CH−1

CHARGING (2UZ−FE) − CHARGING SYSTEM

CHARGING SYSTEM CH0J6−03

ON−VEHICLE INSPECTION
CAUTION:

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

Disconnect the battery cables when the battery is giv-
en a quick charge.

Do not perform tests with a high voltage insulation re-
sistance tester.

Never disconnect the battery while the engine is run-
ning.

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1. CHECK BATTERY ELECTROLYTE LEVEL
Check the electrolyte quantity of each cell.
Upper Level Maintenance−Free Battery:
If under the lower level, replace the battery (or add distilled wa-
ter if possible) and check the charging system.
Except Maintenance−Free Battery:
If under the lower level, add distilled water.
Lower Level

B07241

Except Maintenance−Free Battery 2. Except Maintenance−Free Battery:

CHECK BATTERY SPECIFIC GRAVITY
Check the specific gravity of each cell.
Standard specific gravity: 1.25 to 1.29 at 20°C (68°F)
If the specific gravity is less than specification, charge the bat-
tery.
3. Maintenance−Free Battery:
CHECK BATTERY VOLTAGE
B07242 (a) After having driven the vehicle and in the case that 20
minutes have not passed after having stopped the en-
gine, turn the ignition switch ON and turn on the electrical
system (headlight, blower motor, rear defogger etc.) for
60 seconds to remove the surface charge.
(b) Turn the ignition switch OFF and turn off the electrical sys-
tems.
CH−2
CHARGING (2UZ−FE) − CHARGING SYSTEM

Maintenance−Free Battery (c) Measure the battery voltage between the negative (−)
Voltmeter 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 specification, charge the battery.

B07243

Maintenance−Free Battery HINT:

Check the indicator as shown in the illustration.
CLEAR EYE or
GREEN EYE DARK EYE LIGHT YELLOW
4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND
FUSES
CHARGED DISCHARGED ADD WATER
(a) Check that the battery terminals are not loose or cor-
roded.
(b) Check the fusible link and fuses for continuity.

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5. INSPECT DRIVE BELT
P14937 HINT:
A belt tensioner is used, so checking the belt tension is not nec-
essary.

(a) Visually check the drive belt for excessive wear, frayed
cords etc.
If necessary, replace the drive belt.
HINT:

Cracks on the rib side of a drive belt are considered ac-
ceptable. If the drive belt has chunks missing from the
ribs, it should be replaced.

The drive belt tension can be released by turning the belt
Z00030 tensioner counterclockwise. The pulley bolt for the belt
tensioner has a left−hand thread.
(b) Check the belt tensioner operation.

Check that the belt tensioner moves downward
when the drive belt is pressed down at the points in-
dicated in the illustration with approx. 98 N (10 kgf,
22.0 lbf) of force.

Check the alignment of the belt tensioner pulley to
make sure the drive belt has not slipped off the
pulley.
B00807 If necessary, replace the belt tensioner.
 CH−3
CHARGING (2UZ−FE) − CHARGING SYSTEM

A
Check that the arrow mark on the belt tensioner falls

B within area A of the scale.
If it is outside area A, replace the drive belt.
HINT:

When a new belt is installed, it should lie within area B. If
not, the drive belt is not correct.

B00808

After installing a belt, check that it fits properly in the

ribbed grooves.

Check by hand to confirm that the belt has not slipped out
of the groove on the bottom of the pulley.
6. REMOVE ENGINE UNDER COVER
7. VISUALLY CHECK GENERATOR WIRING AND LIS-
CORRECT WRONG TEN FOR ABNORMAL NOISES

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(a) Check that the wiring is in good condition.
AC2024 (b) Check that there is no abnormal noise from the generator
while the engine is running.
8. CHECK CHARGE WARNING LIGHT CIRCUIT
(a) Warm up the engine and then turn it off.
(b) Switch off all accessories.
(c) Turn the ignition switch ON, and check that the charge
warning light is lit.
(d) Start the engine, and check that the light goes off.
If the light does not go off as specified, troubleshoot the charge
light circuit.

Ammeter 9. INSPECT CHARGING CIRCUIT WITHOUT LOAD

HINT:
Disconnect Wire
from Terminal B 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:

Disconnect the wire from terminal B of the genera-
Generator
Voltmeter tor, and connect it to the negative (−) tester probe
Z03473 of the ammeter.

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:
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: 13.2 − 14.8 V
CH−4
CHARGING (2UZ−FE) − CHARGING SYSTEM

If the voltmeter reading is more than standard voltage, replace

the voltage regulator.
If the voltmeter reading is less than standard voltage, check the
voltage regulator and generator.
10. 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.
11. REINSTALL ENGINE UNDER COVER

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 CH−5
CHARGING (2UZ−FE) − GENERATOR (Standard Spec.)

GENERATOR (Standard Spec.)

COMPONENTS CH0LL−02

Throttle Body Cover

PS Vane Pump

39 (400, 29)
Terminal Cap

Generator Connector

Intake Air Connector

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39 (400, 29)

Generator Wire

Wire Clamp

Generator
39 (400, 29)

39 (400, 29)

Drive Belt

Engine Under Cover (4WD) Engine Under Cover (2WD)

x5

N·m (kgf·cm, ft·lbf) : Specified torque B16525

CH−6
CHARGING (2UZ−FE) − GENERATOR (Standard Spec.)

Rotor Assembly

Drive End Frame Assembly (Stator)

Pulley

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110.5 (1,125, 81)

Brush Holder

Terminal Insulator

Rectifier Holder
(Rectifier)

Seal Plate
Plate Terminal
Rear End Cover
Brush Holder Cover

Voltage Regulator

Rectifier End Frame

Rubber Insulator

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

Non−reusable part B16590
 CH−7
CHARGING (2UZ−FE) − GENERATOR (Standard Spec.)
CH0LM−02

REMOVAL
1. REMOVE ENGINE UNDER COVER
2. REMOVE THROTTLE BODY COVER
3. DISCONNECT CABLE FROM NEGATIVE (−) BATTERY
TERMINAL
4. DISCONNECT INTAKE AIR CONNECTOR FROM
THROTTLE BODY

5. REMOVE GENERATOR DRIVE BELT

Loosen the belt tension by turning the belt tensioner counter-
clockwise, and remove the drive belt.
HINT:
The pulley bolt for the belt tensioner has a left hand thread.
6. REMOVE PS VANE PUMP FROM ENGINE (See page
Turn SR−61)

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7. REMOVE GENERATOR
B00809 (a) Disconnect the generator connector.
(b) Remove the terminal cap and nut, and disconnect the
generator wire.
(c) Disconnect the wire clamp from the cord clip on the gener-
ator.
(d) Remove the bolt, nut and generator.
CH−8
CHARGING (2UZ−FE) − GENERATOR (Standard Spec.)
CH0LN−01

DISASSEMBLY
1. REMOVE REAR END COVER
(a) Remove the nut and terminal insulator.
(b) Remove the bolt 3 nuts, plate terminal and end cover.
(c) Remove the brush holder cover from the brush holder.

B16510

2. REMOVE BRUSH HOLDER

(a) Remove the 2 screws and brush holder.
(b) Remove the seal plate from the rectifier end frame.

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B16392

3. REMOVE VOLTAGE REGULATOR AND RECTIFIER

HOLDER
(a) Remove the 3 screws and voltage regulator.

B16393

(b) Remove the 4 screws and rectifier holder.

(c) Remove the 4 rubber insulators.

B12164

4. REMOVE PULLEY
(a) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
SST 09820−63011
Turn SST (A) Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Check that SST (A) is secured to the rotor shaft.

SST (B)
P13597
 CH−9
CHARGING (2UZ−FE) − GENERATOR (Standard Spec.)

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

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

SST (C) Insert

P10834

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

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Turn P10827

Turn (g) Turn SST (B), and remove SST (A and B).
(h) Remove the pulley nut and pulley.

SST (A)

SST (B)
P13598

5. REMOVE RECTIFIER END FRAME

(a) Remove the 4 nuts.

B16527

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

SST 09286−46011
(c) Remove the generator washer from the rectifier end
SST frame.
6. REMOVE ROTOR FROM DRIVE END FRAME

B04568
CH−10
CHARGING (2UZ−FE) − GENERATOR (Standard Spec.)
CH0LO−02

INSPECTION
1. INSPECT VOLTAGE REGULATOR
(a) Using an ohmmeter, check the continuity between termi-
nals F and B.
Standard:
When the positive and negative poles between termi-
nals F and B are exchanged, there is continuity in one
way but no continuity in another way.
B16396
If the continuity is not as specified, replace the regulator.

(b) Using an ohmmeter, check the continuity between termi-

nals F and E.
Standard:
When the positive and negative poles between termi-
nals F and E are exchanged, there is continuity in one
way but no continuity in another way.
If the continuity is not as specified, replace the regulator.

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B16397

2. INSPECT ROTOR FOR OPEN CIRCUIT

(a) Check the rotor for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the slip rings.
Ohmmeter Standard resistance: 2.1 to 2.5 Ω at 20°C (68°F)
If there is no continuity, replace the rotor.

Continuity
CH0784

(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

No Continuity
B02105

(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 diameters.
Standard diameter: 14.2 to 14.4 mm (0.559 to 0.567 in.)
Minimum diameter: 12.8 mm (0.504 in.)
If the diameter is less than minimum, replace the rotor.

CH1023
 CH−11
CHARGING (2UZ−FE) − GENERATOR (Standard Spec.)

3. INSPECT STATOR FOR OPEN CIRCUIT

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

CH0806

Ohmmeter (b) Check the stator for ground.

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

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B00102

Ohmmeter
4. INSPECT POSITIVE RECTIFIER
(a) Check the positive (+) rectifire.
(1) Using an ohmmeter, connect one tester probe to the
positive (+) terminal and the other to each rectifier
terminal.
Positive (+)
Terminal (2) Reverse the polarity of the tester probes and repeat
Rectifier step (a).
Terminal (3) Check that one shows continuity and the other
B05819 shows no continuity.
If continuity is not as specified, replace the rectifier holder.
(b) Check the negative (−) rectifire.
Ohmmeter Negative (−)
(1) Using an ohmmeter, connect one tester probe to
Terminal
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 EXPOSED BRUSH LENGTH

Using vernier calipers, measure the exposed brush length.
Standard exposed length:
Length 9.5 to 11.5 mm (0.374 to 0.453 in.)
Minimum exposed length: 1.5 mm (0.059 in.)
If the exposed length is less than minimum, replace the brush
holder assembly.

P13535
CH−12
CHARGING (2UZ−FE) − GENERATOR (Standard Spec.)

6. INSPECT BEARING
Check that the bearing is not rough or worn.
If necessary, replace the drive end frame assembly (front bear-
ing) or rotor assembly (rear bearing).

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 CH−13
CHARGING (2UZ−FE) − GENERATOR (Standard Spec.)
CH0LP−01

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

N00556

3. INSTALL RECTIFIER END FRAME

(a) Place the generator washer on the rotor.

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CH1030

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

29 mm
Socket
the rectifier end frame.
Wrench

B04530

(c) Install the 4 nuts.

Torque: 4.5 N·m (46 kgf·cm, 39 in.·lbf)

B16527

4. INSTALL PULLEY
(a) Install the pulley to the rotor shaft by tightening the pulley
nut by hand.
Turn
(b) Hold SST (A) with a torque wrench, and tighten SST (B)
SST (A) clockwise to the specified torque.
SST 09820−63011
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(c) Check that SST (A) is secured to the pulley shaft.
SST (B)
P13597
CH−14
CHARGING (2UZ−FE) − GENERATOR (Standard Spec.)

(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

(f) To torque the pulley nut, turn SST (A) in the direction
shown in the illustration.
Torque: 110.5 N·m (1,125 kgf·cm, 81 ft·lbf)
SST (C)
(g) Remove the generator from SST (C).

Turn
SST (A)

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P04395

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

SST (A)

SST (B)
P13598

5. INSTALL RECTIFIER HOLDER

Inside (a) Install the 4 rubber insulators on the lead wires.
NOTICE:
Be careful of the rubber insulators installation direction.

B05860

(b) Install the rectifier while pushing it with the 4 screws.

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

B12750
 CH−15
CHARGING (2UZ−FE) − GENERATOR (Standard Spec.)

6. INSTALL BRUSH HOLDER AND VOLTAGE REGULA-

TOR
(a) Place the seal plate on the rectifier end frame.

B04532

(b) Place the voltage regulator and brush holder on the recti-
Upward
fier end frame.
NOTICE:
Be careful of the brush holder installation direction.
(c) Install the 5 screws.
Torque: 1.96 N·m (20 kgf·cm, 17 in.·lbf)

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B16394

7. INSTALL REAR END COVER

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

B16395

(b) Install the end cover and plate terminal with the bolt and
3 nuts.
Torque:
Bolt: 3.85 N·m (39 kgf·cm, 34 in.·lbf)
Nut: 4.4 N·m (46 kgf·cm, 39 in.·lbf)

B16391

(c) Install the terminal insulator with the nut.

Torque: 4.1 N·m (41.5 kgf·cm, 36 in.·lbf)
8. CHECK THAT ROTOR ROTATES SMOOTHLY

B16399
CH−16
CHARGING (2UZ−FE) − GENERATOR (Standard Spec.)
CH0LQ−02

INSTALLATION
1. INSTALL GENERATOR
(a) Install the generator with the bolt and nut.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Connect the generator connector.
(c) Connect the generator wire with the nut and rubber.
(d) Install the terminal cap.
(e) Install the wire clamp to the cord clip on the generator.
2. INSTALL PS VANE PUMP (See page SR−69)

3. INSTALL DRIVE BELT

Install the belt by turning the belt tensioner counterclockwise.
HINT:
The pulley bolt for the belt tensioner has a left−hand thread.
4. CONNECT INTAKE AIR CONNECTOR TO THROTTLE
BODY
Turn 5. PERFORM ON−VEHICLE INSPECTION

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(See page CH−1)
B00809 6. INSTALL THROTTLE BODY COVER
7. INSTALL ENGINE UNDER COVER
8. CONNECT CABLE TO NEGATIVE (−) BATTERY TER-
MINAL
 CH−17
CHARGING (2UZ−FE) − GENERATOR (Towing Package Spec.)

GENERATOR (Towing Package Spec.)

CH0LR−02

COMPONENTS

Throttle Body Cover

PS Vane Pump
39 (400, 29)
Terminal Cap

Generator Connector

Intake Air Connector

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39 (400, 29)
Generator Wire

Wire Clamp
39 (400, 29)

15.5 (158, 11)

Generator

39 (400, 29)

Drive Belt

Engine Under Cover (4WD) Engine Under Cover (2WD)

x5

N·m (kgf·cm, ft·lbf) : Specified torque B16356

CH−18
CHARGING (2UZ−FE) − GENERATOR (Towing Package Spec.)

Generator Washer

Rotor

Rear Bearing
Bearing Retainer

Drive End Frame (Stator)

Pulley Bearing Cover

Bearing Cover

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Front Bearing

110.5 (1,125, 81)

Terminal Insulator

Brush Holder

Seal Plate

Seal Plate

Rear End Cover

Rectifier End Frame

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

Non−reusable part B16514
 CH−19
CHARGING (2UZ−FE) − GENERATOR (Towing Package Spec.)
CH0LS−02

REMOVAL
1. REMOVE ENGINE UNDER COVER
2. REMOVE THROTTLE BODY COVER
3. DISCONNECT CABLE FROM NEGATIVE (−) BATTERY
TERMINAL
4. DISCONNECT INTAKE AIR CONNECTOR FROM
THROTTLE BODY

5. REMOVE GENERATOR DRIVE BELT

Loosen the belt tension by turning the belt tensioner counter-
clockwise, and remove the drive belt.
HINT:
The pulley bolt for the belt tensioner has a left−hand thread.
6. REMOVE PS VANE PUMP FROM ENGINE
Turn (See page SR−61)

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7. REMOVE GENERATOR
B00809 (a) Disconnect the generator connector.
(b) Remove the terminal cap and nut, and disconnect the
generator wire.
(c) Disconnect the wire clamp from the cord clip on the gener-
ator.
(d) Remove the bolt, 2 nuts and generator.
CH−20
CHARGING (2UZ−FE) − GENERATOR (Towing Package Spec.)
CH0LT−01

DISASSEMBLY
1. REMOVE REAR END COVER
(a) Remove the 3 nuts and end cover.
(b) Remove the terminal insulator.

B16513

2. REMOVE BRUSH HOLDER

(a) Remove the rear seal plate from the brush holder.
(b) Remove the 2 screws and brush holder.
(c) Remove the front seal plate from the coil assembly.

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B16362

3. REMOVE PULLEY
(a) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
SST 09820−63011
Turn SST (A) Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Check that SST (A) is secured to the rotor shaft.

SST (B)
B16520

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

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

B16524

(e) To loosen the pulley nut, turn SST (A) in the direction
SST (C) shown in the illustration.
NOTICE:
SST (A) To prevent damage to the rotor shaft, do not loosen the
pulley nut more than one−half of a turn.
Turn (f) Remove the generator from SST (C).

B16523
 CH−21
CHARGING (2UZ−FE) − GENERATOR (Towing Package Spec.)

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

Turn (h) Remove the pulley nut and pulley.

SST (A)

SST (B)
B16519

4. REMOVE COIL ASSEMBLY

(a) Remove the 4 bolts.

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B16364

(b) Using SST, remove the coil assembly.

SST
SST 09950−40011 (09951−04020, 09952−04010
09953−04020, 09954−04010, 09955−04071,
09957−04010, 09958−04011)
(c) Remove the generator washer.
5. REMOVE ROTOR FROM DRIVE END FRAME

B16366
CH−22
CHARGING (2UZ−FE) − GENERATOR (Towing Package Spec.)
CH0LU−02

Ohmmeter
INSPECTION
1. INSPECT ROTOR
(a) Check the rotor for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the slip rings.
Continuity Standard resistance: 2.3 to 2.7 Ω at 20°C (68°F)
If there is no continuity, replace the rotor.
Continuity
B12264

(b) Check the rotor for ground.

Ohmmeter
Using an ohmmeter, check that there is no continuity be-
tween the slip ring and rotor.
If there is continuity, replace the rotor.
(c) Check that the slip rings are not rough or scored.
No Continuity If rough or scored, replace the rotor.

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No Continuity
B12265

(d) Using vernier calipers, 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 minimum, replace the rotor.

B12266

2. INSPECT BRUSHES
Using vernier caliper, measure the exposed brush length.
Standard exposed length: 10.5 mm (0.413 in.)
Length Minimum exposed length: 4.5 mm (0.177 in.)
If the exposed length is less than minimum, replace the brushes
and brush holder assembly.
3. INSPECT BEARING
Check the bearing is not rough or worn.
B16374 If necessary, replace the bearing (See page CH−23).
 CH−23
CHARGING (2UZ−FE) − GENERATOR (Towing Package Spec.)
CH0LV−01

REPLACEMENT
1. REPLACE FRONT BEARING
(a) Remove the 4 screws, bearing retainer and bearing.

B16375

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

SST 09950−60010 (09951−00250), 09950−70010
(09951−07100)

SST

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B16518

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

SST 09950−60010 (09951−00470), 09950−70010
SST
(09951−07100)
(d) Install the bearing retainer with the 4 screws.
Torque: 2.6 N·m (27 kgf·cm, 23 in.·lbf)

B16515

2. REPLACE REAR BEARING

(a) Using SST, remove the bearing cover (outside) and bear-
ing.
SST 09820−00021
SST
NOTICE:
Be careful not to damage the fan.
(b) Remove the bearing cover (inside).

B12270

(c) Place the bearing cover (inside) on the rotor.

B12271
CH−24
CHARGING (2UZ−FE) − GENERATOR (Towing Package Spec.)

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

SST 09820−00031
SST

B12272

(e) Using SST, push in the bearing cover (outside).

SST 09285−76010
SST

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B12273
 CH−25
CHARGING (2UZ−FE) − GENERATOR (Towing Package Spec.)
CH0LW−01

Pulley REASSEMBLY
1. INSTALL ROTOR TO DRIVE END FRAME
(a) Place the drive end frame on the pulley.
(b) Install the rotor to the drive end frame.

B16368

2. INSTALL COIL ASSEMBLY

(a) Place the generator washer on the rotor.

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B16521

SST (b) Using SST and a press, slowly press in the coil assembly.
SST 09285−76010

B16512

(c) Install the coil assembly with the 4 bolts.

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

B16364

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)
Turn SST (A)
clockwise to the specified torque.
SST 09820−63011
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(c) Check that SST (A) is secured to the pulley shaft.
SST (B)
B16520
CH−26
CHARGING (2UZ−FE) − GENERATOR (Towing Package Spec.)

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

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

SST (C) Insert

B16524

(f) To torque the pulley nut, turn SST (A) in the direction
shown in the illustration.
SST (C) Torque: 110.5 N·m (1,125 kgf·cm, 81 ft·lbf)
SST (A) (g) Remove the generator from SST (C).

Turn

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B16373

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

Turn

SST (A)

SST (B)
B16519

4. INSTALL BRUSH HOLDER

(a) Place the front seal plate on the coil assembly.

B16363

(b) Place the brush holder on the coil assembly with the pin
facing upward.
NOTICE:
Be careful of the holder installation direction.
Upward
(c) Install the 2 screws.
Torque: 1.8 N·m (18 kgf·cm, 16 in.·lbf)

Pin

B16361
 CH−27
CHARGING (2UZ−FE) − GENERATOR (Towing Package Spec.)

(d) Align the pins of the brush holder with the holes of the rear
seal plate, and install the rear seal plate.

B16360

5. INSTALL REAR END COVER

(a) Install the terminal insulator.
NOTICE:
Be careful of the terminal insulator installation direction.

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B16359

(b) Install the end cover with the 3 nuts.

Torque: 4.6 N·m (47 kgf·cm, 41 in.·lbf)
6. CHECK THAT ROTOR ROTATES SMOOTHLY

B16513
CH−28
CHARGING (2UZ−FE) − GENERATOR (Towing Package Spec.)
CH0LX−02

INSTALLATION
1. INSTALL GENERATOR
(a) Install the generator with the bolt and 2 nuts.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Connect the generator connector.
(c) Connect the generator wire with the nut.
(d) Install the terminal cap.
(e) Install the wire clamp to the cord clip on the generator.
2. INSTALL PS VANE PUMP (See page SR−69)

3. INSTALL DRIVE BELT

Install the belt by turning the belt tensioner counterclockwise.
HINT:
The pulley bolt for the belt tensioner has a left−hand thread.
4. CONNECT INTAKE AIR CONNECTOR TO THROTTLE
BODY
5. PERFORM ON−VEHICLE INSPECTION
Turn

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(See page CH−1)
B00809 6. INSTALL THROTTLE BODY COVER
7. INSTALL ENGINE UNDER COVER
8. CONNECT CABLE TO NEGATIVE (−) BATTERY TER-
MINAL