TOYOTA CAMRY 1999 Service Repair Manual

Z18638
S05461
Upward
Z18640
Z18635
S05069
± CHARGING (5S±FE)GENERATOR
CH±15
1762 Author: Date:
5. INSTALL VOLTAGE REGULATOR AND BRUSH
HOLDER
(a) Place the seal plate on the rectifier end frame.
(b) Place the voltage regulator and brush holder on the recti-
fier end frame.
NOTICE:
Be careful of the holder installation direction.
(c) Install the 5 screws.
Torque: 2.0 N´m (20 kgf´cm, 18 in.´lbf)
(d) Place the brush holder cover on the brush holder.
6. INSTALL REAR END COVER
(a) Install the end cover and plate terminal with the bolt and
3 nuts.
Torque:
Nut: 4.4 N´m (45 kgf´cm, 39 in.´lbf)
Bolt: 3.9 N´m (39 kgf´cm, 35 in.´lbf)
(b) Install the terminal insulator with the nut.
Torque: 4.1 N´m (42 kgf´cm, 36 in.´lbf)
7. CHECK THAT ROTOR ROTATES SMOOTHLY

CH031±01
CH±16
± CHARGING (5S±FE)GENERATOR
1763 Author: Date:
INSTALLATION
Installation is in the reverse order of removal. (See page CH±6)

CH01D±01
Z11577
Except Maintenance±Free Battery
Z11556
Maintenance±Free BatteryVoltmeter
± CHARGING (1MZ±FE)CHARGING SYSTEM
CH±1
1764 Author: Date:
CHARGING SYSTEM
ON±VEHICLE INSPECTION
CAUTION:

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

Disconnect the battery cables when the battery is
given a quick charge.

Do not perform tests with a high voltage insulation
resistance tester.

Never disconnect the battery while the engine is
running.
1. CHECK BATTERY ELECTROLYTE LEVEL
Check the electrolyte quantity of each cell.
(1) Maintenance±Free Battery:
If under the lower level, replace the battery (or add
distilled water if possible). Check the charging sys-
tem.
(2) Except Maintenance±Free Battery:
If under the lower level, add distilled water.
2. Except Maintenance±Free Battery:
CHECK BATTERY SPECIFIC GRAVITY
Check the specific gravity of each cell.
Standard specific gravity: 1.25 ± 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
(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.
(c) Measure the battery voltage between the negative (±)
and positive (+) terminals of the battery.
Standard voltage: 12.5 ± 12.9 V at 20°C (68°F)
If the voltage is less than specification, charge the battery.

Z18811
Maintenance±Free Battery
Type A
Type B
Blue White Red
OK Charging
NecessaryInsufficient
Water
GREEN EYE DARK EYECLEAR EYE or
CHARGED DISCHARGED ADD WATERLIGHT YELLOW
Z00015
Z00038
DENSO
Borroughs
CH0086
CORRECT WRONG CH±2
± CHARGING (1MZ±FE)CHARGING SYSTEM
1765 Author: Date:
HINT:
Check the indicator as shown in the illustration.
4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND
FUSES
(a) Check that the battery terminals are not loose or cor-
roded.
If the terminals are corroded, clean the terminals.
(b) Check the fusible link, H±fuses, M±fuse and fuses for
continuity.
5. INSPECT DRIVE BELTS
(a) Visually check the drive belt for excessive wear, frayed
cords etc.
If any defect has been found, replace the drive belt.
HINT:
Cracks on the rib side of a drive belt are considered acceptable.
If the drive belt has chunks missing from the ribs, it should be
replaced.
(b) Using a belt tension gauge, measure the belt tension.
Belt tension gauge:
DENSO BTG±20 (95506±00020)
Borroughs No. BT±33±73F
Drive belt tension:
New belt175 ± 5 lbf
Used belt115 ± 20 lbf
If the belt tension is not as specified, adjust it.
HINT:

ºNew beltº refers to a belt which has been used less than
5 minutes on a running engine.

ºUsed beltº refers to a belt which has been used on a run-
ning engine for 5 minutes or more.

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

Check with your hand to confirm that the belt has not
slipped out of the groove on the bottom of the pulley.

Z03473
BatteryAmmeter
VoltmeterDisconnect Wire
from Terminal B
Generator
± CHARGING (1MZ±FE)CHARGING SYSTEM
CH±3
1766 Author: Date:

After installing a new belt, run the engine for about 5 min-
utes and recheck the belt tension.
6. VISUALLY CHECK GENERATOR WIRING AND
LISTEN FOR ABNORMAL NOISES
(a) Check that the wiring is in good condition.
(b) Check that there is no abnormal noise from the generator
while the engine is running.
7. CHECK DISCHARGE WARNING LIGHT CIRCUIT
(a) Warm up the engine and then turn it off.
(b) Turn off all accessories.
(c) Turn the ignition switch ºONº. Check that the discharge
warning light is lit.
(d) Start the engine. Check that the light goes off.
If the light does not go off as specified, troubleshoot the dis-
charge light circuit.
8. INSPECT CHARGING CIRCUIT WITHOUT LOAD
HINT:
If a battery/generator tester is available, connect the tester to
the charging circuit as per manufacturer's instructions.
(a) If a tester is not available, connect a voltmeter and amme-
ter to the charging circuit as follows:

Disconnect the wire from terminal B of the genera-
tor, and connect it to the negative (±) tester probe
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: 13.5 ± 15.1 V
If the voltmeter reading is more than standard voltage, replace
the voltage regulator.

P14228
Terminal F CH±4
± CHARGING (1MZ±FE)CHARGING SYSTEM
1767 Author: Date:
If the voltmeter reading is less than standard voltage, check the
voltage regulator and generator as follows:

With terminal F grounded, start the engine and
check the voltmeter reading of terminal B.

If the voltmeter reading is more than standard volt-
age, replace the voltage regulator.

If the voltmeter reading is less than standard volt-
age, check the generator.
9. 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
ºHIº.
(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.

CH01E±01
S05218
Pivot BoltPlate Washer
Adjusting Lock BoltAdjusting Bolt
GeneratorGenerator Wire
Generator Connector
Drive Belt
S05077
PulleyDrive End Flame (Stator)
Front Bearing
Retainer
RotorBearing Cover

Rear Bearing Bearing Cover
Generator Washer
Rectifire End Flame
Cord ClipSeal Plate
Robber Insulator x 4Rectifire Holder Terminal Insulator
Voltage RegulatorBrush HolderBrush Holder CoverRear End CoverPlate Terminal

Non±reusable part
± CHARGING (1MZ±FE)GENERATOR
CH±5
1768 Author: Date:
GENERATOR
COMPONENTS

CH01F±01
P14226
Pivot Bolt
Adjusting
Lock BoltAdjusting Bolt
P14227
CH±6
± CHARGING (1MZ±FE)GENERATOR
1769 Author: Date:
REMOVAL
1. REMOVE DRIVE BELT
Loosen the pivot bolt, adjusting lock bolt, and adjusting bolt,
and remove the drive belt.
Torque:
Pivot bolt: 56 N´m (570 kgf´cm, 41 ft´lbf)
Lock bolt: 18 N´m (180 kgf´cm, 13 ft´lbf)
2. REMOVE GENERATOR
(a) Disconnect the generator connector.
(b) Remove the nut, and disconnect the generator wire.
(c) Disconnect the wire harness from the clip.
(d) Remove the pivot bolt, plate washer, adjusting lock bolt
and generator.

CH01G±01
P14233
Plate Terminal
P14234
S05072
P10835
SST (B)SST (A) Turn
P10834
SST (C)SST (B)
Insert
± CHARGING (1MZ±FE)GENERATOR
CH±7
1770 Author: Date:
DISASSEMBLY
1. REMOVE REAR END COVER
(a) Remove the nut and terminal insulator.
(b) Remove the screw, 3 nuts, plate terminal and end cover.
2. REMOVE BRUSH HOLDER AND VOLTAGE
REGULATOR
(a) Remove the brush holder cover from the brush holder.
(b) Remove the 5 screws, brush holder and voltage regulator.
3. REMOVE RECTIFIER HOLDER
(a) Remove the 4 screws and rectifier holder.
(b) Remove the 4 rubber insulators.
(c) 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) Mount SST (C) in a vise.
(d) Insert SST (B) into SST (C), and attach the pulley nut to
SST (C).

P10827
SST (C)
SST (A)
Turn
P10836
Turn
SST (A)
SST (B)
S05073
P01762
SST CH±8
± CHARGING (1MZ±FE)GENERATOR
1771 Author: Date:
(e) To loosen the pulley nut, turn SST (A) in the direction
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.
(f) Remove the generator from SST (C).
(g) Turn SST (B), and remove SST (A and B).
(h) Remove the pulley nut and pulley.
5. REMOVE RECTIFIER END FRAME
(a) Remove the 4 nuts and cord clip.
(b) Using SST, remove the rectifier end frame.
SST 09286±46011
(c) Remove the generator washer.
6. REMOVE ROTOR FROM DRIVE END FRAME