CH-1

CHARGING - CHARGING SYSTEM

CHARGING SYSTEM
CH065-01

PRECAUTION

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

Disconnect the battery cables when the battery is given a quick charge.

Do not perform tests with a high voltage insulation resistance tester.

Never disconnect the battery while the engine is running.

cardiagn.com

1996 TERCEL (RM440U)

Author
: Date
: 677

CH-2
CHARGING - CHARGING SYSTEM
CH0H6-01

ON-VEHICLE INSPECTION
1. CHECK BATTERY SPECIFIC GRAVITY AND ELEC-
TROLYTE LEVEL
(a) Check the electrolyte quantity of each cell.
If insufficient, refill with distilled (or purified) water.
(b) Check the specific gravity of each cell.
Standard specific gravity:
1.27 - 1.29 at 20°C (68°F)
If the specific gravity is less than specification, charge the bat-
tery.

cardiagn.com
HINT:
Blue White Red Check the indicator as shown in illustration.
2. CHECK BATTERY TERMINALS, FUSIBLE LINK AND
FUSES
(a) Check that the battery terminals are not loose or cor-
roded.
OK Charging Insufficient If the terminals are corroded, clean the terminals.
Necessary Water
(b) Check the fusible link and fuses for continuity.
Z11580 Fusible link MAIN 2.0A
ALT 100A
Hf
H-fuse
AM1 50A
AM2 15A
GAUGE 15A
F
Fuse
IGN 7.5A
ALT-S 7.5A

3. INSPECT DRIVE BELT

(a) Visually check the drive belt for excessive wear, frayed
cords etc.
If any defect is found, replace the drive belt.
HINT:
Cracks on the rib side of a drive belt are considered acceptable.
If the drive belt has chunks missing from the ribs, it should be
replaced.
N00313

1996 TERCEL (RM440U)

 CH-3
CHARGING - CHARGING SYSTEM

DENSO Borroughs (b) Using a belt tension gauge, check the drive belt tension.
Belt tension gauge:
DENSO BTG-20 (95506-00020)
Borroughs No. BT-33-73F
Drive belt tension:
New belt 160 ± 20 lbf
Used belt 100 ± 20 lbf

If the belt tension is not as specified, adjust it.

N00280 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
ribbed grooved.

Check by hand to confirm that the belt has not slipped out
CORRECT WRONG WRONG of the groove on the bottom of the pulley.

cardiagn.com

After installing a new belt, run the engine for about 5 min-
CH0087 utes and recheck the belt tension.
4. 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.
5. INSPECT CHARGE WARNING LIGHT CIRCUIT
(a) Warm up the engine and then turn it off.
(b) Turn off all accessories.
(c) Turn the ignition switch ”ON”. Check that the charge warn-
P13685 ing light is lit.
(d) Start the engine. Check that the light goes off.
If the light does not go off as specified, troubleshoot the charge
light circuit.

Ammeter 6. INSPECT CHARGING CIRCUIT WITHOUT LOAD

Disconnect Wire
from Terminal B
HINT:
If a battery/generator tester is available, connect the tester to
the charging circuit as per manufacturer’s instructions.
Battery (a) If a tester is not available, connect a voltmeter and amme-
B ter to the charging circuit as follows:
Generator
Disconnect the wire from terminal B of the generator
Voltmeter
and connect it to the negative (-) tester probe of the
CH0732 ammeter.

1996 TERCEL (RM440U)

CH-4
CHARGING - CHARGING SYSTEM

Connect the positive (+) tester probe of the amme-

ter to terminal B of the generator.

Connect the positive (+) tester probe of the voltme-
ter to terminal B of the generator.

Ground the negative (-) tester probe of the voltme-
ter.

(b) Check the charging circuit as follows:

Terminal F
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:
at 25°C (77°F) 13.9 - 15.1 V
at 115°C (239°F) 13.5 - 14.3 V

cardiagn.com
If the voltmeter reading is greater than standard voltage, re-
P13734
place the voltage regulator.
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 greater than standard
voltage, replace the voltage regulator.

If the voltmeter reading is less than standard volt-
age, check the generator.
7. 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.

1996 TERCEL (RM440U)

 CH-5
CHARGING - GENERATOR

GENERATOR
CH0H8-01

COMPONENTS

cardiagn.com

1996 TERCEL (RM440U)

Author
: Date
: 681

CH-6
CHARGING - GENERATOR
CH0H9-01

REMOVAL
1. DISCONNECT CONNECTOR AND WIRE FROM
GENERATOR
(a) Disconnect the connector from the generator.
(b) Remove the connector cover and nut, and disconnect the
wire from the generator.

P13685

Adjusting Bolt 2. REMOVE DRIVE BELT

Loosen the pivot bolt and adjusting bolt, and remove the drive
belt.
Torque:
Pivot bolt: 41 N·m (420 kgf·cm, 30 ft·lbf)
Adjusting bolt: 12 N·m (120 kgf·cm, 9 ft·lbf)

cardiagn.com
Pivot Bolt
P21508

3. REMOVE GENERATOR
(a) Remove the pivot bolt, nut and adjusting bolt.
(b) Remove the generator.

1996 TERCEL (RM440U)

 CH-7
CHARGING - GENERATOR
CH0HA-01

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

P13686

Type A
(b) Type A:
Remove the 3 nuts and end cover.

cardiagn.com
Z10245

Type B (c) Type B:

Remove the 3 bolts and end cover.

Z14809

2. REMOVE BRUSH HOLDER AND VOLTAGE

REGULATOR
(a) Remove the 5 screws, brush holder and voltage
regulator.

P13644

(b) Remove the brush holder cover from the brush holder.

P13688

1996 TERCEL (RM440U)

CH-8
CHARGING - GENERATOR

Type A 3. Type A
REMOVE RECTIFIER HOLDER
(a) Remove the 4 screws and rectifier holder.

Z19162

(b) Remove the 4 rubber insulators.

cardiagn.com
Type B 4. Type B:
REMOVE RECTIFIER HOLDER
(a) Remove the 4 screws.
(b) Using needle-nose pliers, straighten the stator lead wire.
(c) Remove the rectifier holder.

Z14812

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

P04209

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

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

SST (C)

P04210

1996 TERCEL (RM440U)

 CH-9
CHARGING - GENERATOR

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

Turn
P04394

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

SST (A)
(h) Remove the pulley nut and pulley.
SST (B)

Turn

cardiagn.com
P04393

Type A 6. REMOVE RECTIFIER END FRAME

(a) Type A
Remove the 4 nuts.

Z19163

Type B (b) Type B:

Remove the 2 nuts, 2 bolts.

Z14814

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

SST 09286-4601 1

SST

P13692

1996 TERCEL (RM440U)

CH-10
CHARGING - GENERATOR

(d) Using snap ring pliers, remove the generator washer from
the rectifier end frame.
7. REMOVE ROTOR FROM DRIVE END FRAME

cardiagn.com

1996 TERCEL (RM440U)

 CH-1 1
CHARGING - GENERATOR
CH0HB-01

INSPECTION
1. INSPECT ROTOR
(a) Check the rotor for open circuit.
Using an ohmmeter, check that there is continuity be-
Ohmmeter tween the slip rings.
Type A: 2.2 - 2.4 Ω at 20°C (68°F)
Type B: 2.8 - 3.0 Ω at 20°C (68°F)
Continuity
CH0784
If there is no continuity, replace the rotor.

(b) Check 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

cardiagn.com
No Continuity
CH0783

(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.

CH1023

Ohmmeter 2. INSPECT STATOR (DRIVE END FRAME)

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

P04189

No Continuity Ohmmeter (b) Check the stator for ground.

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

P04215

1996 TERCEL (RM440U)

CH-12
CHARGING - GENERATOR

3. INSPECT BRUSHES
Using vernier calipers, measure the exposed brush length.
Standard exposed length:
10.5 mm (0.413 in.)
Minimum exposed length:
1.5 mm (0.059 in.)
If the exposed length is less than minimum, replace the brushes
(Type A) or brush holder assembly (Type B).
P13534

Ohmmeter 4. INSPECT RECTIFIERS (RECTIFIRE HOLDER)

(a) Check the positive rectifier.
(1) Using an ohmmeter, connect one tester probe to the
Positive (+) positive (+) terminal and the other to each rectifier
Terminal
terminal.
Rectifier (2) Reverse the polarity of the tester probes and repeat
Terminal
step (a).

cardiagn.com
(3) Check that one shows continuity and the other
P13568 shows no continuity.
If continuity is not as specified, replace the rectifier holder.
Ohmmeter Negative (-)
(b) Check the negative (-) rectifire.
Terminal (1) Using an ohmmeter, connect one tester probe to
each negative (-) terminal and the other to each
rectifier terminal.
(2) Reverse the polarity of the tester probes and repeat
step (a).
(3) Check that one shows continuity and the other
shows no continuity.
P13566 If continuity is not as specified, replace the rectifier holder.

5. INSPECT BEARING
Check the bearing is not rough or worn.

1996 TERCEL (RM440U)

 CH-13
CHARGING - GENERATOR
CH06B-03

REPLACEMENT
1. REPLACE BRUSHES
(a) Unsolder and remove the brush and spring.
(b) Run the wire of a new brush through the spring and the
hole in the brush holder, and insert the spring and brush
into the brush holder.

Z19164

(c) Solder the brush wire to the brush holder at the specified
exposed length.
Exposed length: 10.5 mm (0.413374 - 0.453 in.)
(d) Check that the brush moves smoothly in the brush holder.
(e) Cut off the excess wire.
(f) Apply insulation paint to the soldered area.

cardiagn.com
Z19165

2. REPLACE FRONT BEARING

(a) Remove the 4 screws, bearing retainer and bearing.

P04193

(b) Using a socket wrench and press, press out the

Socket
Wrench bearing.

P04216

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

SST 09950-60010 (09951-00460)
(d) Install the bearing retainer with the 4 screws.
Torque: 2.6 N·m (27 kgf·cm, 23 in.·lbf)

Lowerward

P04217

1996 TERCEL (RM440U)

CH-14
CHARGING - GENERATOR

3. REPLACE REAR BEARING

(a) Using SST, remove the bearing cover (outside) and bear-
SST ing.
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.

Bearing Cover

cardiagn.com
P05052

(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

1996 TERCEL (RM440U)

 CH-15
CHARGING - GENERATOR
CH0HC-01

REASSEMBLY
1. PLACE RECTIFIER END FRAME ON PULLEY
2. INSTALL ROTOR TO DRIVE END FRAME

P04218

3. INSTALL RECTIFIER END FRAME

(a) Install the generator washer to the rectifier end frame.
NOTICE:
Be careful of the generator washer installation direction.

cardiagn.com
(b) Using a 29 mm socket wrench and press, slowly press in
29 mm
Socket the rectifier end frame.
Wrench (c) Type A
Install the 4 nuts.
Torque: 4.5 N·m (46 kgf·cm, 40 in.·lbf)
(d) Type B:
Install the 2 nuts and 2 bolts.
Torque: 4.5 N·m (46 kgf·cm, 40 in.·lbf)
P13695

4. INSTALL PULLEY
SST (A)
(a) Install the pulley to the rotor shaft by tightening the pulley
SST (B)
nut by hand.
(b) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
SST 09820-63010
Turn Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(c) Check that SST (A) is secured to the pulley shaft.
P04209

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

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

SST (C)

P04210

1996 TERCEL (RM440U)

CH-16
CHARGING - GENERATOR

(f) To torque the pulley nut, turn SST (A) in the direction
shown in the illustration.
Torque: 110 N·m (1,125 kgf·cm, 81 ft·lbf)
SST (C) (g) Remove the generator from SST (C).

Turn SST (A)

P04395

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

SST (A)
SST (B)

Turn

cardiagn.com
P04393

Type A 5. Type A
Inside INSTALL RECTIFIER HOLDER
(a) Install the 4 rubber insulators on the lead wires.
NOTICE:
Be careful of the rubber insulators installation direction.

Z19166

Type A (b) Install the rectifier holder while pushing it with the 4
Push screws.
Torque: 1.96 N·m (20 kgf·cm, 17 in.·lbf)

Z19167

Type B 6. Type B:
INSTALL RECTIFIER HOLDER
(a) Install the rectifier holder.
(b) Bend the 4 stator lead wires as shown in the illustration.

Z14817

1996 TERCEL (RM440U)

 CH-17
CHARGING - GENERATOR

Type B (c) Install the 4 screws.

Torque: 1.96 N·m (20 kgf·cm, 17 in.·lbf)

Z14818

7. INSTALL VOLTAGE REGULATOR AND BRUSH

Upward HOLDER
(a) Install the brush holder cover to the brush holder.
NOTICE:
Be careful of the holder installation direction.

cardiagn.com
Protrusion
Z19168

(b) Place the voltage regulator together with the brush holder
horizontally on the rectifier end frame.

Z19169

(c) Install the 5 screws until there is a clearance of approx.

Approx.
1.0 mm 1.0 mm (0.04 in.) between the brush holder and voltage
regulator.

Z19170

Push (d) Fit the brush holder cover.

Z19171

1996 TERCEL (RM440U)

CH-18
CHARGING - GENERATOR

Type A 8. INSTALL REAR END COVER

(a) Type A:
Install the end cover with the 3 nuts.
Torque: 4.4 N·m (45 kgf·cm, 40 in.·lbf)

Z10245

Type B (b) Type B:

Install the end cover with the 3 bolts.
Torque: 4.4 N·m (45 kgf·cm, 40 in.·lbf)
(c) Install the terminal insulator with the nut.
Torque: 4.1 N·m (42 kgf·cm, 36 in.·lbf)
9. CHECK THAT ROTOR ROTATES SMOOTHLY

cardiagn.com
Z14809

1996 TERCEL (RM440U)

 CH-19
CHARGING - GENERATOR
CH06D-03

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

cardiagn.com

1996 TERCEL (RM440U)