2GR-FE CHARGING – CHARGING SYSTEM CH–1

CHARGING SYSTEM
PRECAUTION
CAUTION:
• Check that the battery cables are connected to the
correct terminals.
• Disconnect the battery cables when the battery is
charged quickly.
• Do not perform tests with a high voltage insulation
resistance tester.
• Never disconnect the battery while the engine is
running.
• Check that the charging cable is connected to terminal
B of the generator and the fuse box.
• Do not perform inspection of the generator in which
terminal F is connected to the other terminal.
1. EXPRESSIONS OF IGNITION SWITCH
(a) The type of ignition switch used on this model differs
according to the specifications of the vehicle.
The expressions listed in the table below are used
in this section.
Switch Type Ignition Switch (position) Engine Switch (condition)
Ignition Switch off LOCK Off
Ignition Switch on (IG) ON On (IG)
Expression
Ignition Switch on (ACC) ACC On (ACC)
Engine Start START Start

CH
 CH–2 2GR-FE CHARGING – CHARGING SYSTEM

PARTS LOCATION

COMBINATION METER

ECM

INSTRUMENT PANEL J/B

- IG1 RELAY

ENGINE ROOM R/B AND ENGINE ROOM J/B

- IG2 RELAY

CH

GENERATOR

A114598E01
 2GR-FE CHARGING – CHARGING SYSTEM CH–3

SYSTEM DIAGRAM
w/o Smart Key System:
Engine Room J/B
A42
10 J/C
6
L L L
A1 1H MICON
12 13
E2
Combination
meter
Driver Side J/B Instrument Panel J/B

11 4 1 10
B G O
DH DC IF ID
2
4 15 12 GAUGE NO. 2 7
10 R G V
DH DA IG II
13
10 IG1 Relay 9
W-B G
IF II
1 2
D30 Ignition SW
4 B6 J/C
2 2 6 16 GAUGE NO. 1 AM1 4
L Y BR O
IG B6 B48 D47 IH II
Gen- 3 5 2 AM1 IG1 4
erator 1
IA

Engine Room R/B & J/B

1 120A ALT 1
B B5
B
1 1A
B
C2 10
CH
1 13 ALT-S
G-R W 1
S B6 A2 2 1
3 ST/AM2
B B
C3 1
7
IG2
AM2 Y
1 2
D30 1
IG2 Relay
Ignition SW W
1 1
IG2 5 3
11
6 Y GR
C2 1 1
1 2
1 Short Pin ECU-B
W
1F 2 1 2 1
1
FL MAIN
W-B W-B
W-B

M J Battery
C

C A128060E01
 CH–4 2GR-FE CHARGING – CHARGING SYSTEM

w/ Smart Key System:

Engine Room J/B

A42
J/C 6
10
L L L
A1 1H MICON
12 13

Generator B6 4
L 1
W
B B5
1 13 Instrument Panel J/B
G-R W
S B6 A2
6 GAUGE No. 1 IG1 1
2 2 16
Y B48 BR B
IG B6 D47 IH IA
3 5
J/C 9 10
LG W-B
II IF
E2 2 1
Driver Side J/B
Combination Meter
11 4 1 10
LG B G O
DH DC IF ID
2 GAUGE No. 2
4 15 12 7
R G V
DH DA IG II
13
10

Engine Room R/B and J/B 10 C2

D44
Ignition Control ECU
CH Y
IG2
W
1 5 1
IG1D 3
34 11
Y O W-B
IG2D C2 1 1
35 1 2
Short Pin ECU-B
W-B O
1
1 2 1 2
IG2 ALT-S
Y W
1 1
2 1 1 2
FL MAIN 1 ALT 1
B B
1F 1A

W
1

Battery
M C J

C A128061E01
 2GR-FE CHARGING – CHARGING SYSTEM CH–5

ON-VEHICLE INSPECTION
CAUTION:
If the battery is weak or if the engine is difficult to start,
recharge the battery and perform inspections again
before returning the vehicle to the customer.
1. CHECK BATTERY CONDITION
(a) Check the battery for damage and deformation. If
severe damage, deformation or leakage is found,
replace the battery.
(b) Check the electrolyte quantity of each cell.
For batteries that are maintenance-free:
– If the electrolyte quantity is below the
recommended amount, replace the battery.
For batteries that are not maintenance-free:
– If the electrolyte quantity is below the
recommended amount, add distilled water.
2. CHECK BATTERY TERMINALS, FUSIBLE LINK AND
FUSES
(a) Check that the battery terminals are not loose or
corroded.
If the terminals are corroded, clean the terminals.
(b) Check that the resistance of the fusible link, H-fuse
and fuses is below 1 Ω.
If the fusible link or fuses are not as specified,
replace the past.
3. INSPECT DRIVE BELT
REPLACE BELT (a) Check the belt for wear, cracks and other signs of
damage.
If any defect is found, replace the drive belt.
HINT: CH
Replace the drive belt if any of the following defects
are found:
• The belt has worn out until the wire can be seen.
• The cracks reach the wire in more than one
B000543E09 place.
• The belt has chunks missing from the ribs.
(b) Check that the belt fits properly in the ribbed
grooves.
HINT:
Confirm that the belt has not slipped out of the
groove on the bottom of the pulley by hand.
4. VISUALLY CHECK GENERATOR WIRING
CORRECT INCORRECT
(a) Check that the wiring is in good condition.
5. CHECK FOR ABNORMAL NOISES FROM
B075171E09 GENERATOR
(a) Check that there is no abnormal noise from the
generator while the engine is running.
6. INSPECT CHARGE WARNING LIGHT CIRCUIT
(a) Turn the ignition switch on (IG). Check that the
charge warning light comes on.
 CH–6 2GR-FE CHARGING – CHARGING SYSTEM

(b) Start the engine and check that the light goes off.
If the light does not operate as specified,
troubleshoot the charge warning light circuit.
7. INSPECT CHARGING CIRCUIT WITHOUT LOAD
HINT:
If a battery / generator tester is available, connect the
tester to the charging circuit according to the
manufacturer's instructions.
(a) If a tester is not available, connect a voltmeter and
Ammeter Disconnect Wire
ammeter to the charging circuit as follows:
from Terminal B
(1) Disconnect the wire from terminal B of the
generator and connect it to the negative (-) lead
of the ammeter.
(2) Connect the ammeter's positive (+) lead to
terminal B of the generator.
Generator (3) Connect the voltmeter's positive (+) lead to
Battery Voltmeter terminal B of the generator.
A091071E06 (4) Ground the voltmeter's negative (-) lead.
(b) Check the charging circuit.
(1) Keep the engine speed at 2,000 rpm. Check
the reading on the ammeter and voltmeter.
Standard amperage:
10 A or less
Standard voltage:
13.2 to 14.8 V
If the result is not as specified, replace the
generator.
8. INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn on the
CH high beam headlights and turn the heater blower
switch to the HI position.
(b) Check the reading on the ammeter.
Standard amperage:
30 A or more
HINT:
• If the ammeter reading is less than the standard
amperage, repair the generator.
• If the battery is fully charged, the ammeter
reading will sometimes be less than the standard
amperage.
 2GR-FE CHARGING – GENERATOR CH–7

GENERATOR
2GR-FE CHARGING
ENGINE

COMPONENTS

GENERATOR ROTOR ASSEMBLY

GENERATOR DRIVE BEARING RETAINER

END FRAME

GENERATOR WITH
CLUTCH PULLEY

x4
110 (1,125, 81)
*87 (891, 64) GENERATOR
WASHER

2.3 (23, 20 in.*lbf)

GENERATOR DRIVE END FRAME BEARING

GENERATOR PULLEY CAP

GENERATOR BRUSH HOLDER ASSEMBLY

CH
GENERATOR REAR END COVER

TERMINAL INSULATOR

x3
x2

1.8 (18, 16 in.*lbf) 4.6 (47, 41 in.*lbf)

x4

5.8 (59, 51 in.*lbf)

GENERATOR COIL ASSEMBLY

N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part * For use with SST
A114599E02
 CH–8 2GR-FE CHARGING – GENERATOR

FAN AND GENERATOR V BELT

9.8 (100, 87 in.*lbf)

43 (438, 32)

GENERATOR ASSEMBLY

43 (438, 32)

CH

N*m (kgf*cm, ft.*lbf) : Specified torque

A114559E03
2GR-FE CHARGING – GENERATOR CH–9

REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2. REMOVE V-BANK COVER SUB-ASSEMBLY (See
page FU-12)
3. REMOVE FAN AND GENERATOR V BELT (See page
EM-28)
4. REMOVE GENERATOR ASSEMBLY
(a) Disconnect the wire harness clamp.

A128062

(b) Remove the terminal cap.

(c) Remove the nut and disconnect the wire harness
from terminal B.
(d) Disconnect the generator connector from the
generator assembly.

A128063

(e) Remove the nut from the cylinder block. CH

A128064

(f) Remove the 2 bolts and generator assembly.

A128065
 CH–10 2GR-FE CHARGING – GENERATOR

(g) Remove the bolt and wire harness clamp stay.

A128066

(h) Remove the bolt and bracket.

A128067

DISASSEMBLY
1. REMOVE GENERATOR WITH CLUTCH PULLEY
(a) Using a screwdriver, remove the generator pulley
cap.

CH A128068

(b) Set SST (A) and (B).

SST 09820-63020
(1) Set the rotor shaft to SST (A).
SST (A) (2) Mount SST (A) in a vise.

SST (B)

A128069E01

(c) Install the generator with the SST as shown in the

illustration.
(d) Turn SST (B) clockwise, and loosen the generator
pulley.
(e) Remove the generator from SST.
(f) Remove the pulley from the rotor shaft.

SST (B)
Turn
A128070E01
 2GR-FE CHARGING – GENERATOR CH–11

2. REMOVE GENERATOR REAR END COVER

(a) Remove the 3 nuts and generator rear end cover.

A128071

3. REMOVE TERMINAL INSULATOR

(a) Remove the terminal insulator.

A128072

4. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY

(a) Remove the 2 screws and generator brush holder
assembly.

A128073
CH
5. REMOVE GENERATOR COIL ASSEMBLY
(a) Remove the 4 bolts.

A128074

(b) Using SST, remove the generator coil assembly.

SST SST 09950-40011 (09951-04020, 09952-04010,
09953-04020, 09954-04010, 09955-04071,
Turn 09957-04010, 09958-04011)
Hold (c) Remove the generator washer.
6. REMOVE GENERATOR ROTOR ASSEMBLY
(a) Remove the generator rotor assembly.

A128075E01
 CH–12 2GR-FE CHARGING – GENERATOR

7. REMOVE GENERATOR DRIVE END FRAME

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

A128076

(b) Using SST and a hammer, tap out the generator

drive end frame bearing.
SST 09950-60010 (09951-00250), 09950-70010
SST (09951-07100)

A128077E01

INSPECTION
1. INSPECT GENERATOR WITH CLUTCH PULLEY
Free Lock (a) When rotating the generator pulley, check that it
turns counterclockwise and does not turn clockwise.

CH A128078E01

2. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY

(a) Using vernier calipers, measure the exposed brush
length.
Length Standard exposed length:
10.5 mm (0.413 in.)
Minimum exposed length:
4.5 mm (0.177 in.)
If the exposed length is less than the minimum,
replace the generator brush holder assembly.
A128079E01

3. INSPECT GENERATOR ROTOR ASSEMBLY

(a) Check that the generator rotor bearing is not rough
or worn.
If necessary, replace the generator rotor.

A079306E02
 2GR-FE CHARGING – GENERATOR CH–13

(b) Check the generator rotor for an open circuit.

Ohmmeter
(1) Using an ohmmeter, measure the resistance
between the slip rings.
Standard resistance:
2.3 to 2.7 Ω at 20°C (68°F)
If the result is not as specified, replace the
generator rotor assembly.

B012264E06

(c) Check the generator rotor for a short circuit.

Ohmmeter (1) Using an ohmmeter, measure the resistance
between the each slip ring and rotor.
Standard resistance:
1 MΩ or higher
If the result is not as specified, replace the
generator rotor assembly.

B012265E05

(d) Using vernier calipers, measure the slip ring

diameter.
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.

A075676E07
CH
4. INSPECT GENERATOR DRIVE END FRAME
BEARING
(a) Check the generator drive end frame bearing is not
rough or worn.
If necessary, replace the generator drive end frame
bearing.

A128080

REASSEMBLY
1. INSTALL GENERATOR DRIVE END FRAME
SST
BEARING
(a) Using SST and a press, press in a new generator
drive end frame bearing.
SST 09950-60010 (09951-00470), 09950-70010
(09951-07100)

A128081E01
 CH–14 2GR-FE CHARGING – GENERATOR

(b) Install the bearing retainer with the 4 screws.

Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf)
2. INSTALL GENERATOR ROTOR ASSEMBLY
(a) Install the generator rotor assembly and generator
washer to the drive end frame.

A128076

3. INSTALL GENERATOR COIL ASSEMBLY

Deep socket
(a) Using deep socket wrench (21 mm) and a press,
wrench (21 mm)
slowly press in the generator coil assembly.

A128082E01

(b) Install the 4 bolts.

Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf)

CH A128074

4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

Pin (a) While pushing the 2 brushes to the inside of the
generator brush holder assembly, insert a φ1.0 mm
(0.039 in.) pin into the generator brush holder hole.

A079315E07

(b) Install the brush holder assembly with the 2 screws.

Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf)
(c) Remove the pin from the brush holder assembly.

Pin

A079316E02
 2GR-FE CHARGING – GENERATOR CH–15

5. INSTALL TERMINAL INSULATOR

(a) Install the terminal insulator.
NOTICE:
Pay attention to installation direction of the
terminal insulator.

A128083

6. INSTALL GENERATOR REAR END COVER

(a) Install the end cover with the 3 nuts.
Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)

A128071

7. REMOVE GENERATOR WITH CLUTCH PULLEY

(a) Set SST (A) and (B).
SST 09820-63020
SST (A) (1) Set the rotor shaft to SST (A).
(2) Mount SST (A) in a vise.

SST (B)
A128084E01
CH
(b) Install the generator with the SST as shown in the
illustration.
(c) Turn SST (B) counterclockwise, and tighten the
generator pulley.
SST 09820-63020
Torque: 87 N*m (891 kgf*cm, 64 ft.*lbf)
NOTICE:
Use a torque wrench with a fulcrum length of
380 mm (14.96 in.).
Turn SST (B)
A128085E01 (d) Remove the generator from the SST.
NOTICE:
Check that the generator pulley rotates
smoothly.
(e) Install a new generator pulley cap.
 CH–16 2GR-FE CHARGING – GENERATOR

INSTALLATION
1. INSTALL GENERATOR ASSEMBLY
(a) Install the bracket with the bolt.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
(b) Install the wire harness clamp stay.
Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
(c) Install the generator assembly with the 2 bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
(d) Install the nut to the cylinder block.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
(e) Connect the generator connector to the generator
assembly.
(f) Install the generator wire with the nut.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
(g) Install the terminal cap.
(h) Connect the wire harness clamp.
2. INSTALL FAN AND GENERATOR V BELT (See page
EM-46)
3. INSTALL V-BANK COVER SUB-ASSEMBLY (See
page FU-19)
4. CONNECT BATTERY NEGATIVE TERMINAL
5. PERFORM INITIALIZATION
(a) Some systems need initialization when
disconnecting the battery terminal.

CH