Alternator (FA20)
Components Removal / installation
BATTERY / CHARGING
ALTERNATOR (FA20)
EXPLODED VIEW
REMOVAL
1. Disconnection of the battery ground terminal
CAUTION:
The power windows are equipped with an index function that is linked to the opening and closing of the doors and allows the glass to be opened and closed a little. The molding may be damaged when the doors are opened or closed after disconnecting the battery ground terminal when the glass is completely closed. Therefore, always disconnect the battery ground terminal with the driver’s or passenger’s seat door open (with the glass lowered to a position that allows free door opening and closing).
2. Removal of the fan and alternator V-belt (Refer to
)
)
DISASSEMBLY
1. REMOVE GENERATOR REAR END COVER
2. REMOVE GENERATOR PULLEY
3. REMOVE GENERATOR DRIVE END FRAME ASSEMBLY
(1) Remove the generator drive end frame assembly from the generator rotor assembly.
4. REMOVE GENERATOR DRIVE END FRAME BEARING
(1) Mount the generator drive end frame assembly in a vise between aluminum plates.
(3) Securely attach an appropriate tool (a socket wrench of the correct size, etc.) to the bearing inner race.
(4) Use a press to push the wheel bearing out of the front cover.
5. REMOVE GENERATOR ROTOR BEARING
(1) Use a bearing puller to remove the bearing from the rotor.
6. REMOVE GENERATOR COIL ASSEMBLY
(1) Remove the 6 bolts and generator coil assembly.
7. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
(1) Remove the 4 bolts and generator brush holder assembly.
8. REMOVE BRUSH
9. REMOVE GENERATOR HOLDER WITH RECTIFIER
(1) Remove the terminal cover.
(2) Remove the nut and the terminal.
(3) Remove the 3 bolts and the generator holder with rectifier.
INSPECTION
1. INSPECT BRUSH
2. INSPECT GENERATOR COIL ASSEMBLY
(1) Check the resistance.
(2) Check the resistance.
(a) Measure the resistance according to the value(s) in the table below.
If the result is not as specified, replace the generator coil assembly.
Standard Resistance
| Tester Connection |
Condition |
Specified Condition |
|---|---|---|
| Stator core - Lead wire |
Always |
10 kΩ or higher |
Text in Illustration
| *1 |
Stator core |
| *a |
Lead wire |
3. INSPECT GENERATOR ROTOR ASSEMBLY
(1) Check the generator rotor assembly for an open circuit.
(2) Check if the generator rotor assembly is grounded.
(a) Measure the resistance according to the value(s) in the table below.
If the result is not as specified, replace the generator rotor assembly.
Standard Resistance
| Tester Connection |
Condition |
Specified Condition |
|---|---|---|
| Slip ring - Rotor core |
Always |
10 kΩ or higher |
Text in Illustration
| *1 |
Slip Ring |
| *2 |
Rotor Core |
(3) Check the slip ring diameter.
4. INSPECT GENERATOR HOLDER WITH RECTIFIER
(1) Check the resistance.
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance
If the result is not as specified, replace the generator holder with rectifier.| Tester Connection |
Condition |
Specified Condition |
|---|---|---|
| P1, P2, P3, P4, P5, P6 - B |
P1, P2, P3, P4, P5, P6 (Tester positive) B (Tester negative) |
Below 1 Ω |
| P1, P2, P3, P4, P5, P6 (Tester negative) B (Tester positive) |
10 kΩ or higher |
|
| P1, P2, P3, P4, P5, P6 - E |
P1, P2, P3, P4, P5, P6 (Tester positive) E (Tester negative) |
10 kΩ or higher |
| P1, P2, P3, P4, P5, P6 (Tester negative) E (Tester positive) |
Below 1 Ω |
REASSEMBLY
1. INSTALL GENERATOR HOLDER WITH RECTIFIER
(1) Install the generator holder with rectifier with the 3 bolts.
(2) Install the terminal with the nut.
Standard value:
Standard value:
Tightening torque=8.9N·m
{
91kgf·cm}
{6.6ft·lbf}
(3) Install the terminal cover.
2. INSTALL BRUSH
3. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
(1) Install the generator brush holder assembly with the 4 bolts.
Standard value:
Standard value:
Bolt A
Tightening torque=2.0N·m { 20kgf·cm} {1.5ft·lbf}
Bolt B
Tightening torque=3.9N·m { 40kgf·cm} {2.9ft·lbf}
Tightening torque=2.0N·m { 20kgf·cm} {1.5ft·lbf}
Bolt B
Tightening torque=3.9N·m { 40kgf·cm} {2.9ft·lbf}
4. INSTALL GENERATOR COIL ASSEMBLY
(1) Install the generator coil assembly with the 6 bolts.
Standard value:
Standard value:
Tightening torque=2.0N·m
{
20kgf·cm}
{1.5ft·lbf}
5. INSTALL GENERATOR ROTOR BEARING
(1) Using a press, press in a new generator rotor bearing.
6. INSTALL GENERATOR DRIVE END FRAME BEARING
(1) Set the wheel bearing onto the generator drive end frame and securely attach an appropriate tool (a socket wrench of the correct size, etc.) to the bearing outer race.
(2) Using a press, press in a new generator drive end frame bearing.
(3) Install the bearing retainer with the 4 screws.
Standard value:
Standard value:
Tightening torque=3.9N·m
{
40kgf·cm}
{2.9ft·lbf}
7. INSTALL GENERATOR DRIVE END FRAME ASSEMBLY
(1) Install the generator drive end frame assembly to the generator rotor assembly.
8. INSTALL GENERATOR PULLEY
9. INSTALL GENERATOR REAR END COVER
INSTALLATION
1. Installation of the alternator ASSY
(1) Install the alternator ASSY in place with the two bolts.
Standard value:
Standard value:
Tightening torque=25N·m
{
255kgf·cm}
{18.4ft·lbf}
(2) Connect the connector.
(3) Connect the wiring harness to the B terminal with a nut.
Standard value:
Standard value:
Tightening torque=16N·m
{
163kgf·cm}
{11.8ft·lbf}
(4) Install the terminal cap.
2. Installation of the fan and alternator V-belt
(Refer to )
)3. Connection of the battery ground terminal
Standard value:
Standard value:
Tightening torque=6.0N·m
{
61kgf·cm}
{4.4 ft·lbf}