CH–6

CHARGING SYSTEM – Generator

GENERATOR
REMOVAL OF GENERATOR (4A–FE)

1. DISCONNECT CABLE FROM NEGATIVE TERMINAL

OF BATTERY
CAUTION: Work must be started after approx. 20
seconds or longer from the time the ignition switch is
turned to the “LOCK” position and the negative (–) ter–
minal cable is disconnected from the battery.
2. REMOVE DRIVE BELT
Loosen the pivot nut and adjusting bolt, and remove the
drive belt.

3. REMOVE GENERATOR
(a) Disconnect the generator connector.
(b) Remove the nut, and disconnect the generator
wire.
(C) Remove the pivot nut, bolt, adjusting bolt and
generator.
 CH–7
CHARGING SYSTEM – Generator

REMOVAL OF GENERATOR (3S–GTE)

1. DISCONNECT CABLE FROM NEGATIVE TERMINAL

OF BATTERY
CAUTION: Work must be started after approx. 20
seconds or longer from the time the ignition switch is
turned to the “LOCK” position and the negative (–) ter–
minal cable is disconnected from the battery.
2. DISCONNECT ABS CONTROL RELAY FROM
RADIATOR
3. DISCONNECT A/C RELAY BOX FROM BRACKET
4. REMOVE NO.2 GENERATOR DUCT
5. REMOVE DRIVE BELT
(a) Loosen the idler pulley bolt.
(b) Loosen the adjusting bolt, and remove the drive
belt.
CH–8
CHARGING SYSTEM – Generator

6. DISCONNECT ENGINE WIRE

(a) Disconnect the following connectors and wires:
• Generator connector from lead wire
• Generator wire
• A/C compressor connector
• Engine coolant temperature switch connector
• Oxygen sensor wire clamp from No.1 generator
duct
• Oxygen sensor connector
• Oxygen sensor connector (wiring harness side)
from No.1 generator duct
(b) Remove the two bolts, and disconnect the ground
strap and engine wire from the brackets.

7. REMOVE NO.2 GENERATOR BRACKET

Remove the two bolts and generator bracket.
8. REMOVE ABS ACTUATOR COVER

9. REMOVE GENERATOR
Remove the two bolts and generator.

10. REMOVE NO.1 GENERATOR DUCT

(a) Remove the two nuts and generator duct.
(b) Remove the generator lead wire.
 CH–9
CHARGING SYSTEM – Generator

REMOVAL OF GENERATOR (5S–FE)

1. DISCONNECT CABLE FROM NEGATIVE TERMINAL

OF BATTERY
CAUTION: Work must be started after approx. 20
seconds or longer from the time the ignition switch is
turned to the “LOCK” position and the negative (–) ter–
minal cable is disconnected from the battery.
2. REMOVE DRIVE BELT
(a) Loosen the pivot bolt and adjusting lock bolt.
(b) Loosen the adjusting bolt, and remove the drive
belt.
3. REMOVE GENERATOR
(a) Disconnect the generator connector.
(b) Remove the nut, and disconnect the generator
wire.
(c) Remove the pivot bolt, adjusting lock bolt and
generator.
CH–10
CHARGING SYSTEM – Generator

COMPONENTS
 CH–11
CHARGING SYSTEM – Generator

COMPONENTS (Cont’d)
CH–12
CHARGING SYSTEM – Generator

DISASSEMBLY OF GENERATOR
4A–FE (See page CH–10)
3S–GTE and 5S–FE (See page CH–11)
1. REMOVE REAR END COVER
(a) Remove the nut and terminal insulator.

(b) Remove the three nuts and end cover.

2. REMOVE BRUSH HOLDER AND IC REGULATOR

(a) (M/T (3S–GTE) and A/T)
Remove the brush holder cover from the brush
holder.

(b) Remove the five screws, brush holder and IC regu-

lator.
 CH–13
CHARGING SYSTEM – Generator

3. REMOVE RECTIFIER HOLDER

(a) Remove the four screws and rectifier holder.

(b) Remove the four rubber insulators.

(c) (M/T (3S–GTE) and A/T)

Remove the seal plate.

4. REMOVE PULLEY
(a) Hold SST (A) with a torque wrench, and tighten
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.

(c) As shown in the illustration, mount SST (C) in a

vise, and install the generator to SST (C).
(d) To loosen the pulley nut, turn SST (A) in the direc–
tion shown in the illustration.
NOTICE: To prevent damage to the rotor shaft, do not
loosen the pulley nut more than one–half of a turn.
(e) Remove the generator from SST (C).
(f) Turn SST (B) and remove SST (A and B).
(g) Remove the pulley nut and pulley.
CH–14
CHARGING SYSTEM – Generator

5. REMOVE RECTIFIER END FRAME

(a) Remove the four nuts.

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

SST 09286–46011

(c) (M/T (3S–GTE) and A/T)

Remove the thrust washer.

6. REMOVE ROTOR FROM DRIVE END FRAME

 CH–15
CHARGING SYSTEM – Generator

INSPECTION AND REPAIR OF GENERATOR

Rotor
1. INSPECT ROTOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity be–
tween the slip rings.
Standard resistance (Cold): 2.8 – 3.0

If there is no continuity, replace the rotor.

2. INSPECT ROTOR FOR GROUND

Using an ohmmeter, check that there is no continuity
between the slip ring and rotor.
If there is continuity, replace the rotor.

3. INSPECT SLIP RINGS

(a) Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor.
(b) Using a vernier caliper, 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.

Stator (Drive End Frame)

1. INSPECT STATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
coil leads.
If there is no continuity, replace the drive end frame as–
sembly.

2. INSPECT STATOR FOR GROUND

Using an ohmmeter, check that there is no continuity
between the coil lead and drive end frame.
If there is continuity, replace the drive end frame assembly.
CH–16
CHARGING SYSTEM – Generator

Brushes
1. INSPECT EXPOSED BRUSH LENGTH
Using a vernier caliper or scale, 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 (M/T (4A–FE and 5S–FE)) or brushes and brush
holder assembly (M/T (3S–GTE) and A/T).

2. (M/T (4A–FE AND 5S–FE))

IF NECESSARY, 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.

(c) Solder the brush wire to the brush holder at speci–

fied exposed length.
Exposed length: 10.5 mm (0.413 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.

Rectifiers (Rectifier Holder)

1. INSPECT POSITIVE RECTIFIER
(a) Using an ohmmeter, connect one tester probe to the
positive (+) terminal and the other to each rectifier
terminal.
(b) Reverse the polarity of the tester probes and repeat
step (a).
(c) Check that one shows continuity and the other
shows no continuity.
If continuity is not as specified, replace the rectifier
holder.
 CH–17
CHARGING SYSTEM – Generator

2. INSPECT NEGATIVE RECTIFIER

(a) Using an ohmmeter, connect one tester probe to
each negative (–) terminal and the other to each
rectifier terminal.
(b) Reverse the polarity of the tester probes and repeat
step (a).
(c) Check that one shows continuity and the other
shows no continuity.
If continuity is not as specified, replace the rectifier
holder.

Bearings
1. INSPECT FRONT BEARING
Check that the bearing is not rough or worn.

2. IF NECESSARY, REPLACE FRONT BEARING

(a) Remove the four screws, bearing retainer and bear–
ing.
CH–18
CHARGING SYSTEM – Generator

(b) Using socket wrench and press, press out the bear–
ing.

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

SST 09608–20012 (09608–00030)
(d) Install the bearing retainer with the four screws.

3. INSPECT REAR BEARING

Check that the bearing is not rough or worn.

4. IF NECESSARY, REPLACE REAR BEARING

(a) Using SST, remove the bearing covers and bearing.
SST 09820–00021
NOTICE: Be careful not to damage the fan.
(b) Place the bearing cover on the rotor.

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

SST 09820–00030
 CH–19
CHARGING SYSTEM – Generator

(d) Using SST, push in the bearing cover.

SST 09285–76010

ASSEMBLY OF GENERATOR
4A–FE (See page EM–10 )
3S–GTE and 5S–FE (See page EM–11)
1. INSTALL ROTOR TO RECTIFIER END FRAME
(a) Place the rectifier end frame on the pulley.
(b) Install the rotor to the rectifier end frame.

2. INSTALL RECTIFIER END FRAME

(a) (M/T (3S–GTE) and A/T)
Place the thrust washer on the rotor.

(b) Using a 29 mm socket wrench and press, slowly

press in the rectifier end frame.

(c) Install the four nuts.

CH–20
CHARGING SYSTEM – Generator

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

(d) As shown in the illustration mount SST (C) in a

vise, and install the generator to SST (C).
(e) To torque the pulley nut, turn SST (A) in the direc–
tion shown in the illustration.
Torque: 110 N–m (1,125 kgf–cm, 81 ft–lbf)
(f) Remove the generator from SST (C).
(g) Turn SST (B) and remove SST (A and B).

4. INSTALL RECTIFIER HOLDER

(a) (M/T (3S–GTE) and A/T)
Place the seal plate on the rectifier end frame.

(b) Install the four rubber insulators on the lead wires.

(c) Install the rectifier holder with the four screws.

 CH–21
CHARGING SYSTEM – Generator

5. INSTALL IC REGULATOR AND BRUSH HOLDER

(M/T (4A–FE and 5S–FE))
(a) Install the brush holder cover to the brush holder.
NOTICE: Be careful of the holder installation direc–
tion.
(b) Place the IC regulator together with the brush
holder horizontally on the rectifier end frame.

(c) Install the five screws until there is a clearance of

approx. 1 mm (0.04 in.) between the brush holder
and connector.

(d) Fit the brush holder cover.

(M/T (3S–GTE) and A/T)

(a) Place the IC regulator and brush holder on the recti–
fier end frame.
NOTICE: Be careful of the holder installation direc–
tion.
(b) Install the five screws until there is a clearance of
approx. 1 mm (0.04 in.) between the brush holder
and connector.

(c) Place the brush holder cover on the brush holder.

CH–22
CHARGING SYSTEM – Generator

6. INSTALL REAR END COVER

(a) Install the end cover with the three nuts.

(b) Install the terminal insulator with the nut.

7. CHECK THAT ROTOR ROTATES SMOOTHLY

 CH–23
CHARGING SYSTEM – Generator

INSTALLATION OF GENERATOR (4A–FE)

(See page CH–6)
1. INSTALL GENERATOR
(a) Mount the generator on the generator brackets
with the pivot bolt, nut and adjusting bolt. Do not
tighten the bolt and nut yet.
(b) Connect the generator connector.
(c) Connect the generator wire with the nut.
2. INSTALL DRIVE BELT
Adjust the drive belt tension.
(See step 3 on page CH–3)
Drive belt tension: New belt 160 ±20 lbf
Used belt 130 ±20 lbf
3. CONNECT CABLE TO NEGATIVE TERMINAL OF
BATTERY
4. PERFORM ON–VEHICLE INSPECTION
(See steps 5 to 7 on pages CH–4 to 5)

INSTALLATION OF GENERATOR (3S–GTE)

(See page CH–7)
1. INSTALL NO.7 GENERATOR DUCT
(a) Install the generator lead wire.
(b) Remove the generator duct with the two nuts.

2. INSTALL GENERATOR
Install the generator with the two bolts.
Torque:
12 mm head bolt 19 N–m (195 kgf–cm, 14 ft–lbf)
14 mm head bolt 52 N–m (530 kgf–cm, 38 ft–Ibf)
3. INSTALL ABS ACTUATOR COVER

4. INSTALL NO.2 GENERATOR BRACKET

Install the generator bracket with the two bolts.
Torque:
To turbine outlet elbow
43 N–m (440 kgf–cm, 32 ft–lbf)
To No.1 generator bracket
39 N–m (400 kgf–cm, 29 ft–lbf)
CH–24
CHARGING SYSTEM – Generator

5. INSTALL ENGINE WIRE

(a) Install the engine wire and ground strap with the
two bolts.
(b) Connect the following connectors and wires:
• Generator connector from lead wire
• Generator wire
• A/C compressor connector
• Engine coolant temperature switch connector
• Oxygen sensor wire clamp from No.1 generator
duct
• Oxygen sensor connector
• Oxygen sensor connector (wiring harness side)
from No.1 generator duct

6. INSTALL DRIVE BELT

Adjust the drive belt tension.
(See step 3 on page CH–2)
Drive belt tension:
w/ A/C New belt 165 ± 10 lbf
Used belt 115 ± 20 lbf
w/o A/C New belt 150 ± 25 lbf
Used belt 130 ± 25 lbf
7. INSTALL A/C RELAY BOX TO BRACKET
8. INSTALL ABS CONTROL RELAY TO RADIATOR
9. INSTALL NO.2 GENERATOR DUCT
10. CONNECT CABLE TO NEGATIVE TERMINAL OF
BATTERY
11. PERFORM ON–VEHICLE INSPECTION
(See steps 5 to 7 on pages CH–4 and 5)
 CH–25
CHARGING SYSTEM – GENERATOR

INSTALLATION OF GENERATOR (5S–FE)

(See page CH–9)
1. INSTALL GENERATOR
(a) Mount the generator on the generator brackets
with the pivot bolt and adjusting lock bolt. Do not
tighten the bolts yet.
(b) Connect the generator connector.
(c) Connect the generator wire with the nut.

2. INSTALL DRIVE BELT

Adjust the drive belt tension.
(See step 3 on page CH–3)
Drive belt tension:
w/ A/C New belt 165 ± 10 lbf
Used belt 110 ± 10 lbf
w/o A/C New belt 125 ± 25 lbf
Used belt 95 ± 20 lbf

3. CONNECT CABLE TO NEGATIVE TERMINAL OF

BATTERY
4. PERFORM ON–VEHICLE INSPECTION
(See steps 5 to 7 on pages CH–4 to 5)