CH-1

CHARGING - CHARGING SYSTEM

CHARGING SYSTEM CH03U-03

ON-VEHICLE INSPECTION
CAUTION:

Check that the battery cables are connected to the
correct terminals.

Disconnect the battery cables when the battery is giv-
en a quick charge.

Do not perform tests with a high voltage insulation re-
sistance tester.

Never disconnect the battery while the engine is run-
ning.
1. CHECK BATTERY ELECTROLYTE LEVEL
Check the electrolyte quantity of each cell.
Maintenance-Free Battery:
If under the lower level, replace the battery (or add distilled wa-
ter if possible). Check the charging system.
Except Maintenance-Free Battery:
If under the lower level, add distilled water.

Except Maintenance-Free Battery 2. Except Maintenance-Free Battery:

CHECK BATTERY SPECIFIC GRAVITY
Check the specific gravity of each cell.
Standard specific gravity: 1.25 - 1.29 at 20°C (68°F)
If the specific gravity is less than specification, charge the bat-
tery.

Z11577

Maintenance-Free Battery Voltmeter 3. Maintenance-Free Battery:

CHECK BATTERY VOLTAGE
(a) After having driven the vehicle and in the case that 20
minutes have not passed after having stopped the en-
gine, turn the ignition switch ON and turn on the electrical
system (headlight, blower motor, rear defogger etc.) for
60 seconds to remove the surface charge.
(b) Turn the ignition switch OFF and turn off the electrical sys-
Z11556 tems.
(c) Measure the battery voltage between the negative (-)
and positive (+) terminals of the battery.
Standard voltage: 12.5 - 12.9 V at 20°C (68°F)
If the voltage is less than specification, charge the battery.

2001 AVALON (RM808U)

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: Date
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CH-2
CHARGING - CHARGING SYSTEM

Maintenance-Free Battery HINT:

Type A Check the indicator as shown in illustration.
4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND
FUSES
CLEAR EYE or
GREE NEYE DARK EYE LIGHT YELLOW (a) Check that the battery terminals are not loose or cor-
roded.
CHARGED DISCHARGED ADD WATER (b) Check the fusible link and fuses for continuity.

Type B
Blue White Red

OK Charging Insufficient
Necessary Water
Z18811

5. INSPECT DRIVE BELT

(a) Visually check the belt for excessive wear, frayed cords
etc.
If any defect has been found, replace the drive belt.
HINT:
Cracks on the rib side of a belt are considered acceptable. If the
belt has chunks missing from the ribs, it should be replaced.

P13121

DENSO Borroughs (b) Using a belt tension gauge, measure the drive belt ten-
sion.
Belt tension gauge:
DENSO BTG-20 (95506-00020)
Borroughs No. BT-33-73F
Drive belt tension:
New belt 175 ± 5 lbf
Used belt 115 ± 20 lbf
Z00038
If the belt tension is not as specified, adjust it.

HINT:

”New belt” refers to a belt which has been used less than
5 minutes on a running engine.

”Used belt” refers to a belt which has been used on a run-
ning engine for 5 minutes or more.

After installing a belt, check that it fits properly in the
CORRECT WRONG ribbed grooves.

Check with your hand to confirm that the belt has not
P13120 slipped out of the groove on the bottom of the pulley.

2001 AVALON (RM808U)

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: Date
: 1275

 CH-3
CHARGING - CHARGING SYSTEM

After installing a new belt, run the engine for about 5 min-
utes and recheck the belt tension.

6. VISUALLY CHECK GENERATOR WIRING AND

LISTEN FOR ABNORMAL NOISES
(a) Check that the wiring is in good condition.
(b) Check that there is no abnormal noise from the generator
while the engine is running.
7. CHECK DISCHARGE WARNING LIGHT CIRCUIT
(a) Warm up the engine and then turn it off.
(b) Turn off all accessories.
P19934 (c) Turn the ignition switch ”ON”. Check that the discharge
warning light is lit.
(d) Start the engine. Check that the light goes off.
If the light does not go off as specified, troubleshoot the dis-
charge light circuit.

Ammeter 8. INSPECT CHARGING CIRCUIT WITHOUT LOAD

Disconnect Wire HINT:
from Terminal B If a battery/generator tester is available, connect the tester to
the charging circuit as per the manufacturer’s instructions.
Battery Voltmeter (a) If a tester is not available, connect a voltmeter and amme-
ter to the charging circuit as follows:

Disconnect the wire from terminal B of the genera-
Generator
tor, and connect it to the negative (-) probe of the
Z03473 ammeter.

Connect the positive (+) probe of the ammeter to
terminal B of the generator.

Connect the positive (+) probe of the voltmeter to
terminal B of the generator.

Ground the negative (-) probe of the voltmeter.
(b) Check the charging circuit as follows:
With the engine running from idling to 2,000 rpm, check
the reading on the ammeter and voltmeter.
Standard amperage: 10 A or less
Standard voltage: 13.2 -14.8 V

2001 AVALON (RM808U)

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: Date
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CH-4
CHARGING - CHARGING SYSTEM

If the voltmeter reading is more than standard voltage, replace

the voltage regulator.

Terminal F If the voltmeter reading is less than standard voltage, check the
voltage regulator and generator as follows:

With terminal F grounded, start the engine and
check the voltmeter reading of terminal B.

If the voltmeter reading is more than standard volt-
age, replace the voltage regulator.

If the voltmeter reading is less than standard volt-
age, check the generator.
P20106 9. INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn on the high
beam headlights and place the heater blower switch at
”HI”.
(b) Check the reading on the ammeter.
Standard amperage: 30 A or more
If the ammeter reading is less than the standard amperage, re-
pair the generator.
HINT:
If the battery is fully charged, the indication will sometimes be
less than standard amperage.

2001 AVALON (RM808U)

Author
: Date
: 1277

 CH-5
CHARGING - GENERATOR

GENERATOR
CH03V-02

COMPONENTS

Generator Wire
Plate Washer

Pivot Bolt Generator Connector

Wire Clamp

Adjusting Bolt Wire Clamp

Generator

Drive Belt
Adjusting Lock Bolt

B09070

Retainer Bearing Cover

Front Bearing Thrust Washer
Drive End Flame (Stator)
Bearing Cover
Pulley
Rear Bearing
Plate Terminal

Rotor
Terminal Insulator

Seal Plate

Cord Clip

Rear End Cover

Rectifire End Flame
Brush Holder Cover
x4 Brush Holder
x4 Voltage Regulator
Rectifire Holder

Non-reusable part Robber Insulator B09071

2001 AVALON (RM808U)

Author
: Date
: 1278

 CH-7
CHARGING - GENERATOR
CH03X-01

DISASSEMBLY
1. REMOVE REAR END COVER
(a) Remove the nut and terminal insulator.

P20102

(b) Remove the screw, 3 nuts, plate terminal and end cover.

Plate Terminal

P14233

2. REMOVE BRUSH HOLDER AND VOLTAGE REGULA-

TOR
(a) Remove the brush holder cover from the brush holder.
(b) Remove the 5 screws, brush holder and voltage regulator.

P14234

3. REMOVE RECTIFIER HOLDER

(a) Remove the 4 screws and rectifier holder.
(b) Remove the 4 rubber insulators.
(c) Remove the seal plate.

P20103

4. REMOVE PULLEY
(a) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
Turn SST 09820-63010
SST (A) Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Check that SST (A) is secured to the rotor shaft.

SST (B)
P10835

2001 AVALON (RM808U)

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CH-8
CHARGING - GENERATOR

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

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

SST (C) Insert

P10834

(e) 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
SST (A) pulley nut more than one-half of a turn.
(f) Remove the generator from SST (C).

Turn P10827

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

(h) Remove the pulley nut and pulley.

Turn
SST (A)

SST (B)
P10836

5. REMOVE RECTIFIER END FRAME

(a) Remove the wire clamp.
(b) Remove the 4 nuts and cord clip.

P19942

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

SST 09286-4601 1
(d) Remove the thrust washer.
6. REMOVE ROTOR FROM DRIVE END FRAME
SST

P01762

2001 AVALON (RM808U)

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: Date
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 CH-9
CHARGING - GENERATOR
CH03Y-01

INSPECTION
1. INSPECT ROTOR
(a) Inspect the rotor for open circuit.
Using an ohmmeter, check that there is continuity be-
Ohmmeter tween the slip rings.
Standard resistance: 2.1 - 2.5 Ω at 20°C (68°F)
If there is no continuity, replace the rotor.
Continuity
CH0784

(b) Inspect the rotor for ground.

Using an ohmmeter, check that there is no continuity be-
tween the slip ring and rotor.
If there is continuity, replace the rotor.
Ohmmeter

No Continuity
B02105

(c) Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor.
(d) Using vernier calipers, measure the slip ring diameter.
Standard diameter: 14.2 - 14.4 mm (0.559-0.567 in.)
Minimum diameter: 12.8 mm (0.504 in.)
If the diameter is less than minimum, replace the rotor.

CH0192

2. INSPECT STATOR (DRIVE END FLAME)

(a) Inspect the stator for open circuit.
Continuity
Using an ohmmeter, check that there is continuity be-
tween the coil leads.
Ohmmeter If there is no continuity, replace the drive end frame assembly.

P00484

(b) Inspect the stator for ground.

Using an ohmmeter, check that there is no continuity be-
Continuity
tween the coil lead and drive end frame.
If there is continuity, replace the drive end frame assembly.
Ohmmeter

P00482

2001 AVALON (RM808U)

Author
: Date
: 1282

CH-10
CHARGING - GENERATOR

3. INSPECT BRUSHES
Using a vernier caliper, measure the exposed brush length.
Standard exposed length: 10.5 mm (0.413 in.)
Minimum exposed length: 1.5 mm (0.059 in.)
Length
If the exposed length is less than minimum, replace the brushes
and brush holder assembly.

P13535

4. INSPECT RECTIFIERS (RECTIFIRE HOLDER)

(a) Check the positive (+) rectifire.
(1) Using an ohmmeter, connect one tester probe to the
Positive (+) positive (+) terminal and the other to each rectifier
Ohmmeter Terminal terminal.
(2) Reverse the polarity of the tester probes and repeat
Rectifire step (a).
Terminal
(3) Check that one shows continuity and the other
P00480 shows no continuity.
If continuity is not as specified, replace the rectifier holder.
(b) Check the negative (-) rectifire.
Negative (-) (1) Using an ohmmeter, connect one tester probe to
Terminal each negative (-) terminal and the other to each
rectifier terminal.
Ohmmeter (2) Reverse the polarity of the tester probes and repeat
step (a).
(3) Check that one shows continuity and the other
shows no continuity.
P00481 If continuity is not as specified, replace the rectifier holder.
5. INSPECT BEARING
Check that bearing is not rough or worn.
If necessary, replace the bearing (See page CH-1 1).

2001 AVALON (RM808U)

Author
: Date
: 1283

CH-16
CHARGING - GENERATOR
CH041-01

INSTALLATION
Installation is in the reverse order of removal (See page CH-6 ).

2001 AVALON (RM808U)

Author
: Date
: 1289

 CH-13
CHARGING - GENERATOR
CH040-02

REASSEMBLY
1. INSTALL ROTOR TO DRIVE END FRAME
(a) Place the rectifier end frame on the pulley.
Pulley (b) Install the rotor to the rectifier end frame.

P01364

2. INSTALL RECTIFIER END FRAME

(a) Place the thrust washer on the rotor.

P00427

(b) Using a 29 mm socket wrench and press, slowly press in

29 mm
Socket
the rectifier end frame.
Wrench

P01763

A (c) NUT A:
B
Install the cord clip and 4 nuts.
Torque: 4.5 N·m (46 kgf·cm, 40 in.·lbf)
(d) NUT B:
A Install the cord clip and 4 nuts.
A Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(e) Install the wire clamp.

P19942

3. INSTALL PULLEY
(a) Install the pulley to the rotor shaft by tightening the pulley
nut by hand.
Turn (b) Hold SST (A) with a torque wrench, and tighten SST (B)
SST (A)
clockwise to the specified torque.
SST 09820-63010
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
SST (B) (c) Check that SST (A) is secured to the pulley shaft.
P10835

2001 AVALON (RM808U)

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: 1286

CH-14
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 (A)

SST (C) Insert

P10834

(f) To torque the pulley nut, turn SST (A) in the direction
shown in the illustration.
Torque: 110.5 N·m (1,125 kgf·cm, 81 ft·lbf)
SST (C)
(g) Remove the generator from SST (C).
SST (A)

Turn

P10829

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

Turn
SST (A)

SST (B)
P10836

4. INSTALL RECTIFIER HOLDER

(a) Place the seal plate on the rectifier end frame.

P00428

(b) Install the 4 rubber insulators on the lead wires.

P00645

2001 AVALON (RM808U)

Author
: Date
: 1287

 CH-15
CHARGING - GENERATOR

(c) Install the rectifier holder with the 4 screws.

Torque: 2.9 N·m (30 kgf·cm, 26 in.·lbf)

P20103

5. INSTALL VOLTAGE REGULATOR AND BRUSH

Upward HOLDER
(a) Place the voltage regulator and brush holder on the recti-
fier end frame.
NOTICE:
Be careful of the holder installation direction.
(b) Install the 5 screws.
Torque: 2.0 N·m (20 kgf·cm, 18 in.·lbf)
S05460

(c) Place the brush holder cover on the brush holder.

P14235

6. INSTALL REAR END COVER

(a) Install the end cover and plate terminal with the 3 nuts and
Plate Terminal screw.
Torque:
Screw: 3.9 N·m (39 kgf·cm, 35 in.·lbf)
Nut: 4.4 N·m (45 kgf·cm, 39 in.·lbf)

P14233

(b) Install the terminal insulator with the nut.

Torque: 4.1 N·m (41.5 kgf·cm, 36 in.·lbf)
7. CHECK THAT ROTOR ROTATES SMOOTHLY

P20102

2001 AVALON (RM808U)

Author
: Date
: 1288

CH-6
CHARGING - GENERATOR
CH03W-02

REMOVAL
1. REMOVE DRIVE BELT
Loosen the pivot bolt, adjusting lock bolt and adjusting bolt, and
remove the drive belt.
Torque:
Lock bolt: 18 N·m (180 kgf·cm, 13 ft·lbf)
Pivot bolt: 56 N·m (570 kgf·cm, 41 ft·lbf)

P19938

2. REMOVE GENERATOR
(a) Disconnect the generator connector.
(b) Remove the nut, and disconnect the generator wire.
Torque: 9.8 N·m (100 kgf·cm, 86 in.·lbf)
(c) Disconnect the wire harness from the clip.
(d) Remove the pivot bolt, plate washer, adjusting lock bolt
and generator.

P19978

2001 AVALON (RM808U)

Author
: Date
: 1279

 CH-1 1
CHARGING - GENERATOR
CH03Z-02

REPLACEMENT
1. REPLACE FRONT BEARING
(a) Remove the 4 screws and bearing retainer.

P14225

(b) Using a socket wrench and press, press out the bearing.
Socket Wrench

P00628

(c) Using SST and a press, press in a new bearing.

SST SST 09950-60010 (09951-00520)
(d) Install the bearing retainer with the 4 screws.
Torque: 3.0 N·m (31 kgf·cm, 27 in.·lbf)

P00479

2. REPLACE REAR BEARING

(a) Using SST,remove the bearing cover (outside) and bear-
ing.
SST SST 09820-00021
NOTICE:
Be careful not to damage the fan.
(b) Remove the bearing cover (inside).

N00581

(c) Place the bearing cover (inside) on the rotor.

P13567

2001 AVALON (RM808U)

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: 1284

CH-12
CHARGING - GENERATOR

(d) Using SST and a press, press in a new bearing.

SST 09820-00030
SST

N00578

(e) Using SST, push in the bearing cover (outside).

SST 09285-76010

SST

P00074

2001 AVALON (RM808U)

Author
: Date
: 1285

 CH-17
CHARGING - IGNITION RELAY (No.1)

Driver Side J/B IGNITION RELAY (No.1) SF0DX-05

INSPECTION
Ignition 1. REMOVE IGNITION RELAY (Marking: IG1)
Relay

B09784

Ohmmeter No Continuity 2. INSPECT IGNITION RELAY

(a) Inspect the relay continuity.
1 (1) Using an ohmmeter, check that there is no continu-
2
ity between terminals 1 and 2.
If there is continuity, replace the relay.
3 (2) Check that there is continuity between terminals 3
4
and 4.
If there is no continuity, replace the relay.
Continuity B09785

Ohmmeter Continuity (b) Inspect the relay operation.

(1) Apply battery positive voltage across terminals 3
and 4.
1 (2) Using an ohmmeter, check that there is continuity
2
3 between terminals 1 and 2.
If there is no continuity, replace the relay.
4
3. REINSTALL IGNITION RELAY

Battery B09786

2001 AVALON (RM808U)

Author
: Date
: 1290