Charging System: Precautions CH-2 Troubleshooting CH-2 On-Vehicle Inspection CH-2 Alternator CH-6
Charging System: Precautions CH-2 Troubleshooting CH-2 On-Vehicle Inspection CH-2 Alternator CH-6
Charging System: Precautions CH-2 Troubleshooting CH-2 On-Vehicle Inspection CH-2 Alternator CH-6
Page
PRECAUTIONS .................................................... CH-2
TROUBLESHOOTING .......................................... CH-2
ON-VEHICLE INSPECTION ..................................... CH-2
ALTERNATOR ...................................................... CH-6
CH-2 CHARGING SYSTEM - Precautions, Troubleshooting,On-Vehicle Inspection
PRECAUTIONS
1. Check that the battery cables are connected t o the cor-
rect terminals.
+
TROUBLESHOOTING
Problem Possible cause Remedy
Discharge warning Drive belt loose or worn Adjust or replace drive belt CH-3
light does not go out Battery cables loose, corroded or worn Repair or replace cables
with engine running
Fuse blown Check "ENGINE" fuse
(battery requlres f re-
quent recharging) Fusible link blown Replace fusible link
IC regulator or alternator faulty Check charging system CH-4
Wiring faulty Repair wiring
I
ON-VEHICLE INSPECTION
1. INSPECT BATTERY SPECIFIC GRAVITY AND
ELECTROLYTE LEVEL
(a) Check the specific gravity of each cell.
Upper Standard specific gravity
'Level
When fully charged at 20°C (68OF): 1.25 -
If n o t w i t h i n specifications, charge the battery.
(b) Check the electrolyte quantity of each cell.
If insufficient, refill w i t h distilled (or purified) water
r
1
I
Nippondenso Borroughs ( b ) Using a belt tension gauge, check the drive belt
tension.
Belt tension gauge:
Nippondenso BTG-20 ( 9 5 5 0 6 - 0 0 0 2 0 ) or
Borroughs No. BT-33-73F
Drive belt tension:
New belt 1 7 5 + 5 Ib
Used belt 1 1 5 + 2 0 Ib
If necessary, adjust the drive belt tension.
HINT:
"New belt" refers t o a belt which has been used less
than 5 minutes on a running engine.
"Used belt" refers t o a belt which has been used on a
running engine for 5 minutes or more.
After installing the drive belt, check that i t fits properly
in the ribbed irooves. Check w i t h your hand t o confirm
that the belt has not slipped out of the groove on the
CORRECT WRONG WRONG
bottom of the crank pulley.
After installing a new belt, run the engine for about 5
minutes and then recheck the tension.
\-H-,
from Terminal I3
Alternator
HINT: If a batterylalternator tester is available, connect
the tester t o the charging circuit according t o the manufac-
turer's instructions.
(a) If a tester is n o t available, connect a voltmeter and
ammeter t o the charging circuit as follows:
Disconnect the wire f r o m terminal B of the alter-
nator and connect the wire t o the negative ( - ) ter-
1 Voltmeter minal of the ammeter.
CH0732 Connect the test lead f r o m the positive ( + )termi-
nal of the ammeter t o terminal B of t h e alternator.
+
Connect the positive ( ) lead of the voltmeter t o
terminal B of the alternator.
Ground the negative ( - ) lead of the voltmeter.
ALTERNATOR
COMPONENTS
Dr~veEnd Frame
Pulley
79 Cover
IC Regulator
I .-a
r m i n a l insulator @
Recitifier End Frame
I
-+ Recitifier Holder
Spring Alternator Washer
F
Brush
(AIT) and 7M-GTE
Front Bearing m
Rubber Insulator
Rear End Cover
Terminal Insulator
!
7 Recitifier Holder
Seal 'plate
) ~rish
Holder
Brush Holder
CH0631
CH0656
CHARGING SYSTEM - Alternator CH-7
REMOVAL OF ALTERNATOR
DISCONNECT CABLE FROM NEGATIVE TERMINAL OF
BATTERY
CAUTION: Work must be started after approx. 20 se-
conds or longer from the time the ignition switch is turned
t o the "LOCK" position and the negative ( - ) terminal ca-
ble is disconnected from the battery.
REMOVE ALTERNATOR
(a) Remove the pivot bolt, n u t and adjusting lock bolt.
(b) Remove the alternator.
DISASSEMBLY OF ALTERNATOR
(See page CH-6)
1. REMOVE REAR END COVER
(a) Remove the n u t and terminal insulator f r o m the posi-
+
t i v e ( ) terminal.
(b) Remove the three nuts and rear end cover.
5. REMOVE PULLEY
(a) Hold SST ( A ) w i t h a torque wrench, and tighten SST
(B) clockwise t o the specified torque.
SST 09820-63010
Torque: 400 kg-cm ( 2 9 ft-lb, 3 9 N - m )
( b ) Check that SST ( A ) is secured t o the rotor shaft.
No continuity CHOISI
Stator
1. INSPECT STATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between
t h e coil leads.
If there is n o continuity, replace the drive end frame as-
sembly.
Continuity CH0245
1
/
No continuity
-
CH0246
CHARGING SYSTEM - Alternator CH-11
Brushes
1. INSPECT EXPOSED BRUSH LENGTH
Using a scale, measure the exposed brush length.
Standard exposed length: 1 0 . 5 mm ( 0 . 4 1 3 in.)
Minimum exposed length: 1 . 5 mm ( 0 . 0 5 9 in.)
[7M-GE ( M I T ) ]
If the exposed length is less than minimum, replace the
brushes.
[7M-GE (AIT) and 7M-GTEI
If the exposed length is less than minimum, replace the
brush holder.
2. [7M-GE ( M I T ) ]
IF NECESSARY, REPLACE BRUSHES
(a) Unsolder and remove the brush and spring.
(b) Run wire of the brush through the hole in the brush
holder, and insert the spring and brush into the brush
holder.
(c) Solder the brush wire t o the brush holder at the ex-
posed length.
Exposed length: 1 0 . 5 mm ( 0 . 4 1 3 in.)
(dl Check that the brush moves smoothly in the brush
holder.
(e) Cut off the excess wire.
(f) Apply insulation paint t o the soldered point.
Rectifier
Terminal
CHM65
Pun"=,
Bearings
1. INSPECT FRONT BEARING
Check t h a t the bearing is n o t rough or w o r n .
(c) Using SST and a press, press a new front bearing into
the drive end frame.
SST 0 9 6 0 8 - 2 0 0 1 2 ( 0 9 6 0 8 - 0 0 0 3 0 )
(dl Install the bearing retainer with the four screws.
ASSEMBLY OF ALTERNATOR
(See page CH-6)
1. INSTALL ROTOR TO DRIVE END FRAME
4. INSTALL PULLEY
(a) Install the pulley t o the rotor shaft b y tightening the
pulley n u t by hand.
(b) Hold SST ( A ) w i t h a torque wrench, and tighten SST
(0) clockwise t o the specified torque.
SST 09820-63010
Torque: 4 0 0 kg-cm ( 2 9 ft-lb,39 N - m )
(c) Check that SST ( A ) is secured t o the pulley shaft.
INSTALLATION OF ALTERNATOR
INSTALL ALTERNATOR
Mount the alternator on the engine bracket with the pivot
bolt, nut and adjusting lock bolt. Do not tighten the bolts.
HINT:
"New belt" refers t o a belt which has been used less
than 5 minutes on a running engine.
"Used belt" refers t o a belt which has been used on a
running engine for 5 minutes or more.
After installing the drive belt, check that i t fits properly
in the ribbed grooves. Check w i t h your hand t o confirm
that the belt has not slipped out of the groove on the
CORRECT WRONG WRONG
bottom of the crack pulley.
After installing a new belt, run the engine for about 5
minutes and then recheck the tension.
(c) Tighten the pivot and adjusting lock bolts.