ALTERNATOR 5 ALTERNATOR CROSS-SECTIONAL VIEW RF-CX Model B terminal L torminal \ S terminal Except RF-CX Model ae S terminal TEGO 5-215 ALTERNATOR CHARGING SYSTEM I Diode trio Tgnition| eoull F Terminal 22 coll Rotor coil rani Caution B Terminal b Terminal a) Be sure the battery connections are not -§ Terminal reversed. because this will damage the rec- tifier. b)Do not use high-voltage testers such as a megger, because they will damage the rec- tifier. ¢) Remember that battery voltage is always applied to the alternator B terminal. )Do not ground the L terminal while the en- gine is running. e)Do not start the engine while the connec- tor is disconnected from the L and S ter- minals. « ce 4 dALTERNATOR 5 ‘TROUBLESHOOTING Preliminary Check 1, Turn the ignition switch ON, anc chack that the alternator warning light illuminates. 2. Start the engine, and check that the atternat F warning light goes off Alternator 3) warning light 1, Alternator warning light always not illuminate (Check that her warnieg lights Mumnate when NG, ignition ston 0? OK oF #9t0 (Reter to page 522, 33, 34) Perform TEST 1. (Reler to page 5-25, OK Alternator warning ight ereut maluneton 2. Alternator warning light illuminates when engine running Peter TEST 2. (Rar o page 625) Wing harass ratincton Na EST 1. (Reler to page 525) [NEC regulator, brush, or rotor col maftuncton, {Refer to page 5—32, 33, 34.) ok _| Pert TEST (Ree fo page 5-26) L"@. Tic seguir, cor coo bush maturcton (Refer to page 5—32 or 5-33.) ox @) Poor comecion oi rogatve bate cabe 8} Poor comecton atwean ates” connecor Gp) and ponte tate tora oy Sito cote odes aon Geter i page 830 or 38 5-235 avterNator 3. Alternator warning light operates properly, but battery discharged ok, Pore TESTA as ages 5) | 9%. Ry coma Ne Peron TEST 2) [MEL poor TESTS Weta pape 50) ox [ox Ne rm ox toe tho page 522 or 34) Perform TEST 5 (Refer to page 526) Ne ‘C regulator, bush, or rotor coll malfunction. ox ‘Check olner elestrcal components, (poy an poste are tern fer eos Se SHE) 4. Battery overcharged Povo TEST ae page 5-28 ] 4a sora Less nan 12:1 More than 14.70 (aise why aah (______c requiator maturction eroary TE Feler to page 5-27) [Na OK ' Wiring harness mattuncion. (ALTERNATOR 5 Warning Disconnect the nagative battery terminal when disconnect or reconnect B terminal. TEST 1 4. Disconnect the altemator connector (2-pin} 2. Connect the SST. coun 49 GO18 001 4. Connect the red clip of the adapter harness to the battery (+), and check that the red lamp and green iamp illuminate. 5, Start the engine and check that both lamps go off TEST 2 1. Connect an ammeter (75A min.) between the wire and the B terminal 2. Turn all headlights ard sccess07les On, and depress the Erake pec! 3. Start the engine ard check that output current is 70A (RF-CX: 75A) or more at 2,500—3,000 rpm of the engne speed. Caution | Do not ground the B terminal. B terminal5 AvTeRNATOR TEST 3 4. Turn all electric loads off and release the brake pedal 2. Check that output current is 5A oF more at 2,500—3,000 rpm of the engine speed, TEST 4 1. Turn all electric loads off and release the brake pedal 2. Check that output voltage between S terminal and ground is within specication at 2,500—3,000 rpm of the engin speed Voltage: 14.1—14.7V TEST 5 4, Turn the ignition switch ON. 2. Check that terminal voltage is within spec fication Voltage: 1—5V J LL terminal «~ owALTERNATOR 5 TEST 6 1. Turn the ignition switch ON. the brake pedal 2 Turn all electric loads otf and release 3. Check that votage between S terminal and ground is battery voltage. REMOVAL (GASOLINE) Remove in the sequence shown in the figure 1, Disconnect the negative battery terminal 2. Disconnect the wre and connector from the al temator. 3. Remove the bolts, 4. Remove ihe V-belt 5, Remove the alternator to upper side (LHD) or oy side (RHD} REMOVAL (DIESEL) 4, Disconnect the negative battery terminal 2. Remove the right hand driveshatt (Refer to Sec: tion 9). 3. Disconnect the wire and connector from the al ternator, 4, Looser the idle pulley nuts ang rer belts 5. Remove the bolts and remove the alternator trom under the vehicle ve the drive 5275 AtTERNATOR DISASSEMBLY Disassemble in the sequence shown in the figure. 4. Lock nut (RE-CX) 6. Pulley 2. Pulley (RF. CX) 7 Rear bracket 3. Bolt 8 Stator 4. Front bracket and rotor 9. Brusn holder assembly 5. Look nut 10. RectifierALTERNATOR 5 Front bracket Pulley Rotor ae Locknut 1. Place a soldering iron (2000) on the bearing box for 3 or 4 minutes to heat t to about 50—60°C. (122—140°F). Pull out the three bolts, and then insert a screw: Gr ver between the stator and trent bracket anc separate them. Note a) If the bearing box is not heated, the bear ing cannot be pulled out because the rear bearing and rear bracket fit together very tightly. b) Be careful not to force the screwdriver in too far. The stator may become scratched. 2. Separate the rear and ‘ront sections. Note Be careful not to lose the stopper spring that, fits around the circumference of the rear bearing. 8, Place the rotor ina vise and loosen the pulley nut, then disassemole the puley, rotor, and tront bracket5 acteRNATOR i Bearing puller Bushing Rear cover 4, Replace the front bearing Using a socket which exactly fits on the outer race of the bearing, carefully press in the bearing, Use a hang press or a vise. 5. Replace the rear bearing The bearing can be pulled off by using a bearing puller. When tis pressed on, press it on 80 that the groove at the bearing circumference is at the slp ing side. 6, Remove the nut of the 8 terminal and the insula- tion bushing 7. Remave the rectitier holding sorews and the orush holder holding screw 8. Separate the rear bracket and she stator. 9. Use a soldering iron to remove the solder from the rectifier and the stalor leads, and then remove the IC reguiator. Caution Disconnect quickly, use the soldering iron no ‘more than about 5 seconds because the rec- tifier may be damaged If it is overheated.Remove solder Wear limit line.2, mark. 2-3 mm (0.079~ 0.118 in) Brush holder fend line ALTERNATOR 5 10. Replace the brushes Remove the solder from the pigtail, and then re: move the brush. 11. When soldering the brush, solder the pigtail so that the wear limit line of the brush projects 2—3 mm (0.078—0.118 in) out from the end of the brush holder,5 avterNator INSPECTION Rotor 1. Wiring damage (1) Chook the resistance between the sip ings us ing an ohmmeter Specification: 2—6 2 (2) itis not within specttication, replace the rotor 2. Groune of the field coil (1) Check tor continuity between the sip ring and the core using an ohmmeter (2) Replace the rotor if there is continuity 3 Sip ring surface ¥ the sip ting surface is rough, use a lathe or fine sandpaper to repal Stator + Wiring damage (1) Check for continuity between t leads using an ohmmeter. (2) Replace the stator i there is no continuity tor coil 2. Ground of the stator coil (1) Check for continuity between the stator coil leads and the core using a circuit tester. (2) Replace the stator i there is continuityALTERNATOR 5 Standard Wear limit line Brush Ifthe brushes are worn almost to or beyond the limit replace them Standard: 16.5 mm (0.650 in) 21.5 mm (0.846 in}—RF-CX Minimum: 8 mm (0.315 in) Brush Spring 1, Measure the force of the brush spring using a spring pressure gauge. Replace the spring if necessary Standard force: 3.0—4.2 N (810-430 g, 10.9—15.2 02) Minimum: 1.72.5 N (170-250 g, 6.0—8.8 02) Note Read the spring pressure gauge at the brush tip projection of 2 mm (0.079 in). Bearing 1, Check for abnormal noise, looseness, or insufficient lubrication, 2. Replace the bearing{s) if here is any abnormaity5 ALTERNATOR yyy 4@—|-|-4 2 Rectifier 4. Check for contnuily of the diodes using an ‘ohmmeter. [Negative iach) | Postive (Red) Contnuiy E Yes 8 PBs Pa Na. L No. E No PPP B Yee t ves 2, Repiace the rectifier. CeALTERNATOR 5 ‘Stopper spring ASSEMBLY Assemble in the reverse order of disassembly, refer ring to assembly note, Assembly Note Stopper spring installation 1. Fitthe stopper spring into the eccentric groove of the rear bearing crcumference 2. Check that the protruding part ofthe spring is fitec into the deepest part of the groove Front bracket and rotor When assembling the ‘font bracket and roter, tight en the locknut to the specified torque. Tightening torqu 4988 Nm (5—9 m-kg, 36—65 ft-lb) Brush lifting 1. Before assembly, use a finger to hold the brushes into the brush halder: then pass @ wie (2 mm, 40—50 mm, 0.08 in, 1.6—2.0 in} through the hole shown In the figure 2. Seoure the brushes in position Note Be sure to remove wire after assembly is com- pleted. Rear bearing installation 1. Heat the rear bracket 2 Press the rear bearing into the rear bracket. 3. Check that the rotor turn5 ALTERNATOR INSTALLATION Note When installing the alternator, tighten the bolts to the specified torque. Install in the reverse order of removal Tightening torque: 37.3—52 Nm (3.8—5.3 mekg, 27.5—38.3 ft-lb) 18.6--25.5 Nm. m-kg, 13.7—18.8 ft-b) ..37—52 Nm (3.8—5.3 m-kg, 27.5—38.3 ft-lb)€ ALTERNATOR 5 Adjusting bar bolt Mounting bolt Alternator” drive pulley Mounting bolt Drive pulley ‘Adjusting bolt |-Idler pulley ‘Comprex pulley Locknut Adjusting bolt Idler pulley oar) \V-BELT TENSION (GASOLINE) Adjustment 1. Loosen the alternator mounting boll and adjusting bar bot, 2, Adjust tne alternator belt detiection while pushing the V-belt with a force of 98 N (19 kg, 22 ft-lb) Deflection: New: 6—8 mm (0.24—0.31 in) Used: 7—9 mm (0.27—0.35 in) 3. Tighten the bolts and recheck the tension. \V-BELT TENSION (DIESEL) Adjustment 1. Looson the alternator idler pulley focknut 2. Aciust the alternator belt deflection while pushing tne V-belt with a force of 98 N (10 kg, 22 ft-Ib). Deflection: Alternator New: 8—10 mm (0.31—0.3: Used: 9—11 mm (0.35—0.43 in) ‘Comprex ‘New: 4.0—5.0 mm (0.16—0.20 in) Used: 4.55.5 mm (0.18—0.21 in) 3. Tighten the bolts and nuts and recheck the tens 5.37