Temporarily install the generator with the 2 bolts.

Connect the vacuum pump oil outlet hose.

Install 2 new gaskets and the vacuum pump oil inlet hose with the union bolt.

• Момент затяжки:
• 14 N*m{ 140 kgf*cm, 10 ft.*lbf}

Connect the vacuum pump hose.

Attach the vacuum pump oil inlet hose to the cord clip.

Install the generator wire with the nut.

• Момент затяжки:
• 9.8 N*m{ 100 kgf*cm, 87 in.*lbf}

Install the terminal cap.

Connect the generator connector.

Temporarily install the cooler compressor with the 2 bolts.

Temporarily install the idle pulley bracket with the 4 bolts.

Tighten the 6 bolts in the sequence shown in the illustration.

• Момент затяжки:
• for bolt A:
• 45 N*m{ 459 kgf*cm, 33 ft.*lbf}
• except bolt A:
• 25 N*m{ 250 kgf*cm, 18 ft.*lbf}

Connect the wire harness with the bolt.

• Момент затяжки:
• 13 N*m{ 131 kgf*cm, 9 ft.*lbf}

Connect the cooler compressor connector.

Install the fan and generator V belt (See page ).

Using SST and a press, press in the generator rotor.

• SST
• 09285-76010

Place the washer on the generator rotor.

Using a 17 mm socket wrench and press, slowly press on the rectifier end frame.

Install the cord clip and 4 nuts.

• Момент затяжки:
• 5.9 N*m{ 60 kgf*cm, 52 in.*lbf}

Install the 4 rubber insulators to the lead wires.

Text in Illustration

Inside

• ПРИМЕЧАНИЕ:

• Be careful to install the rubber insulators in the correct direction.

While pushing down on the rectifier holder, install it with the 4 screws.

• Момент затяжки:
• 2.9 N*m{ 30 kgf*cm, 26 in.*lbf}

Text in Illustration

Push

Install the regulator with the 3 screws.

• Момент затяжки:
• 2.0 N*m{ 20 kgf*cm, 18 in.*lbf}

Install the plate seal.

Install the brush holder with the 2 screws.

• Момент затяжки:
• 2.0 N*m{ 20 kgf*cm, 18 in.*lbf}

Text in Illustration

Upper

Install the brush holder cover.

Install the rear end cover and rectifier plate with the bolt and 3 nuts.

• Момент затяжки:
• for nut:
• 4.4 N*m{ 45 kgf*cm, 39 in.*lbf}
• for bolt:
• 3.9 N*m{ 40 kgf*cm, 35 in.*lbf}

Install the terminal insulator with the nut.

• Момент затяжки:
• 4.1 N*m{ 42 kgf*cm, 36 in.*lbf}

Align the matchmarks and install the vacuum pump with the 4 bolts.

• Момент затяжки:
• 7.8 N*m{ 80 kgf*cm, 69 in.*lbf}

Check the generator rotor for an open circuit.

Measure the resistance according to the value(s) in the table below.

• Standard Resistance:

• Tester Connection	Condition	Specified Condition
  Slip ring - Slip ring	20°C (68°F)	2.1 to 2.5 Ω

Text in Illustration

*1

Slip Ring

If the result is not as specified, replace the generator rotor assembly.

Check if the generator rotor is grounded.

Measure the resistance according to the value(s) in the table below.

• Standard Condition:

• Tester Connection	Condition	Specified Condition
  Slip ring - Rotor core	Always	10 kΩ or higher

Text in Illustration

*1	Slip Ring
*2	Rotor Core

If the result is not as specified, replace the generator rotor assembly.

Check that the slip rings are not rough or scored.

If they are rough or scored, replace the generator rotor assembly.

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:
• 14.0 mm (0.551 in.)

If the diameter is less than the minimum, replace the generator rotor assembly.

Inspect the bearing.

Check the stator for an open circuit.

Measure the resistance according to the value(s) in the table below.

• Standard Resistance:

• Tester Connection	Condition	Specified Condition
  Coil lead - Coil lead	Always	Below 1 Ω

Text in Illustration

*1

Coil Lead

If the result is not as specified, replace the generator assembly.

Check the stator for a short circuit.

Measure the resistance according to the value(s) in the table below.

• Standard Resistance:

• Tester Connection	Condition	Specified Condition
  Coil lead - Drive end frame	Always	10 kΩ or higher

Text in Illustration

*1	Coil Lead
*2	Drive End Frame

If the result is not as specified, replace the generator assembly.

Inspect the bearing.

Using a vernier caliper, measure the exposed brush length.

• Standard exposed 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.

Check the positive terminal of the rectifier.

Check the negative terminal of the rectifier.

Measure the resistance according to the value(s) in the table below.

• Standard Resistance:

• Tester Connection	Condition	Specified Condition
  Terminal F - Terminal B	Always	Below 1 Ω or higher than 10 kΩ

If the result is not as specified, replace the generator regulator assembly.

• УКАЗАНИЕ:

• When the ohmmeter leads are initially touched to the regulator, one of the above values is output. When the leads are reversed, the reading changes to the other value.

Measure the resistance according to the value(s) in the table below.

• Standard Resistance:

• Tester Connection	Condition	Specified Condition
  Terminal F - Terminal E	Always	Below 1 Ω or higher than 10 kΩ

If the result is not as specified, replace the generator regulator assembly.

• УКАЗАНИЕ:

• When the ohmmeter leads are initially touched to the regulator, one of the above values is output. When the leads are reversed, the reading changes to the other value.

Mount the generator in a vise between aluminum plates.

Insert a screwdriver to hold the generator rotor.

Install a bolt and nut to the outside of the pulley so that the bolt head and nut clamp the pulley, and then position a dial indicator as shown in the illustration.

Turn the pulley and measure the backlash between the generator rotor and vacuum pump shaft.

• Maximum backlash:
• 1.6 mm (0.0630 in.)

If the backlash is more than the maximum, replace the generator rotor and vacuum pump shaft.

Place matchmarks as shown in the illustration.

Remove the 4 bolts and vacuum pump.

Remove the nut and terminal insulator.

Remove the bolt, 3 nuts, rectifier plate and rear end cover.

Remove the brush holder cover.

Remove the 2 screws and brush holder.

Remove the plate seal.

Remove the 3 screws and generator regulator.

Remove the 4 screws and generator holder with rectifier.

Remove the 4 rubber insulators.

Remove the 4 nuts and cord clip.

Using SST, remove the rectifier end frame.

• SST
• 09286-46011

Text in Illustration

*a	Hold
	Turn

Remove the washer from the rotor.

Using SST and a press, press out the rotor.

• SST
• 09950-60010(09951-00180)
  09950-70010(09951-07100)

Remove the fan and generator V belt (See page ).

Remove the 4 bolts and idle pulley bracket.

Disconnect the connector.

Remove the 3 bolts and disconnect the cooler compressor.

• УКАЗАНИЕ:

• It is not necessary to completely remove the cooler compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.

Remove the terminal cap.

Remove the nut and generator wire.

Disconnect the generator connector.

Disconnect the vacuum pump hose.

Remove the union bolt to disconnect the vacuum pump oil inlet hose and remove the 2 gaskets.

Detach the vacuum pump oil inlet hose from the cord clip.

Disconnect the vacuum pump oil outlet hose.

Remove the 2 bolts and generator.

Check the battery for damage and deformation. If severe damage, deformation or leakage is found, replace the battery.

Check the electrolyte quantity of each cell.

• УКАЗАНИЕ:

• Before checking the battery voltage, turn off all the electrical systems (headlights, blower motor, rear defogger, etc.).

Turn the ignition switch off and turn on the headlights for 20 to 30 seconds. This removes the surface charge from the battery.

Measure the battery voltage between the negative (-) and positive (+) terminals of the battery.

• Standard voltage:
• 12.5 to 12.9 V at 20°C (68°F)

If the voltage is less than the specification, recharge the battery.

Check that the battery terminals are not loose or corroded.

If the terminals are corroded, clean the terminals.

Measure the resistance of the H-fuses and fuses.

• Standard Resistance:
• Below 1 Ω

If the result is not as specified, replace the fuses.

Убедитесь в отсутствии износа, трещин и других признаков повреждения.

При обнаружении следующих дефектов замените вентилятор и поликлиновой ремень генератора.

Убедитесь в том, что приводной ремень правильно располагается в углублениях шкива.

• УКАЗАНИЕ:

• Рукой проверьте, не выскользнул ли ремень из канавок в нижней части шкива. Если ремень выскользнул из канавки шкива, замените поликлиновой ремень. Правильно установите новый поликлиновой ремень.

Убедитесь, что индикаторная метка натяжителя находится в диапазоне A, как показано на рисунке.

Если метка находится вне зоны A, замените поликлиновой ремень вентилятора и генератора.

Visually check the generator wiring.

Listen for abnormal noises from the generator.

Turn the ignition switch to ON. Check that the charge warning light comes on.

Start the engine and check that the light goes off.

If the light does not operate as specified, troubleshoot the charge warning light circuit.

Connect a voltmeter and ammeter to the charging circuit as follows.

Disconnect the wire from terminal B of the generator, and then connect it to the negative (-) lead of an ammeter.

Text in Illustration

*1	Battery
*2	Terminal B
*3	Generator

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

Connect the positive (+) lead of a voltmeter to the positive (+) terminal of the battery.

Ground the negative (-) lead of the voltmeter.

Check the charging circuit.

With the engine running at 2000 rpm, turn the high beam headlights on and turn the heater blower switch to the HI position.

Check the reading on the ammeter.

• Standard current:
• 30 A or higher

If the ammeter reading is below the standard current, repair the generator.

• УКАЗАНИЕ:

• If the battery is fully charged, the indication will sometimes be less than the standard current. If this is the case, add more electrical load (operate the wipers, rear window defogger, etc.) and check the reading on the ammeter again.