light goes off.
If the light does not go off as specified, troubleshoot the charge
light circuit.

Ammeter 9. INSPECT CHARGING CIRCUIT WITHOUT LOAD

HINT:
Disconnect Wire
from Terminal B If a battery/generator tester is available, connect the tester to
the charging circuit as per manufacturer’s instructions.
Battery (a) If a tester is not available, connect a voltmeter and amme-
B ter to the charging circuit as follows:

Disconnect the wire from terminal B of the genera-
Generator
Voltmeter tor, and connect it to the negative (-) tester probe
Z03473 of the ammeter.

Connect the positive (+) tester probe of the amme-
ter to terminal B of the generator.

Connect the positive (+) tester probe of the voltme-
ter to terminal B of the generator.

Ground the negative (-) tester probe of the voltme-
ter.
(b) 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 value is not specified, check the generator.
10. INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn on the high
beam headlights and place the heater blower switch at HI.
(b) Check the reading on the ammeter.
Standard amperage:
30 A or more
If the ammeter reading is less than the standard amperage, re-
pair the generator.
HINT:
If the battery is fully charged, the indication will sometimes be
less than standard amperage.
11. REINSTALL ENGINE UNDER COVER NO.1

2004 LAND CRUISER (RM1071U)

Author
: Date
: 1839

 CH-1
CHARGING - CHARGING SYSTEM

CHARGING SYSTEM
CH06F-01

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.

2004 LAND CRUISER (RM1071U)

Author
: Date
: 1836

 CH-5
CHARGING - GENERATOR

GENERATOR
CH06H-09

COMPONENTS
9.8 (100, 87 in.·lbf)
PS Vane Pump Pulley
Generator
Wire
Generator Connector

39 (400, 29)

A/C Discharge Tube 15.5 (158, 11)

Clamp Generator
39 (400, 29)
Radiator Reservoir Tank
Clamp

Radiator Lower Grommet

Clamp Hose
5.0 (50, 43 in.·lbf)
Radiator Upper
Hose
Bracket
Bracket Wire
Fan Shroud
20 (200, 15)

A/T Oil Cooler Hose

20 (200, 15)
Radiator Asembly

20 (200, 15)

Fan Pulley
Generator Drive Belt

Fan with
Fluid Coupling Engine Under Cover No. 1
x8
N·m (kgf·cm, ft·lbf) : Specified torque
B16651

2004 LAND CRUISER (RM1071U)

Author
: Date
: 1840

CH-6
CHARGING - GENERATOR

Generator Washer
Rotor

Rear Bearing
Bearing Retainer
2.6 (27, 23 in.·lbf)
Drive End Frame (Stator)

Bearing Cover
Pulley

2.6 (27, 23 in.·lbf)

Front Bearing 4.6 (47, 41 in.·lbf)

Rear End Cover

110.3 (1,125, 81)

4.6 (47, 41 in.·lbf)

Terminal Insulator
1.8 (18, 16 in.·lbf)
5.8 (59, 51 in.·lbf)

Seal Plate

Seal Plate 4.6 (47, 41 in.·lbf)

End Cover
Brush Holder

5.8 (59, 51 in.·lbf)

Rectifier End Frame

N·m (kgf·cm, ft·lbf) : Specified torque

Non-reusable part B16652

2004 LAND CRUISER (RM1071U)

Author
: Date
: 1841

CH-8
CHARGING - GENERATOR
CH06J-03

DISASSEMBLY
1. REMOVE REAR END COVER
(a) Remove the 3 screws and rear end cover.

B16654

2. REMOVE END COVER

(a) Remove the 3 nuts and end cover.
(b) Remove the terminal insulator.

B16655

3. REMOVE BRUSH HOLDER

(a) Remove the rear seal plate from the brush holder.
(b) Remove the 2 screws and brush holder.
(c) Remove the front seal plate from the coil assembly.

B16362

4. REMOVE PULLEY
(a) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
SST 09820-6301 1
Turn SST (A)
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Check that SST (A) is secured to the rotor shaft.

SST (B)
B16369

(c) Mount SST (C) in a vise.

(d) Insert SST (B) into SST (C), and attach the pulley nut to
SST (B) SST (C).
SST (C)
Insert

B16371

2004 LAND CRUISER (RM1071U)

Author
: Date
: 1843

 CH-9
CHARGING - GENERATOR

(e) To loosen the pulley nut, turn SST (A) in the direction
SST (C)
shown in the illustration.
NOTICE:
SST (A) To prevent damage to the rotor shaft, do not
loosen the pulley nut more than one-half of a turn.
(f) Remove the generator from SST (C).

Turn B16372

(g) Turn SST (B), and remove SST (A and B).

Turn (h) Remove the pulley nut and pulley.

SST (A)

SST (B) B16370

5. REMOVE COIL ASSEMBLY

(a) Remove the 4 bolts.

B16656

(b) Using SST, remove the coil assembly.

SST SST 09950-4001 1 (09951-04020, 09952-04010
09953- 04020, 09954- 04010, 09955- 04071,
09958-0401 1)
(c) Remove the generator washer.
6. REMOVE ROTOR FROM DRIVE END FRAME

B16366

2004 LAND CRUISER (RM1071U)

Author
: Date
: 1844

CH-10
CHARGING - GENERATOR
CH0M4-01

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 - 2.7 Ω at 20°C (68°F)
If there is no continuity, replace the rotor.

B12264

(b) Check the rotor for ground.

Ohmmeter
Using an ohmmeter, check that there is no continuity be-
tween the slip ring and rotor.
If there is continuity, replace the rotor.
(c) Check that the slip rings are not rough or scored.
No Continuity If rough or scored, replace the rotor.

B12265

(d) 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.

B12266

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 minimum, replace the brushes
and 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).

2004 LAND CRUISER (RM1071U)

Author
: Date
: 1845

CH-16
CHARGING - GENERATOR
CH06N-05

INSTALLATION
1. INSTALL GENERATOR
(a) Install the generator with the bolt and 2 nuts.
Torque:
Bolt: 39 N·m (400 kgf·cm, 29 ft·lbf)
Nut 10 mm: 39 N·m (400 kgf·cm, 29 ft·lbf)
Nut 8 mm: 15.5 N·m (158 kgf·cm, 11 ft·lbf)
(b) Connect the generator connector.
B16653
(c) Connect the generator wire with the nut.
Torque: 9.8 N·m (100 kgf·cm, 87 in.·lbf)
(d) Install the terminal cap.
(e) Install the wire clamp to the cord clip on the generator.
2. INSTALL PS VANE PUMP PULLEY
(See page SR-47 )
3. INSTALL RADIATOR ASSEMBLY
(See page CO-19 )

4. INSTALL GENERATOR DRIVE BELT

Install the belt by turning the belt tensioner counterclockwise.
HINT:
The pulley bolt for the belt tensioner has a left - hand thread.
5. FULL ENGINE COOLANT
6. START ENGINE AND CHECK FOR LEAKS
7. RECHECK ENGINE COOLANT LEVEL
8. PERFORM ON-VEHICLE INSPECTION
B00809 (See page CH-2 )
9. INSTALL ENGINE UNDER COVER NO.1

2004 LAND CRUISER (RM1071U)

Author
: Date
: 1851

 CH-13
CHARGING - GENERATOR
CH0M6-01

Pulley REASSEMBLY
1. INSTALL ROTOR TO DRIVE END FRAME
(a) Place the drive end frame on the pulley.
(b) Install the rotor to the drive end frame.
2. INSTALL COIL ASSEMBLY
(a) Place the generator washer on the rotor.

B16368

SST (b) Using SST and a press, slowly press in the coil assembly.
SST 09285-76010

B12276

(c) Install the coil assembly with the 4 bolts.

Torque: 5.8 N·m (59 kgf·cm, 51 in.·lbf)

B16656

3. INSTALL PULLEY
(a) Install the pulley to the rotor shaft by tightening the pulley
nut by hand.
(b) Hold SST (A) with a torque wrench, and tighten SST (B)
Turn SST (A) clockwise to the specified torque.
SST 09820-6301 1
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(c) Check that SST (A) is secured to the pulley shaft.
SST (B)
B16369

(d) Mount SST (C) in a vise.

(e) Insert SST (B) into SST (C), and attach the pulley nut to
SST (A) SST (C).

SST (C)
Insert

B16371

2004 LAND CRUISER (RM1071U)

Author
: Date
: 1848

CH-14
CHARGING - GENERATOR

(f) To torque the pulley nut, turn SST (A) in the direction
shown in the illustration.
SST (C)
Torque: 110.3 N·m (1,125 kgf·cm, 81 ft·lbf)
(g) Remove the generator from SST (C).
SST (A)

Turn

B16373

(h) Turn SST (B), and remove SST (A and B).

Turn

SST (A)

SST (B)
B16370

4. INSTALL BRUSH HOLDER

(a) Place the front seal plate on the coil assembly.

B16363

(b) Place the brush holder on the coil assembly with the pin
facing upward.
NOTICE:
Be careful of the holder installation direction.
Upward
(c) Install the 2 screws.
Torque: 1.8 N·m (18 kgf·cm, 16 in.·lbf)

Pin

B16361

(d) Align the pins of the brush holder with the holes of the rear
seal plate, and install the rear seal plate.

B16360

2004 LAND CRUISER (RM1071U)

Author
: Date
: 1849

 CH-15
CHARGING - GENERATOR

5. INSTALL END COVER

(a) Install the terminal insulator.
NOTICE: Be careful of the terminal insulator installation
direction.

B16359

(b) Install the end cover with the 3 nuts.

Torque: 4.6 N·m (47 kgf·cm, 41 in.·lbf)

B16655

6. INSTALL REAR END COVER

Install the rear end cover with the 3 scerws.
Torque: 4.6 N·m (47 kgf·cm, 41 in.·lbf)
7. CHECK THAT ROTOR ROTATES SMOOTHLY

B16654

2004 LAND CRUISER (RM1071U)

Author
: Date
: 1850

 CH-7
CHARGING - GENERATOR
CH06I-04

REMOVAL
1. DRAIN ENGINE COOLANT
(See page CO-2 )
2. REMOVE GENERATOR DRIVE BELT
Loosen the belt tension by turning the belt tensioner counter-
clockwise, and remove the drive belt.
HINT:
The pulley bolt for the belt tensioner has a left - hand thread.
B00809
3. REMOVE ENGINE UNDER COVER NO.1
4. REMOVE RADIATOR ASSEMBLY
(See page CO-17 )
5. REMOVE PS VANE PUMP PULLEY
(See page SR-40 )

6. REMOVE GENERATOR
(a) Disconnect the generator connector.
(b) Remove the rubber cap and nut, and disconnect the gen-
erator wire.
(c) Disconnect the generator wire clamp from the cord clip on
the generator.
(d) Remove the bolt, 2 nuts and generator.

B16653

2004 LAND CRUISER (RM1071U)

Author
: Date
: 1842

 CH-1 1
CHARGING - GENERATOR
CH0M5-01

REPLACEMENT
1. REPLACE FRONT BEARING
(a) Remove the 4 screws, bearing retainer and bearing.

B16375

(b) Using SST and a hammer, tap out the bearing.

SST 09950- 60010 (09951- 00250), 09950- 70010
(09951-07100)

Socket Wrench

SST

B16387

(c) Using SST and a press, press in a new bearing.

SST 09950- 60010 (09951- 00470), 09950- 70010
SST
(09951-07100)
(d) Install the bearing retainer with the 4 screws.
Torque: 2.6 N·m (27 kgf·cm, 23 in.·lbf)

B16386

2. REPLACE REAR BEARING

(a) Using SST, remove the bearing cover (outside) and bear-
ing.
SST 09820-00021
SST
NOTICE:
Be careful not to damage the fan.

B12270

(b) Using SST and a press, press in a new bearing.

SST 09820-00031
SST

B12272

2004 LAND CRUISER (RM1071U)

Author
: Date
: 1846

CH-12
CHARGING - GENERATOR

(c) Using SST, push in the bearing cover (outside).

SST 09285-76010
SST

B12273

2004 LAND CRUISER (RM1071U)

Author
: Date
: 1847