19–9

STARTING & CHARGING – GENERATOR ASSY

OVERHAUL

190OK–01

1. REMOVE GENERATOR REAR END COVER

(a) Remove the 2 terminal covers by turning them counter-
clockwise.

A80108

(b) Remove the screw and 2 nuts, and then detach the gener-
ator rear end cover.

B09748

2. REMOVE REGULATOR SUB–ASSY GENERATOR

W/BRUSH
(a) Remove the 3 screws and the regulator sub–assy gener-
ator w/ brush.

B09749

3. REMOVE STATOR SUB–ASSY GENERATOR

W/RECTIFIRE
(a) Remove the 4 bolts.

B09750

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

19–10
STARTING & CHARGING – GENERATOR ASSY

(b) Using a screwdriver, pry out the stator sub–assy genera-

tor w/rectifire.
4. REMOVE BEARING SET GENERATOR

B10446

5. REMOVE PULLEY SET GENERATOR

(a) Clamp the swivel arm in a vise.
NOTICE:
Be careful not to damage the fan.
(b) Using an impact wrench or internal serration on rotor shaft
end together with a torque wrench,remove the nut and
spring washer, then detach the pulley.

B10014

6. REMOVE GENERATOR ROTOR ASSY

(a) Using a press, press out the generator rotor assy and
spacer ring.

B10015

Ohmmeter 7. INSPECT GENERATOR ROTOR ASSY

(a) Inspect the generator rotor assy for open circuit.
(1) Using an ohmmeter, check that there is continuity
between the slip rings.
Standard resistance: 2.27 to 2.53
at 20
C (68
F)
If there is no continuity, replace the generator rotor assy.

Continuity B10452

(b) Inspect the generator rotor assy for ground.

Ohmmeter
(1) Using an ohmmeter, check that there is no continu-
ity between the slip ring and the generator rotor
assy.
If there is continuity, replace the generator rotor assy.

No Continuity B10453

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

 19–11
STARTING & CHARGING – GENERATOR ASSY

(c) Inspect the slip rings.

(1) Check that the slip rings are not rough or scored.
If rough or scored, replace the generator rotor assy.
(2) Using vernier calipers, measure the slip ring diame-
ter.
Standard diameter: 15.3 to 15.5 mm (0.602 to 0.610 in.)
Minimum diameter: 14.3 mm (0.561 in.)
If the diameter is less than minimum, replace the generator ro-
B00896 tor assy.

8. INSPECT STATOR SUB–ASSY GENERATOR

Positive (+) Terminal Rectifier Terminal
W/RECTIFIRE
(a) Inspect the positive (+) rectifier.
Ohmmeter (1) Using an ohmmeter, connect one tester probe to the
positive (+) terminal and the other to each rectifier
terminal.
(2) Reverse the polarity of the tester probes and repeat
step (1).
No Continuity
B09842 (3) Check that one shows continuity and the other
shows no continuity.
If result is not as specified, replace the stator sub–assy genera-
tor w/ rectifire.

(b) Inspect the negative (–) rectifier.

Negative (–) Terminal Rectifier Terminal
(1) Using an ohmmeter, connect one tester probe to
each negative (–) terminal and the other to each
Ohmmeter rectifier terminal.
(2) Reverse the polarity of the tester probes and repeat
step (1).
(3) Check that one shows continuity and the other
shows no continuity.
No Continuity If result is not as specified replace the stator sub–assy genera-
B09843

tor w/ rectifire.
(c) Inspect the stator for open circuit.
Rectifier Terminal
Using an ohmmeter, check that there is continuity be-
tween the rectifier terminals.
Ohmmeter If there is no continuity, replace the stator sub–assy generator
w/ rectifire.

Continuity
B09844

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

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STARTING & CHARGING – GENERATOR ASSY

Length 9. INSPECT BRUSH

(a) Using vernier calipers, measure the brush length.
Standard exposed length:
11.0 to 13.6 mm (0.433 to 0.535 in.)
Minimum exposed length: 1.5 mm (0.059 in.)
If the expose length is less than minimum, replace the voltage
regulator and the brush assembly.

B09845

10. INSTALL GENERATOR ROTOR ASSY

(a) Using SST and a press, press in the generator rotor assy.
SST SST 09285–76010
NOTICE:
Avoid misalignment during pressing

B10019

11. INSTALL PULLEY SET GENERATOR

(a) Clamp the rotor in a soft jaw vise.
(b) Install the pulley with the spring washer and nut.
Torque: 65 N
m (663 kgf
cm, 48 ft
lbf)

B10014

12. INSTALL BEARING SET GENERATOR

(a) Insert the fitting ring into in the position shown in the il-
lustration.
(b) Align the key of the fitting ring with the keyway of the stator
sub–assy generator w/ rectifire.
(c) Install the bearing.

B09847

13. INSTALL STATOR SUB–ASSY GENERATOR

W/RECTIFIRE
(a) Align the key of the drive end frame with the keyway of the
stator sub–assy generator w/ rectifire.
(b) Install the stator sub–assy generator w/ rectifire with the
4 bolts.
Torque: 3.5 N
m (36 kgf
cm, 31 in.
lbf)

B09750

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

 19–13
STARTING & CHARGING – GENERATOR ASSY

14. INSTALL REGULATOR SUB–ASSY GENERATOR

W/BRUSH
(a) Attach the brushes and the terminals to the rectifier end
frame of the regulator sub–assy generator w/ brush.

B09848

(b) Install the regulator sub–assy generator w/ brush with the

with Washer
3 screws.
HINT:
Install the screw with the plate washer to the position shown in
the illustration.
Torque:
2.2 N
m (22 kgf
cm, 19 in.
lbf) for without washer
without
1.2 N
m (12 kgf
cm, 11 in.
lbf) for with washer
Washer
B10021

Nut A Screw
15. INSTALL GENERATOR REAR END COVER
(a) Install the generator rear end cover with the 2 nuts and the
screw.
Torque:
19.5 N
m (199 kgf
cm, 14 ft
lbf) for nut A
12 N
m (122 kgf
cm, 9 ft
lbf) for nut B
Nut B
2.4 N
m (24 kgf
cm, 21 in.
lbf) for screw

B09748

(b) Install the 2 terminal covers by turning them clockwise.

A80108

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)