1NZ-FE CHARGING – CHARGING SYSTEM CH–3

SYSTEM DIAGRAM

Ignition Switch

AM1 IG1

AM2 IG2

AM1 AM2 GAUGE

To
Combination ECM
Meter
ALT MAIN (Charge
Warning
Light)

To
A/C
Amplifier

CH

B L IG M
Stator Coil L IG M

Voltage Regulator

Rotor Coil
F
E

Generator Assembly

A117217E01
 CH–4 1NZ-FE CHARGING – CHARGING SYSTEM

ON-VEHICLE INSPECTION
1. CHECK BATTERY CONDITION
NOTICE:
If the battery is weak or if the engine is difficult to
start, perform the following procedures.
(a) Check the battery for damage and deformation. If
severe damage, deformation or leakage is found,
replace the battery.
(b) Check the electrolyte quantity of each cell.
(1) For maintenance-free batteries:
• If the electrolyte quantity is below the lower
line, replace the battery.
• If the electrolyte quantity is above the lower
line, check the battery voltage when
cranking the engine. If the voltage is less
than 9.6 V, recharge or replace the battery.
HINT:
) A116909 Before checking the battery voltage, turn off all
the electrical systems (headlights, blower
motor, rear defogger, etc.).
(2) For non-maintenance-free batteries:
• If the electrolyte quantity is below the lower
line, add distilled water to each cell. Then,
recharge the battery and check the
electrolyte's specific gravity.
Standard specific gravity:
1.25 to 1.29 at 20°C (68°F)
CH • If the electrolyte quantity is above the lower
line, check the battery voltage when
) A116907 cranking the engine. If the voltage is less
than 9.6 V, recharge or replace the battery.
HINT:
Before checking the battery voltage, turn off all
the electrical systems (headlights, blower
motor, rear defogger, etc.).
2. CHECK BATTERY TERMINALS AND FUSES
(a) Check that the battery terminals are not loose or
corroded.
If the terminals are corroded, clean the terminals.
(b) Measure the resistance of the fusible links, H-fuse
and fuses.
Standard resistance:
Below 1 Ω
If the results are not as specified, replace the fuses
as necessary.
 1NZ-FE CHARGING – CHARGING SYSTEM CH–5

3. CHECK V-RIBBED BELT

INCORRECT (a) Check the belt for wear, cracks and other signs of
damage.
If any defect is found, replace the drive belt.
HINT:
Replace the drive belt, if the following defects are
found:
• The belt is worn out and wire is exposed.
• The cracks reach the wire in more than one
A111818E01 place.
• The belt has chunks missing from the ribs.
(b) Check that the belt fits properly in the ribbed
grooves.
HINT:
With your hand, confirm that the belt has not slipped
out of the grooves on the bottom of the pulley.
4. VISUALLY CHECK GENERATOR WIRING
(a) Check that the wiring is in good condition.
CORRECT INCORRECT
5. LISTEN FOR ABNORMAL NOISE FROM
A111819E01 GENERATOR
(a) Check that the generator does not emit any
abnormal noise while the engine is running.
6. CHECK CHARGE WARNING LIGHT CIRCUIT
(a) Turn the ignition switch ON. Check that the charge
warning light turns on.
(b) Start the engine and check that the light turns off.
If the light does not operate as specified,
troubleshoot the charge warning light circuit. CH
 CH–6 1NZ-FE CHARGING – CHARGING SYSTEM

7. CHECK CHARGING CIRCUIT WITHOUT LOAD

Disconnected (a) Connect a voltmeter and ammeter to the charging
Wire from circuit as follows.
Terminal B HINT:
If a battery/generator tester is available, connect the
A tester to the charging circuit according to the
manufacturer's instructions.
 (1) Disconnect the wire from terminal B of the
generator and connect it to the negative (-) lead
of the ammeter.
(2) Connect the ammeter's positive (+) lead to
terminal B of the generator.
(3) Connect the voltmeter's positive (+) lead to
positive (+) terminal B of the battery.
(4) Ground the voltmeter's negative (-) lead.
(b) Check the charging circuit.
(1) Keep the engine speed at 2,000 rpm. Check
the reading on the ammeter and voltmeter.
Standard amperage:
10 A or less
V Standard voltage:
12.9 to 14.9 V
 HINT:
• If the voltmeter reading is more than the
standard voltage, replace the voltage
regulator.
A110265E07
• If the voltmeter reading is less than the
standard voltage, check the voltage
regulator and generator.
CH 8. CHECK CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn on the
high beam headlights and turn the heater blower
switch to the HI position.
(b) Check the reading on the ammeter.
Standard amperage:
30 A or more
HINT:
• If the ammeter reading is less than the standard
amperage, repair the generator.
• If the battery is fully charged, the indication will
sometimes be less than the standard amperage.
 1NZ-FE CHARGING – GENERATOR CH–9

REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
2. REMOVE GENERATOR ASSEMBLY
Terminal Cap (a) Remove the terminal cap.
(b) Remove the nut and generator wire.
(c) Disconnect the generator connector.
(d) Remove the wire harness clamp.

Connector

A082713E02

(e) Loosen bolts A and B.

(f) Release the fan and generator V-belt tension, and
remove the fan and generator V-belt.

CH
A077852E02

(g) Remove bolt A, the nut and the adjusting bar.

A082714E01

(h) Remove bolt B and the generator.

B A077854E01
 CH–10 1NZ-FE CHARGING – GENERATOR

SST (A)
DISASSEMBLY
1. REMOVE GENERATOR PULLEY
(a) Hold SST (A) with a torque wrench, and tighten SST
(B) clockwise to the specified torque.
SST 09820-63010 (09820-06010, 09820-06020)
Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
NOTICE:
SST (B) Check that SST is secured to the rotor shaft.
B000765E02

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

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

SST (B)
Insert
SST (C)

B016524E01

(d) To loosen the pulley nut, turn SST (A) in the

direction shown in the illustration.
NOTICE:
SST (C)
To prevent damage to the rotor shaft, do not
loosen the pulley nut more than one-half of a
SST (A)
turn.
(e) Remove the generator from SST (C).
CH
B016373E01

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

SST (A) (g) Remove the pulley nut and pulley.

SST (B)

B000766E02

2. REMOVE REAR END COVER

(a) Remove the nut and terminal insulator.
(b) Remove the bolt, 3 nuts, plate terminal and end
cover.

A082696
 1NZ-FE CHARGING – GENERATOR CH–11

3. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY

(a) Remove the brush holder cover from the brush
holder.
(b) Remove the 2 screws and brush holder.
4. REMOVE GENERATOR REGULATOR ASSEMBLY
(a) Remove the 3 screws and generator regulator.

A082697

5. REMOVE GENERATOR HOLDER WITH RECTIFIER

(a) Remove the 4 screws and holder with rectifier.

A082698

6. REMOVE GENERATOR RECTIFIER END FRAME

(a) Remove the 4 rubber insulators.
(b) Remove the seal plate.
(c) Remove the 4 nuts and cord clip.

CH
A082699

(d) Using SST, remove the rectifier end frame.

SST 09286-46011
SST
7. REMOVE GENERATOR ROTOR ASSEMBLY
(a) Remove the generator washer from the rotor.
(b) Remove the rotor from the drive end frame.
NOTICE:
Do not drop the rotor.

A082700E02

INSPECTION
1. INSPECT GENERATOR REGULATOR ASSEMBLY
(a) Measure the resistance between the regulator
terminals (F) and (B).
Standard resistance:
F
Below 1 Ω or more than 10 kΩ
B HINT:
When the ohmmeter's leads are initially touched to
A059143E02
the regulator, one of the above values will be output.
When the leads are reversed, the reading will
change to the other reading.
 CH–12 1NZ-FE CHARGING – GENERATOR

If the result is not as specified, replace the

generator regulator.
(b) Measure the resistance between the regulator
terminals (F) and (E).
Standard resistance:
Below 1 Ω or more than 10 kΩ
HINT:
When the ohmmeter's leads are initially touched to
the regulator, one of the above values will be output.
E F
When the leads are reversed, the reading will
change to the other reading.
A059144E02 If the result is not as specified, replace the
generator regulator.
2. INSPECT GENERATOR ROTOR ASSEMBLY
(a) Check the rotor for an open circuit.
(1) Measure the resistance between the slip rings.
Standard resistance:
2.1 to 2.5 Ωat 20°C (68°F)
If the result is not as specified, replace the rotor
assembly.

CH00784

(b) Check if the rotor is grounded.

(1) Measure the resistance between the slip ring
and rotor.
Standard resistance:
CH 10 kΩ or higher
If the result is not as specified, replace the rotor
assembly.
(c) Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor assembly.
B002105

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

diameter.
Standard diameter:
14.2 to 14.4 mm (0.559 to 0.567 in.)
Minimum diameter:
12.8 mm (0.504 in.)
If the diameter is less than the minimum, replace the
rotor assembly.

A038110
 1NZ-FE CHARGING – GENERATOR CH–13

3. INSPECT GENERATOR HOLDER WITH RECTIFIER

(a) Inspect the positive (+) rectifier.
Positive (+) (1) Using an ohmmeter, connect one tester probe
Terminal to the positive (+) terminal and the other to
each rectifier terminal.
(2) Reverse the polarity of the tester probes and
repeat the step above.
(3) Check that one shows a resistance of below 1
Rectifier Terminal Ω and the other shows a resistance of 10 kΩ or
A082701E02 higher.
If the result is not as specified, replace the
rectifier holder.
(b) Inspect the negative (-) rectifier.
(1) Using an ohmmeter, connect one tester probe
Negative (-) Terminal to each negative (-) terminal and the other to
each rectifier terminal.
(2) Reverse the polarity of the tester probes and
repeat the step above.
(3) Check that one shows a resistance of below 1
Ω and the other shows a resistance of 10 kΩ or
higher.
A082702E02 If the result is not as specified, replace the
rectifier holder.
4. INSPECT DRIVE END FRAME
(a) Check the stator coil for an open circuit.
(1) Measure the resistance between the coil leads.
Standard resistance:
Below 1 Ω
If the result is not as specified, replace the drive CH
end frame.

A082703

(b) Check the stator for ground.

(1) Measure the resistance between the coil lead
and drive end frame.
Standard resistance:
10 kΩ or higher
If the result is not as specified, replace the drive
end frame.
(c) Check that the bearing is not rough or worn.
If necessary, replace the generator assembly.
A082704
 CH–14 1NZ-FE CHARGING – GENERATOR

5. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY

(a) Using a vernier caliper, measure the exposed brush
length.
Standard exposed length:
Length
9.5 to 11.5 mm (0.374 to 0.453 in.)
Minimum exposed length:
4.5 mm (0.177 in.)
If the exposed length is less than the minimum,
replace the brush holder assembly.
P013535E03

CH
 1NZ-FE CHARGING – GENERATOR CH–15

REASSEMBLY
1. INSTALL GENERATOR ROTOR ASSEMBLY
(a) Install the generator rotor.
(b) Install the generator washer onto the rotor.
2. INSTALL GENERATOR RECTIFIER END FRAME
A B
19 mm (a) Using a 19 mm socket wrench and press, slowly
Socket press in the rectifier end frame.
Wrench (b) Install the 4 nuts and cord clip.
Torque: 4.5 N*m (46 kgf*cm, 40 in.*lbf) for nut A
5.4 N*m (55 kgf*cm, 48 in.*lbf) for nut B
(c) Install the seal plate onto the rectifier end frame.

A A
A082705E01

(d) Install the 4 rubber insulators onto the lead wires.

Inside NOTICE:
Be careful that the rubber insulators are in the
right direction.
3. INSTALL GENERATOR HOLDER WITH RECTIFIER
(a) Install the rectifier holder while pushing it with the 4
screws.
Torque: 2.9 N*m (30 kgf*cm, 26 in.*lbf)
A082706E02 4. INSTALL GENERATOR REGULATOR ASSEMBLY
(a) Install the 3 screws and generator regulator.
Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf)
5. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
(a) Install the brush holder with the 2 screws. CH
Upward Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf)
NOTICE:
Be careful that the holder is in the right direction
when installing.
(b) Install the brush holder cover.
6. INSTALL REAR END COVER
(a) Install the end cover and plate terminal with the bolt
A082712E02
and 3 nuts.
Torque: 3.9 N*m (40 kgf*cm, 34 in.*lbf) for bolt
4.4 N*m (45 kgf*cm, 39 in.*lbf) for nut
(b) Install the terminal insulator with the nut.
Torque: 4.1 N*m (42 kgf*cm, 36 in.*lbf)
7. INSTALL GENERATOR PULLEY
SST (A) (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) clockwise to the specified torque.
SST 09820-63010 (09820-06010, 09820-06020)
Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
(c) Check that SST (A) is secured to the pulley shaft.
SST (B)
B000765E02
 CH–16 1NZ-FE CHARGING – GENERATOR

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

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

SST (B)
Insert
SST (C)

B016524E01

(f) To torque the pulley nut, turn SST (A) in the

direction shown in the illustration.
SST (C) Torque: 133 N*m (1,356 kgf*cm, 98 ft.*lbf)
(g) Remove the generator from SST (C).
SST (A)

B016523E01

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

SST (A)

CH SST (B)

B000766E02

INSTALLATION
1. INSTALL GENERATOR ASSEMBLY
(a) Temporarily install the generator with bolt B.

B A077854E01

(b) Temporarily install the adjusting bar with bolt A, and

tighten the nut to the specified torque.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)

A082714E01
 1NZ-FE CHARGING – GENERATOR CH–17

(c) Temporarily install the fan and generator V-belt onto

each pulley.
INCORRECT (d) Insert the adjusting bar between the engine
mounting bracket and generator. Push the adjusting
bar towards the vehicle front to adjust the V-belt
CORRECT A tension.
NOTICE:
Do not insert the adjusting bar between the oil
control valve and generator because it could
B A082715E02 damage the oil control valve.
(e) First tighten bolt A, and then tighten bolt B.
Torque: 18.5 N*m (189 kgf*cm, 14 ft.*lbf) for bolt
A
54 N*m (551 kgf*cm, 40 ft.*lbf) for bolt B
(f) Install the wire harness clamp.
(g) Connect the generator connector.
(h) Install the generator wire with the nut.
Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf)
(i) Install the terminal cap.
2. INSPECT GENERATOR V BELT (See page EM-7)
3. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
4. PERFORM INITIALIZATION
(a) Perform initialization (see page ).
NOTICE:
Certain systems need to be initialized after
disconnecting and reconnecting the cable from
the negative (-) battery terminal.
CH
1NZ-FE CHARGING – CHARGING SYSTEM CH–1

CHARGING SYSTEM
PRECAUTION
1. Check that the battery cables are connected to the
correct terminals.
2. Disconnect the battery cables when the battery is
quickly charged.
3. Do not perform tests with a high voltage insulation
resistance tester.
4. Never disconnect the battery cable while the engine
is running.
5. Check that the charging cable nut is tightened on
terminal B of the generator and the fuse box.
6. If the generator is installed to the vehicle, do not
perform checks on terminal F.

CH
 CH–2 1NZ-FE CHARGING – CHARGING SYSTEM

PARTS LOCATION

GENERATOR

FUSIBLE LINK BLOCK

- MAIN H-FUSE
- ALT H-FUSE
ENGINE ROOM JUNCTION BLOCK
- AM2 FUSE

CH COMBINATION METER
- CHARGE WARNING LIGHT A/C Amplifier

ECM

INSTRUMENT PANEL JUNCTION BLOCK

- AM1 H-FUSE
- GAUGE FUSE

A117218E01
 1NZ-FE CHARGING – GENERATOR CH–7

GENERATOR
1NZ-FE CHARGING
ENGINE

COMPONENTS

GENERATOR V BELT

11 (112, 8)

18.5 (189, 14)

ADJUSTING BAR

9.8 (100, 7)

GENERATOR ASSEMBLY

54 (551, 40)

CH
GENERATOR WIRE

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

A117139E01
 CH–8 1NZ-FE CHARGING – GENERATOR

GENERATOR WASHER

GENERATOR ROTOR ASSEMBLY

DRIVE END FRAME

133 (1,356, 98)

GENERATOR PULLEY

GENERATOR BRUSH HOLDER ASSEMBLY

2.0 (20, 18 in.*lbf) 4.4 (45, 39 in.*lbf)

FRONT SEAL PLATE

CH TERMINAL INSULATOR
4.1 (42, 36 in.*lbf)

5.4 (55, 48 in.*lbf)

BRUSH
CORD CLIP HOLDER
COVER PLATE TERMINAL

3.9 (40, 34 in.*lbf)

2.0 (20, 18 in.*lbf) REAR END COVER

GENERATOR REGULATOR ASSEMBLY

GENERATOR HOLDER WITH RECTIFIER

2.9 (30, 26 in.*lbf)

4.5 (46, 40 in.*lbf) RUBBER INSULATOR

GENERATOR RECTIFIER END FRAME

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

A117210E01