TOYOTA RAV4 2006 Service Repair Manual

CH–122GR-FE CHARGING – GENERATOR
CH
REMOVAL
1. REMOVE RADIATOR ASSEMBLY
(a) Remove the radiator (see page CO-36).
2. REMOVE FRONT WHEEL RH
3. REMOVE ENGINE UNDER COVER REAR RH (See
page EM-21)
4. REMOVE FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-7)
5. REMOVE RADIATOR RESERVOIR TANK (See page
CO-19)
6. REMOVE FAN AND GENERATOR V BELT (See page
EM-8)
7. REMOVE GENERATOR ASSEMBLY
(a) Disconnect the 2 wire harness clamps.
(b) Remove the terminal cap.
(c) Remove the nut and disconnect the generator wire
from terminal B.
(d) Disconnect the generator connector from the
generator.
(e) Remove the bolt from the cylinder block.
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2GR-FE CHARGING – GENERATORCH–13
CH
(f) Remove the 2 bolts and generator.
DISASSEMBLY
1. REMOVE GENERATOR PULLEY WITH CLUTCH
(a) Using a screwdriver, puncture the center of the cap
and pry it off the pulley.
NOTICE:
Do not reuse the cap.
(b) Install SST to the pulley as shown in the illustration.
SST 09820-63020
(c) Mount SST (A) in a vise.
(d) Turn SST (B) clockwise to loosen the pulley.
(e) Remove the pulley.
2. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
(a) Remove the bolt and wire harness clamp stay.
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CH–142GR-FE CHARGING – GENERATOR
CH
(b) Remove the bolt and bracket.
(c) Remove the 3 nuts and generator rear end cover.
(d) Remove the terminal insulator.
(e) Remove the 2 screws and generator brush holder.
3. REMOVE GENERATOR ROTOR ASSEMBLY
(a) Remove the 4 bolts.
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2GR-FE CHARGING – GENERATORCH–15
CH
(b) Using SST, remove the generator rectifier end
frame.
SST 09950-40011 (09951-04020, 09952-04010,
09953-04020, 09954-04010, 09955-04071,
09957-04010, 09958-04011)
(c) Remove the washer.
(d) Remove the generator rotor.
INSPECTION
1. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY
(a) Using a vernier caliper, measure the brush length.
Standard length:
9.5 to 11.5 mm (0.374 to 0.453 in.)
Minimum length:
4.5 mm (0.177 in.)
If the brush length is less than the minimum, replace
the generator brush holder assembly.
2. INSPECT GENERATOR ROTOR ASSEMBLY
(a) Check the resistance.
(1) Measure the resistance between the slip rings.
Standard resistance:
2.3 to 2.7
at 20C (68F)
If the result is not as specified, replace the
generator rotor assembly.
(2) Measure the resistance between the slip ring
and rotor core.
Standard resistance:
1 M
or higher
If the result is not as specified, replace the
generator rotor assembly.
(b) Check the slip ring diameter.
(1) Using a vernier caliper, measure the slip ring
diameter.
Standard diameter:
14.2 to 14.4 mm (0.559 to 0.567 in.)
Minimum diameter:
14 mm (0.551 in.)
If the diameter is less than the minimum,
replace the generator rotor assembly.
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CH–162GR-FE CHARGING – GENERATOR
CH
(c) Check the appearance.
(1) Check that the bearing is not rough or worn.
OK:
The bearing rotates smoothly.
If the result is not as specified, replace the
generator rotor assembly.
3. INSPECT GENERATOR DRIVE END FRAME
BEARING
(a) Check that the bearing is not rough or worn.
OK:
The bearing rotates smoothly.
If the bearing does not rotate smoothly, replace the
bearing.
4. INSPECT GENERATOR PULLEY WITH CLUTCH
(a) Hold the center of the pulley, and confirm that the
outer ring turns counterclockwise and does not turn
clockwise.
If the result is not as specified, replace the
generator pulley with clutch.
REPLACEMENT
1. REPLACE GENERATOR DRIVE END FRAME
BEARING
(a) Remove the 4 screws and bearing retainer.
(b) Using SST and a hammer, tap out the bearing.
SST 09950-60010 (09951-00250), 09950-70010
(09951-07100)
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2GR-FE CHARGING – GENERATORCH–17
CH
(c) Using SST and a press, press in a new bearing.
SST 09950-60010 (09951-00250), 09950-70010
(09951-07100)
(d) Install the bearing retainer with the 4 screws.
Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf)
REASSEMBLY
1. INSTALL GENERATOR ROTOR ASSEMBLY
(a) Install the washer onto the generator rectifier end
frame.
(b) Install the generator rotor onto the generator
rectifier end frame.
(c) Using a 21 mm deep socket wrench and press,
slowly push the generator drive end frame onto the
generator rectifier frame.
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CH–182GR-FE CHARGING – GENERATOR
CH
(d) Install the 4 bolts.
Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf)
2. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
(a) While pushing the 2 brushes into the generator
brush holder, insert a
1.0 mm (0.039 in.) pin into
the generator brush holder.
(b) Install the generator brush holder with the 2 screws.
Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf)
(c) Pull the pin out of the generator brush holder.
(d) Install the terminal insulator onto the generator
rectifier end frame.
(e) Install the generator rear end cover with the 3 nuts.
Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)
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2GR-FE CHARGING – GENERATORCH–19
CH
(f) Install the bracket with the bolt.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
(g) Install the wire harness clamp stay.
Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
3. INSTALL GENERATOR PULLEY WITH CLUTCH
(a) Install the pulley by hand.
(b) Install SST to the pulley as shown in the illustration.
SST 09820-63020
(c) Turn SST (B) counterclockwise to tighten the pulley.
Torque: 111 N*m (1125 kgf*cm, 81 ft.*lbf)
(d) Install a new cap to the pulley.
(e) Check that the generator pulley rotates smoothly.
INSTALLATION
1. INSTALL GENERATOR ASSEMBLY
(a) Install the generator with the 2 bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
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CH–202GR-FE CHARGING – GENERATOR
CH
(b) Install the bolt to the cylinder block.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
(c) Connect the generator connector to the generator.
(d) Connect the generator wire with the nut.
Torque: 9.8 N*m (100 kgf*cm, 88 in.*lbf)
(e) Install the terminal cap.
(f) Connect the 2 wire harness clamps.
2. INSTALL FAN AND GENERATOR V BELT (See page
EM-8)
3. INSTALL RADIATOR RESERVOIR TANK (See page
CO-21)
4. INSTALL FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-9)
5. INSTALL ENGINE UNDER COVER REAR RH (See
page EM-41)
6. INSTALL FRONT WHEEL RH
7. INSTALL RADIATOR ASSEMBLY
(a) Install the radiator (see page CO-40).
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AX–6U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM
AX
SYSTEM DIAGRAM
The configuration of the electronic control system in the
U140F automatic transaxle is as shown in the following chart.
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