Page 1
CHARGING SYSTEM
PRECAUTIONS ........................................... CH– 2
CHARGING SYSTEM CIRCUIT .................. CH– 3
IN-VEHICLE INSPECTION ......................... CH– 4
BATTERY ................................................ CH– 4
ALTERNATOR ........................................ CH– 4
ALTERNATOR ............................................. CH– 8
COMPONENTS ...................................... CH– 8
DISASSEMBLY ....................................... CH– 9
INSPECTION .......................................... CH–10
ASSEMBLY ............................................. CH–15
SERVICE SPECIFICATIONS ...................... CH–18
SST .............................................................. CH–18
TIGHTENING TORQUE .............................. CH–18
CH
JCH00001-00000
TO INDEX
Page 2
PRECAUTIONS
1. Prior to the inspection, be sure to turn OFF the ignition switch.
2. Never touch the terminals of the battery which is mounted on the vehicle immediately after the vehicle
has been operated.
3. Since the battery electrolyte harms or damages the skin and clothes, pay utmost attention to handling
of the battery.
4. The following shows how to apply first aid in the event that unexpected incidents happen in connection
with the battery electrolyte.
CH–2
(1) When you swallow the electrolyte:
Immediately rinse your mouth with clean water. Drink raw eggs, milk or a large quantity of water. Lie
down and remain quiet. At the same time, call an ambulance or a doctor to receive medical treatments at a medical agency.
(2) When the electrolyte gets into your eyes:
Flush the electrolyte gets away from your eyes with a large quantity of clean running water for at
least 15 minutes. At the same time, call an ambulance or a doctor to receive medical treatments at a
medical agency.
(3) When the electrolyte splashes on your skin or clothes:
Flush the electrolyte away with a large quantity of clean running water, until there in no more electrolyte there. Then, neutralize the spot with soap water. After this treatment, call a doctor or consult
with a doctor for advice.
(4) When the electrolyte is spilled over the floor:
Flush the electrolyte away with a large quantity of clean running water, until there in no more electrolyte there. Then, neutralize the spot with hydrated lime.
(5) When the electrolyte gets to a vehicle body:
Flush the electrolyte away from the affected section with a large quantity of clean running water, until
there is no more electrolyte there.
JCH00002-00000
JCH00003-00000
Page 3
CHARGING SYSTEM CIRCUIT
CH–3
L
O
A
D
Battery
F/L
2.0
IG switch
Engine
10 A
Gauge
10 A
IG
IG
B
Battery charge
indicator lamp
LL
IC regulator
MIC
E
E
Alternator
F
P
B
RATED OUTPUT: 70 A
JCH00004-00001
JCH00000-00002
RATED OUTPUT: 80 A
L
O
A
D
F/L
2.0
IG switch
Battery
Engine
10 A
Gauge
10 A
Battery charge
indicator lamp
B
IG
LL
IG
MIC
B
P
F
E
IC regulator
E
Alternator
Page 4
IN-VEHICLE INSPECTION
BATTERY
1. If the battery case exhibits cracks, replace the battery with
a satisfactory one.
2. If contamination, foreign matters or corrosion is found at
the battery terminals, clean the battery.
3. Check that the battery terminals are connected with the
cable securely without any looseness.
4. Ensure that the standard cover is mounted at the positive
pole of the battery.
5. Ensure that a thin film of lithium grease has been applied
to the negative pole of the battery.
6. Check to see if the electrolyte level of each cell of the battery has reached the specified level indicated on the battery case. If the level is below the specified level, replenish distilled water to the specified level.
CH–4
Revision 2
7. To check the charging condition of the battery, measure
the specific gravity of each cell of the battery with a hydrometer. In the case of a maintenance-free battery, take a
reading of the indicator provided at the battery. If the battery is inadequately charged, charge the battery in accordance with the instructions of the charger manufacturer.
Specified Value:
When fully-charged: 1.25 - 1.28 (at 20°C)
ALTERNATOR
Check of drive belt
1. Visually check the drive belt for wear or cracks.
2. If there is any evidence which shows that the contact surface with the pulley has lost elasticity or slipping occurred
in the surface, replace the drive belt or check the drive
belt for tension.
3. Check and adjustment of tension of drive belt
(In the case of M101, M201 series)
(1) Check of tension of drive belt
Apply a force of 98 N to the position between the water
pump pulley and the power steering pulley, as shown
in the right figure. Measure the deflection amount.
Specified Values
SST
A
B
YCH00005-00003
YCH00006-00004
YCH00007-00005
YCH00008-00006
New belt
10.5 - 12.5 mm
490 - 690 N
Used belt
14.5 - 16.5 mm
340 - 440 N
Belt deflection amount
Belt tension
V
Terminal B
Page 5
NOTE:
• The tension can be measured by using a belt tension
gauge.
• When installing a new belt, set the values to the median values of the specified values for new belts.
• When installing the belt that has been used on a running engine for more than five minutes, it should be adjusted to the median values of the specified values for
used belts.
(2) Adjustment of tension of drive belt
q Loosen the nut B. Then, loosen the bolt A. Under
this condition, no belt tension is applied to the tensioner.
w Tighten the nut B by hand to such an extent that
the tensioner may be retained without any excessive looseness.
e Tighten the bolt A so that the belt tension may
reach the specified value. Proceed to tighten the
nut B fully to tighten the tensioner securely.
Tightening Torque: 35.2 - 52.8 N·m
NOTE:
• As for the bolt A, be very careful not to over-tighten it
beyond of a tension of 8 N·m.
r Loosen the bolt A to a tightening torque of 3.9 to
4.1 N·m. (For this operation, loosen the bolt A
about 1/2 turn.)
t Check the tension of the drive belt.
(In the case of J102 series)
(1) Check of tension of drive belt
Apply a force of 98 N to the position between the water
pump pulley and the tensioner, as shown in the right
figure. Measure the deflection amount.
Specified Values
NOTE:
• The tension can be measured by using a belt tension
gauge.
• When installing a new belt, set the values to the median values of the specified values for new belts.
• When installing the belt that has been used on a running engine for more than five minutes, it should be adjusted to the median values of the specified values for
used belts.
Revision 2
CH–5
A
B
Tensioner
YCH00009-00000
YCH00010-00008
YCH00011-00009
New belt
9.0 - 11.0 mm
490 - 690 N
Used belt
13.0 - 15.0 mm
340 - 440 N
Belt deflection amount
Belt tension
Water pump pulley
Measuring section
Alternator pulley
Tensioner
A
B
Air conditioner
pulley
Crankshaft pulley
Page 6
(2) Adjustment of tension of drive belt
q Loosen the nut B.
w Adjust the tension by turning the bolt A and mov-
ing the idler pulley.
e Tighten the nut B.
Tightening Torque: 35.2 - 52.8 N·m
r Check the tension of the drive belt.
CH–6
Revision 1
(In the case of S221 series)
(1) Check of tension of drive belt
Apply a force of 98 N to the position between the water
pump pulley and the power steering pump pulley, as
shown in the right figure. Measure the deflection
amount.
Specified Values
NOTE:
• The tension can be measured by using a belt tension
gauge.
• When installing a new belt, set the values to the median values of the specified values for new belts.
• When installing the belt that has been used on a running engine for more than five minutes, it should be adjusted to the median values of the specified values for
used belts.
(2) Adjustment of tension of drive belt
q Loosen the bolt A and the lower side bolt of the al-
ternator.
w Tighten the nut B, using the SST given below. This
will adjust the tension by moving the alternator.
SST: 09286-87701-000
e Tighten the bolt A and the lower side bolt of the al-
ternator.
Tightening Torque:
Upper side bolt: 15.2 - 22.8 N·m (Bolt A)
Lower side bolt: 35.2 - 52.8 N·m
r Check the tension of the drive belt
A
B
Alternator
Crank pulley
Water pump pulley
Idler pulley
Tension
measurement
section
PS pump pulley
sCH00002-00001
sCH00003-00002
sCH00004-00003
Deflection W/PS
L/PS
Tension
New belt
11 - 13 mm
9.5 - 11.5 mm
490 - 690 N
Used belt
15 - 17 mm
13.5 - 15.5 mm
340 - 440 N
SST
A
B
Page 7
Check of battery charge warning circuit
Set the ignition switch to the ON position. Visually check to
see if the charge warning lamp goes on.
Then, start the engine. At this time, visually check to see if
the charge warning lamp goes out.
NOTE:
• The battery charge warning light is provided in the
combination meter.
Check of alternator
Ensure that the connector section of the wiring of the alternator is securely connected.
Check to see if abnormal noise is emitted from the alternator while the engine is operating.
Check of charging circuit under unloaded state
Connect the terminal B of the alternator with the negative
(–) terminal of the battery by means of a voltmeter.
Turn OFF all switches of the headlamps and other devices
which will become electric loads.
Start the engine and warm it up.
Raise the engine revolution speed to 2500 rpm. At this
time, measure the voltage.
Specified Value: 14.2 - 14.8 V
NOTE:
• If the measured value exceeds the specified value, replace the IC regulator.
Revision 1
CH–6-1
sCH00005-00004
sCH00006-00005
sCH00007-00006
sCH00008-00000
V
Terminal B
Page 8
If the measured voltage is less than the specified value,
ground the terminal F of the alternator to the alternator
proper, as shown in the right figure. Raise the engine revolution speed to 2500 rpm. At this time, measure the voltage.
NOTE:
• If the measured value exceeds the specified value, replace the IC regulator.
• If the measured value is less than the specified value,
disassemble the alternator.
Check of charging circuit under loaded state
1. Disconnect the cable from the terminal B of the alternator
and the battery.
2. Connect the terminal B of the alternator with the positive
terminal (+) of the battery by means of an ammeter.
3. Turn ON the headlamp switch with the high beam position
selected.
4. Turn ON the switch of the heater blower with the Hi position selected.
5. Start the engine and warm it up.
6. Raise the engine revolution speed to 2500 rpm. At this
time, measure the current.
Specified Value: More than 30 A
NOTE:
• If the measured value less than the specified value, re-
place the alternator. However, there may be cases
where the reading of the ammeter will not reach 30 A
when the battery is fully charged.
CH–7
JCH00017-00014
JCH00018-00015
JCH00019-00000
A
Terminal B
12V
Page 9
ALTERNATOR
COMPONENTS
CH–8
q
w
y
!0
!1
!2
u
e
!4
r
t
!3
i
o
!5
!7
!6
!8
@0
@1
@2
!9
15.2 - 22.8
35.2 - 52.8
94.0 - 127.0
B
JCH00020-00016
q Generator cap
w Alternator assembly
e Pulley lock nut
r Alternator pulley
t Spacer collar
y Drive end frame assembly
u Stud bolt
i Front bearing
o Retainer plate
!0 Alternator rotor assembly
!1 Rear bearing
!2 Bearing cover
!3 Wave washer
!4 Rectifier end frame
!5 Nut
!6 Insulator terminal
!7 Rectifier holder
!8 Generator regulator assembly (IC regulator)
!9 Brush
@0 Brush spring
@1 Brush holder
@2 Rear end cover
: Tightening torque
Unit : N·m
Page 10
CH–9
DISASSEMBLY
1. Remove the alternator pulley lock nut by means of an impact wrench, while holding the shaft by using a hexagonal
box wrench.
NOTE:
• Be sure to use an impact wrench having a hexagonal
hole.
2. Remove the alternator pulley and spacer collar.
3. Remove the attaching nut of the insulator terminal.
4. Pull out the insulator terminal.
5. Remove the three rear end cover attaching nuts.
6. Remove the rear end cover.
7. Remove the brush holder by removing the two attaching
screws.
8. Remove the IC regulator by removing the three attaching
screws.
9. Remove the rectifier holder by removing the four attaching
screws and one attaching bolt.
10. Remove the rectifier end frame by removing the four attaching nuts.
JCH00026-00021
JCH00027-00022
JCH00028-00023
JCH00029-00024
JCH00030-00025
Rear end
cover
Nut
Insulator
terminal
Nut
Bolt wit washer
Screw
Page 11
11. Remove the wave washer from the alternator rotor assembly.
12. Remove the alternator rotor assembly from the drive end
frame assembly.
NOTE:
• If any difficulty is encountered in removing the alterna-
tor rotor assembly, lightly tap the rotor shaft with a plastic hammer or the like.
INSPECTION
Rotor
1. Inspection of rotor for open circuit
Using an ohmmeter, check to see if the specified resistance exists between the rotor slip rings.
Standard Resistance: 2.9 ± 0.2 Ω
If the resistance does not conform to the specification, replace the rotor.
2. Inspection of rotor for ground
Ensure that no continuity exists between the rotor slip
rings and the rotor core.
If continuity exists, replace the rotor.
3. Inspection of slip rings
(1) Check to see if the slip ring surface exhibits rough-
ness, abnormal wear and/or burning.
Replace the rotor, if necessary.
NOTE:
• When correcting the smear and roughness of the slip
ring, polish the slip ring, using fine sand paper (#300 -
500). In this case, the slip ring can be used, until the
outer diameter of the slip ring is reduced 0.4 mm from
that of a new one.
JCH00031-00026
JCH00032-00027
JCH00033-00028
JCH00034-00029
JCH00035-00030
CH–10
Page 12
CH–11
(2) Measure the outer diameter of the slip ring, using
vernier calipers.
Standard Diameter: 14.4 mm
Minimum Diameter: 14.0 mm
If the slip ring diameter is less than the minimum diameter, replace the rotor assembly.
Stator
1. Inspection of stator for open circuit
Using an ohmmeter, check to see if any open circuit of the
stator coil is present between the leads.
If no continuity exists, replace the end frame assembly.
Specified Resistance: About 0.2 Ω
NOTE:
• If no continuity exists, there is no possibility that the
stator coil itself exhibits open wire. Therefore, check
the connecting section of the lead wire.
2. Inspection of stator for short circuit
Using an ohmmeter, check to see if any short circuit of the
stator coil is present between the coil lead and the drive
end frame.
If continuity exists, replace the drive end frame assembly.
Specified Resistance: More than 1 kΩ
Brush and brush holder
1. Measurement of exposed brush length
Measure the exposed brush length, using a scale.
Standard Exposed Length: 10.5 mm
Minimum Exposed Length: 8.4 mm
If the exposed length is less than the minimum requirement, replace the brushes.
2. Replacement of brushes
(1) Remove the brush and spring from the brush holder by
melting the solder by means of a soldering iron.
JCH00036-00031
JCH00037-00032
JCH00038-00033
JCH00039-00034
JCH00040-00035
Page 13
(2) Install the brush cord in the brush holder with the
spring fitted in place.
(3) Solder the brush cord in the brush holder in such a
way that the exposed length of the brush meets the
specification.
Standard Exposed Length: 10.5 mm
(4) Ensure that the brush moves freely in the brush holder.
(5) Cut off any excess wire and apply insulation paint.
Rectifier
NOTE:
• Be sure to confirm the specification of the ohmmeter to
be used for inspection before putting it into use.
• The current flow direction differs according to the design of an ohmmeter.
<Reference>
• The measured resistance should be about the same as
those of other rectifiers, for the measurement results
differ according to the input voltage of each tester.
• If the measured resistance of the rectifier differs more
than 20 percent, replace the rectifier holder.
JCH00041-00036
JCH00042-00037
JCH00043-00038
JCH00044-00039
JCH00045-00000
CH–12
Page 14
CH–13
1. Inspection of rectifier at positive side
(1) While using an ohmmeter, connect one tester probe to
the positive terminal. Also, connect the other probe to
each of the rectifier terminals.
(2) Repeat the same steps described in (1) above with the
polarity of the tester probes reversed this time.
(3) Ensure that continuity exists either in the step (1) or in
the step (2) and no continuity exists at the other test.
If not, replace the rectifier holder.
2. Inspection of rectifier at negative side
(1) While using an ohmmeter, connect one tester probe to
each negative terminal. Also, connect the other probe
to each rectifier terminal.
(2) Repeat the same steps described in (1) above with the
polarity of the tester probes reversed this time.
(3) Ensure that continuity exists either in the step (1) or in
the step (2) and no continuity exists at the other test.
If not, replace the rectifier holder.
Bearing
1. Inspection of front bearing
Ensure that the front bearing turns smoothly.
Replace the front bearing, if necessary.
Negative
Positive
Positive terminal
Rectifier terminal
JCH00046-00040
JCH00047-00041
JCH00048-00042
JCH00049-00043
JCH00050-00044
Positive
Negative
Negative terminal
Positive
Negative
Rectifier terminal
Negative
Positive
Page 15
2. Replacement of front bearing
(1) Remove the four screws and retainer plate.
(2) Remove the front bearing from the drive end frame,
using a suitable socket wrench in conjunction with a
press.
CAUTION:
• Be very careful not to damage the coil and stud bolts
during the front bearing removal.
(3) Press a new front bearing into the drive end frame,
using a suitable socket wrench in conjunction with a
press.
CAUTION:
• Be sure to hold the outer race of the new front bearing
during the installation. Holding of the inner race or side
cover will cause the front bearing to be damaged.
(4) Attach the retainer plate to the drive end frame with the
four screws.
3. Inspection of rear bearing
Ensure that the rear bearing turns smoothly.
Replace the rear bearing, if necessary.
JCH00051-00045
JCH00052-00046
JCH00053-00047
JCH00054-00048
JCH00055-00049
CH–14
Page 16
CH–15
4. Replacement of rear bearing
(1) Remove the rear bearing cover from the rotor, using an
armature bearing puller.
CAUTION:
• Be very careful not to damage the fan during the re-
moval.
SST: 09820-00021-000
(2) Place the parts on the rotor in the following order.
Spacer
New rear bearing
New bearing cover
(3) Press the assembled parts into the rotor, using a hy-
draulic press in combination with a suitable attachment.
NOTE:
• Care must be exercised so that the point where the
rear bearing is assembled to the rotor shaft may not
deform an bearing cover.
Therefore, be sure to select a suitable attachment to
assemble the bearing cover.
5. Inspection/replacement of stud bolt
Visually inspect the thread portion of the stud bolt.
If any damage exists, replace the stud bolt.
ASSEMBLY
1. Install the rotor in the drive end frame assembly.
JCH00056-00050
JCH00057-00051
JCH00058-00052
JCH00059-00053
JCH00060-00054
Page 17
2. Installation of rectifier end frame on drive end frame
(1) Place the wave washer on the rear bearing.
(2) Install the rectifier end frame on the drive end frame
with the four attaching nuts.
CAUTION:
• Be very careful not to damage the coil cord during the
installation.
3. Installation of rectifier holder, IC regulator and brush holder
(1) Attach the rectifier holder to the rectifier end frame with
the coil wires passed through the aperture of the rectifier holder.
(2) Secure the rectifier holder to the rectifier end frame by
installing the attaching bolt with washer.
(3) Connect the coil wires to the rectifier holder with the at-
taching screws.
(4) Install the rectifier holder and IC regulator with the at-
taching screws.
NOTE:
• Make sure that the IC regulator has been installed
properly with the attaching screws.
(5) Install the brush holder in such a way that a gap of at
least 1 mm is provided between the brush holder and
the IC regulator.
Secure the brush holder with the two screws.
JCH00061-00055
JCH00000-00056
JCH00062-00057
JCH00064-00059
JCH00065-00060
CH–16
Bolt wit washer
Screw
Page 18
CH–17
4. Installation of rear end cover.
(1) Install the rear end cover on the alternator.
(2) Secure the rear end cover with the three attaching
nuts.
(3) Install the insulator terminal.
(4) Secure the insulator terminal attaching nut.
5. Attach the alternator pulley and spacer collar to the rotor
shaft.
6. Tighten the pulley lock nut to the specified tightening
torque.
Tightening Torque: 94.0 - 127.0 N·m
7. Ensure that the rotor turns smoothly.
Nut
Rear end
cover
Nut
Insulator
terminal
JCH00066-00061
JCH00067-00062
JCH00068-00063
JCH00069-00064
Page 19
CH–18
Revision 1
SERVICE SPECIFICATIONS
SST
TIGHTENING TORQUE
Battery
J102, J122
(Except tropical, general and A/T specifications)
70 A
J102, J122
(Tropical, general and A/T specifications)
80 A
M101 (Except Europe hot area specifications), M111
M101 (Europe hot area specifications)
Alternator:
Specific gravity Standard
Amperage
Resistance
Standard
Minimum
Standard
Minimum
Adjusting voltage
Rated output
Rotor coil resistance
Slip ring diameter
Brush exposed length
IC regulating voltage
2.9 Ω at 20°C (68°F)
14.4 mm
14.0 mm
10.5 mm
8.4 mm
14.2 - 14.8 volts
1.25 - 1.28
Shape Part No. Part name
09820-00021-000 Alternator bearing puller
09286-87701-000 Alternator adjusting bar
Tightening components
Tightening torque
N·m
15.2 - 22.8
35.2 - 52.8
kgf-m
1.6 - 2.3
3.6 - 5.4
Alternator attaching bolt
Bolt (upper side)
Flange bolt (lower side)
94.0 - 127.0 9.6 - 13.0
Pulley lock nut
JCH00070-00000
sCH00010-00007
sCH00011-00000
TO INDEX TO NEXT SECTION
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