July 1: So it begins. Don't worry, this is not in the correct legal jurisdiction!

Charging System (2AR-FE): Generator: Inspection

INSPECT GENERATOR BRUSH HOLDER ASSEMBLY
1. 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.
  
  Fig 1: Measuring Brush Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT GENERATOR ROTOR ASSEMBLY

Check the rotor for an open circuit.

Measure the resistance according to the value(s) in the table below.

Standard Resistance

RESISTANCE SPECIFICATION

Tester Connection	Condition	Specified Condition
Slip ring - Slip ring	20°C (68°F)	2.3 to 2.7 Ω

If the result is not as specified, replace the rotor assembly.

Fig 2: Inspecting Generator Rotor Assembly For Open Circuit

G04975742

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check if the rotor is grounded.

Measure the resistance according to the value(s) in the table below.

Standard Resistance

RESISTANCE SPECIFICATION

Tester Connection	Condition	Specified Condition
Slip ring - Rotor core	Always	10 kΩ or higher

If the result is not as specified, replace the rotor assembly.

Fig 3: Inspecting Generator Rotor Assembly For Rotor Grounded

G04975743

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the slip ring diameter.
1. Using a vernier caliper, measure the diameter of each slip ring.
  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.
  
  Fig 4: Measuring Diameter Of Slip Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Check the appearance.
1. Check that the bearing is not rough or worn and that it rotates smoothly.
  If the result is not as specified, replace the generator rotor assembly.
  
  Fig 5: Checking Bearing For Rough Or Worn And Rotates Smoothly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT GENERATOR DRIVE END FRAME BEARING
1. Check that the bearing is not rough or worn and that it rotates smoothly.
  If the bearing does not rotate smoothly, replace the bearing.
  
  Fig 6: Inspecting Generator Drive End Frame Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT GENERATOR PULLEY WITH CLUTCH
1. 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.
  
  Fig 7: Inspecting Generator Pulley With Clutch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002