TOYOTA SUPRA 1997 Service Repair Manual

CH03O-01
CH0784
Ohmmeter
Continuity
CH0783
Ohmmeter
Continuity
CH1023
P10622
Continuity
Ohmmeter
P10623
No Continuity
Ohmmeter
- CHARGINGGENERATOR
CH-1 1
1534 Author
: Date
:
1997 SUPRA (RM502U)
INSPECTION
1. INSPECT ROTOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
slip rings.
Standard resistance: 2.7 - 3.1 W at 20°C (68°F)
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.
4. 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 assembly.
5. 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.

P13535
Length
P10624
Ohmmeter
Positive (+)
Terminal
Rectifier
Terminal
P10625
Ohmmeter
Negative (-)
Terminal CH-12
- CHARGINGGENERATOR
1535 Author
: Date
:
1997 SUPRA (RM502U)
6. INSPECT EXPOSED BRUSH LENGTH
Using a vernier caliper, measure the exposed length.
Standard exposed length:
9.5 - 11.5 mm (0.347 - 0.453 in.)
Minimum exposed length:
1.5 mm (0.059 in.)
If the exposed length is less than minimum, replace the brush
holder.
7. INSPECT POSITIVE RECTIFIER
(a) Using an ohmmeter, connect one tester probe to the posi-
tive (+) 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.
8. INSPECT NEGATIVE RECTIFIER
(a) Using an ohmmeter, connect one tester probe to each
negative (-) terminal and the other to each rectifier termi-
nal.
(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.
9. INSPECT FRONT BEARING
Check that the bearing is not rough or worn.
10. INSPECT REAR BEARING
Check that the bearing is not rough or worn.

CH03P-02
P10627
P10628
Socket
Wrench
P21010
SST
N00581
SST
P13567
- CHARGINGGENERATOR
CH-13
1536 Author
: Date
:
1997 SUPRA (RM502U)
REPLACEMENT
1. REPLACE FRONT BEARING
(a) Remove the 4 screws, bearing retainer and bearing.
(b) Using a socket wrench and press, press out the bearing.
(c) Using SST and a press, press in a new bearing.
SST 09950-60010 (09951-00500)
(d) Install the bearing retainer with the 4 screws.
Torque: 3.0 N´m (31 kgf´cm, 27 in.´lbf)
2. REPLACE REAR BEARING
(a) Using SST, remove the bearing cover (outside) and bear-
ing.
SST 09820-00021
NOTICE:
Be careful not to damage the fan.
(b) Remove the beating cover (inside).
(c) Place the bearing cover (inside) on the rotor.

N00578
SST
P00074
SST
CH-14
- CHARGINGGENERATOR
1537 Author
: Date
:
1997 SUPRA (RM502U)
(d) Using SST and a press, press in a new bearing.
SST 09820-00030
(e) Using SST, push in the bearing cover (outside).
SST 09285-76010

CH03Q-01
P10637
P10640
29 mm
Socket
Wrench
P10635
P10835
Turn
SST (A)
SST (B)
Z00045
SST (C)
- CHARGINGGENERATOR
CH-15
1538 Author
: Date
:
1997 SUPRA (RM502U)
REASSEMBLY
1. PLACE DRIVE END FRAME ON PULLEY
2. INSTALL ROTOR TO DRIVE END FRAME
3. INSTALL RECTIFIER END FRAME
(a) Place the generator washer on the rotor.
(b) Using a 29 mm socket wrench and press, slowly press in
the rectifier end frame.
(c) Install the 3 nuts.
Torque: 4.5 N´m (46 kgf´cm, 40 in.´lbf)
4. 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) Mount SST (C) in a vise.
(e) Insert SST (B) into SST (C), and attach the pulley nut to
SST (C).
(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)
(g) Remove the generator from SST (C).

P10836
SST (A)
SST (B)Turn
P10837
P10830
Push
P11842
P11839
CH-16
- CHARGINGGENERATOR
1539 Author
: Date
:
1997 SUPRA (RM502U)
(h) Turn SST (B), and remove SST (A and B).
5. INSTALL RECTIFIER HOLDER
(a) Install the 4 rubber insulators on the lead wires.
(b) Install the rectifier holder while pushing it with the 4
screws.
Torque: 2.9 N´m (30 kgf´cm, 26 in.´lbf)
6. INSTALL WIRE CLIP
Install the wire clip with the nut.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
7. INSTALL VOLTAGE REGULATOR AND BRUSH
HOLDER
(a) Place the seal plate on the rectifier end frame.

S05216
Upward
P11840
Brush Holder Cover
P11838
Plate Terminal
- CHARGINGGENERATOR
CH-17
1540 Author
: Date
:
1997 SUPRA (RM502U)
(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.
8. 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 (40 kgf´cm, 35 in.´lbf)
(b) Install the terminal insulator with the nut.
Torque: 6.5 N´m (67 kgf´cm, 58 in.´lbf)
9. CHECK THAT ROTOR ROTATES SMOOTHLY

ST04C-02
S05224
Engine Wire Bracket
Starter Wire Starter
Starter Connector ST-2
- STARTINGSTARTER
1509 Author
: Date
:
1997 SUPRA (RM502U)
STARTER
COMPONENTS

Z18832
Magnetic Switch AssemblyReturn SpringStarter Housing
Idler Gear
Steel Ball
Dust protector
Brush Holder
Dust ProtectorField Frame (Field Coil)Armature
Front Bearing Starter Clutch Assembly

Rear Bearing
O-Ring

O-RingBearing
End Cover
Terminal Insulator

Terminal C kit Part Magnetic Switch AssemblyContact Plate
Insulation Paper Terminal Insulator Terminal BoltTerminal Insulator Terminal
Bolt
Lead Clamp
End CoverPlungerLead
Terminal
Contact PlatePacking

Terminal 30 kit Part
O-Ring

Gasket
17 (170,12)
Wave Washer
Terminal Insulator
O-Ring17 (170,12)
N´m (kgf´cm, ft´lbf) : Specified torque

Non-reusable part
Wave Washer

O-Ring
- STARTINGSTARTER
ST-3
1510 Author
: Date
:
1997 SUPRA (RM502U)

ST04D-01
P11571
P12358
ST-4
- STARTINGSTARTER
1511 Author
: Date
:
1997 SUPRA (RM502U)
REMOVAL
REMOVE STARTER
(a) Remove the rubber cap and nut, and disconnect the start-
er wire.
(b) Disconnect the starter connector.
(c) Remove the 2 bolts and starter.
Torque: 37 N´m (380 kgf´cm, 27 ft´lbf)