Disassembly

3UZ-FE CHARGING: GENERATOR: DISASSEMBLY

1. REMOVE GENERATOR REAR END COVER





(a) Remove the 3 nuts and end cover.

(b) Remove the terminal insulator.

2. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY





(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.

3. REMOVE GENERATOR PULLEY





(a) Hold SST (A) with a torque wrench and tighten SST (B) clockwise to the specified torque.

SST : 09820-63011

Torque : 39 Nm (400 kgf-cm, 29 ft-lbf)

(b) Check that SST (A) is secured to the rotor shaft.





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

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





(e) To loosen the pulley nut, turn SST (A) in the direction shown in the illustration.

NOTICE:
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).





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

(h) Remove the pulley nut and pulley.

4. REMOVE GENERATOR COIL ASSEMBLY





(a) Remove the 4 bolts.





(b) Using SST, remove the coil.

SST : 09950-40011

09951-04020

09952-04010

09953-04020

09954-04010

09955-04071

09958-04011

(c) Remove the generator washer.

5. REMOVE GENERATOR ROTOR ASSEMBLY

6. INSPECT GENERATOR ROTOR ASSEMBLY





(a) Check the rotor for an open circuit.

(1) Using an ohmmeter, measure the resistance between the slip rings.

Standard resistance:

2.1 to 2.5 Ohms at 20°C (68°F)

(1) If the result is not as specified, replace the generator rotor.





(b) Check if the rotor is grounded.

(1) Using an ohmmeter, measure the resistance between the slip ring and the rotor core.

Standard resistance:

10 kOhms or higher

(1) If the result is not as specified, replace the generator rotor.





(c) Inspect the slip rings.

(1) Check that the slip rings are not rough or scored.

If rough or scored, replace the rotor assembly.

(d) Using a vernier caliper, measure the slip ring diameter.

Standard diameter:

12.8 to 14.4 mm (0.504 to 0.567 in.)

(d) If the diameter is less than the minimum, replace the rotor assembly.

7. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY





(a) Using a vernier caliper, measure the exposed brush length.

Standard exposed length:

1.5 to 11.5 mm (0.059 to 0.453 in.)

(a) If the length is less than the minimum, replace the brush holder assembly.

8. INSPECT BEARING

(a) Check that the bearing is not rough or worn.

If necessary, replace the bearing.