2AZ-FE CHARGING – CHARGING SYSTEM CH–1

CHARGING SYSTEM
PRECAUTION
1. Check that the battery cables are connected to the
correct terminals.
2. Disconnect the battery cables if a quick charge is
given to the battery.
3. Do not perform tests with a high voltage insulation
resistance tester.
4. Never disconnect the battery while the engine is
running.
5. Check that the charging cable is tightly connected
onto terminal B of the generator and the fuse box.
6. Do not check whether the generator generates
current or not while terminal F is connected to the
other terminals.

CH
 CH–2 2AZ-FE CHARGING – CHARGING SYSTEM

PARTS LOCATION

COMBINATION METER ASSEMBLY

- CHARGE WARNING LIGHT

GENERATOR
INSTRUMENT PANEL JUNCTION BLOCK
- GAUGE1 FUSE
BATTERY CURRENT SENSOR - GAUGE2 FUSE

ENGINE ROOM NO. 1 RELAY BLOCK, JUNCTION BLOCK

- ALT H-FUSE

CH

A122807E01
 2AZ-FE CHARGING – CHARGING SYSTEM CH–3

SYSTEM DIAGRAM

Battery Current Sensor ECM

VC5
VCIB
IB
IB

E2
EIB

THB
THB

GAUGE2
from RL0
Power Source
DF
Combination Meter
(Charge Warning Light)
GAUGE1
from
Ignition Switch

ALT
from
Power Source

B IG L RL0 M

Stator Coil

Rotor Coil

CH
E
Generator
A126786E01
 CH–4 2AZ-FE CHARGING – CHARGING SYSTEM

ON-VEHICLE INSPECTION
1. CHECK BATTERY CONDITION
NOTICE:
If the battery is weak or if the engine is difficult to
start, perform the following procedures.
(a) Check the battery for damage and deformation. If
severe damage, deformation or leakage is found,
replace the battery.
(b) Check the electrolyte quantity of each cell.
(1) For maintenance-free batteries:
• If the electrolyte quantity is below the lower
line, replace the battery.
• If the electrolyte quantity is above the lower
line, check the battery voltage when
cranking the engine. If the voltage is less
than 9.6 V, recharge or replace the battery.
HINT:
) A116909 Before checking the battery voltage, turn off
all the electrical systems (headlights, blower
motor, rear defogger, etc.).
(2) For non-maintenance-free batteries:
• If the electrolyte quantity is below the lower
line, add distilled water to each cell. Then,
recharge the battery and check the
electrolyte's specific gravity.
Standard specific gravity:
1.25 to 1.29 at 20°C (68°F)
If the electrolyte quantity is above the lower
line, check the battery voltage when
) A116907 cranking the engine. If the voltage is less
than 9.6 V, recharge or replace the battery.
HINT:
Before checking the battery voltage, turn off
all the electrical systems (headlights, blower
motor, rear defogger, etc.).
2. INSPECT BATTERY TERMINAL AND FUSE
(a) Visually check the battery terminals.
(1) Check that the battery terminals are not loose
or corroded.
(b) Measure the resistance of the H-fuses and fuses.
Standard resistance:
Below 1 Ω
If the results are not as specified, replace the fuses
as necessary.
CH
 2AZ-FE CHARGING – CHARGING SYSTEM CH–5

3. INSPECT V-RIBBED BELT

(a) Visually check the belt for excessive wear, frayed
cords, etc.
If any defects are found, replace the V-ribbed belt.
HINT:
Cracks on the rib side of the belt are considered
acceptable. If the belt has chunks missing from the
ribs, it should be replaced.

A095340E01

(b) Check that the belt fits properly in the ribbed

grooves.
HINT:
Confirm by hand that the belt has not slipped out of
the grooves on the bottom of the pulley.
4. INSPECT GENERATOR WIRING
(a) Visually check the generator wiring.
CORRECT INCORRECT
(1) Check that the wiring is in good condition.
A111819E01 5. CHECK FOR ABNORMAL NOISES
(a) Listen for abnormal noises from the generator.
(1) Check that no abnormal noises are heard from
the generator while the engine is running.
6. INSPECT CHARGE WARNING LIGHT CIRCUIT
(a) Turn the ignition switch ON. Check that the charge
warning light comes on.
(b) Start the engine and check that the light goes off.
If the light does not operate as specified,
troubleshoot the charge warning light circuit.
7. INSPECT CHARGING CIRCUIT WITHOUT LOAD
Disconnect Wire
from Terminal B (a) Connect a voltmeter and ammeter to the charging
circuit as follows.
(1) Disconnect the wire from terminal B of the
generator, then connect it to the negative (-)
lead of an ammeter.
(2) Connect the positive (+) lead of the ammeter to
terminal B of the generator.
(3) Connect the positive (+) lead of a voltmeter to
A088419E04 terminal B of the generator.
(4) Ground the negative (-) lead of the voltmeter.
(b) Check the charging circuit.
(1) Keep the engine speed at 2,000 rpm and check
the reading on the ammeter and voltmeter.
Standard amperage:
10 A or less
Standard voltage: CH
12.1 to 15.4 V
If the result is not as specified, replace the
generator.
HINT:
If the battery is not fully charged, the ammeter
reading will sometimes be more than the
standard amperage.
 CH–6 2AZ-FE CHARGING – CHARGING SYSTEM

8. INSPECT CHARGING CIRCUIT WITH LOAD

(a) With the engine running at 2,000 rpm, turn the high
beam headlights ON and turn the heater blower
switch to the "HI" position.
(b) Check the reading on the ammeter.
Standard amperage:
30 A or more
If the ammeter reading is less than the standard
amperage, repair the generator.
HINT:
If the battery is fully charged, the indication will
sometimes be less than the standard amperage. If
this is the case, add more electrical load (operate
the wipers, rear window defogger, etc.) and check
the reading on the ammeter again.

CH
 2AZ-FE CHARGING – GENERATOR CH–7

GENERATOR
2AZ-FE CHARGING
ENGINE

COMPONENTS

9.8 (100, 7)
GENERATOR WIRE

GENERATOR CONNECTOR
WIRE HARNESS CLAMP BRACKET

8.4 (85, 74 in.*lbf)

52 (530, 38)

21 (215, 16)

GENERATOR ASSEMBLY

FAN AND GENERATOR V BELT

FRONT SUSPENSION MEMBER REINFORCEMENT RH

96 (979, 16)
CH
FRONT FENDER APRON SEAL RH

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

A122808E01
 CH–8 2AZ-FE CHARGING – GENERATOR

2.3 (23, 20 in.*lbf)

110 (1,122, 82)

x4

WASHER

GENERATOR ROTOR ASSEMBLY

BEARING RETAINER PLATE

GENERATOR DRIVE END FRAME BEARING

PULLEY CAP GENERATOR DRIVE END FRAME

GENERATOR PULLEY WITH CLUTCH

GENERATOR BRUSH HOLDER ASSEMBLY

4.6 (47, 41 in.*lbf)

TERMINAL INSULATOR 1.8 (18, 16 in.*lbf)

x3
x2

x4
5.8 (59, 51 in.*lbf)

GENERATOR REAR END COVER

4.6 (47, 41 in.*lbf)

CH CORD CLIP
GENERATOR RECTIFIER END FRAME

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

Non-reusable part
A124643E01
 2AZ-FE CHARGING – GENERATOR CH–9

REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
2. REMOVE FAN AND GENERATOR V BELT
(a) Remove the belt (see page EM-6).
3. REMOVE GENERATOR ASSEMBLY
(a) Disconnect the generator connector.
(b) Remove the terminal cap.
(c) Remove the nut and disconnect the generator wire.
(d) Remove the bolt and wire harness clamp bracket.
(e) Remove the wire harness clamps.

A122809

(f) Remove the 2 bolts and generator.

A122810

DISASSEMBLY
1. REMOVE GENERATOR PULLEY WITH CLUTCH
(a) Remove the cap from the pulley.
(1) Using a screwdriver, puncture the center of the
cap and pry it off.
NOTICE:
Do not reuse the cap.

A126771

(b) Install SST to the pulley and vise as shown in the

illustration.
SST 09820-63020
(c) Mount SST (A) in a vise.
CH
SST (A)
SST (B)

A126778E01
 CH–10 2AZ-FE CHARGING – GENERATOR

(d) Turn SST (B) clockwise to loosen the pulley.

(e) Remove the pulley.

SST (B)

A126779E01

2. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY

(a) Remove the 3 nuts and generator rear end cover.

A130331

(b) Remove the terminal insulator.

A097461E01

(c) Remove the 2 screws and generator brush holder.

A097462E01

3. REMOVE GENERATOR ROTOR ASSEMBLY

(a) Remove the bolt and cord clip.
CH

A097464E01
 2AZ-FE CHARGING – GENERATOR CH–11

(b) Remove the 4 bolts.

A097465E01

(c) Using SST, remove the coil.

SST SST 09950-40011 (09951-04020, 09952-04010,
09953-04020, 09954-04010, 09955-04071,
09957-04010)
(d) Remove the washer.
(e) Remove the generator rotor.

A122144E01

Length
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
A079305E04
the generator brush holder assembly.

2. INSPECT GENERATOR ROTOR ASSEMBLY

Slip Ring
(a) Check the resistance.
(1) Measure the resistance between the slip rings.
Standard resistance:
2.3 to 2.7 Ω at 20°C (68°F)
If the result is not as specified, replace the
generator rotor assembly.

A097476E02

(2) Measure the resistance between the slip ring

Slip Ring
and rotor core.
Standard resistance:
1 MΩ or higher CH
If the result is not as specified, replace the
generator rotor assembly.

Rotor Core

A097477E02
 CH–12 2AZ-FE CHARGING – GENERATOR

(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.
A097470E02

(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.

A097469E01

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.

A097471E01

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.
Free Lock
If the result is not as specified, replace the
generator pulley with clutch.

A126783E01

REPLACEMENT
1. REPLACE GENERATOR DRIVE END FRAME
CH BEARING
(a) Remove the 4 screws and bearing retainer.

A126772
 2AZ-FE CHARGING – GENERATOR CH–13

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

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

SST

A126773E01

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

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

A126774E01

(d) Install the bearing retainer with the 4 screws.

Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf)

A126772

REASSEMBLY
1. INSTALL GENERATOR ROTOR ASSEMBLY
(a) Install the washer onto the generator rectifier end
frame.

A097468

(b) Install the generator rotor onto the generator

rectifier end frame.

CH

A097467E01
 CH–14 2AZ-FE CHARGING – GENERATOR

(c) Using a 32 mm socket wrench and press, slowly

32 mm push the generator drive end frame onto the
Socket
generator rectifier end frame.
Wrench

A097475E02

(d) Tighten the 4 bolts.

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

A097465E01

(e) Install the cord clip with the bolt.

Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)

A097464E01

2. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

Pin
(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.

A079315E04

(b) Install the generator brush holder with the 2 screws.

Pull out Pin
Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf)
(c) Pull the pin out of the generator brush holder.
CH

A097463E02
 2AZ-FE CHARGING – GENERATOR CH–15

(d) Install the terminal insulator onto the generator

rectifier end frame.

A097461E01

(e) Install the generator rear end cover with the 3 nuts.
Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)
3. INSTALL GENERATOR PULLEY WITH CLUTCH
(a) Install the pulley by hand.

A098216E01

(b) Install SST to the pulley and vise as shown in the

illustration.
SST 09820-63020

SST (A)
SST (B)

A126778E01

(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.

SST (B)

A126782E01

Wire Harness INSTALLATION

Clamp Bracket 1. INSTALL GENERATOR ASSEMBLY
Rib (a) Confirm that the wire harness of the crankshaft
position sensor is secured to the wire harness
CH
clamp bracket through the back of the rib of the
timing chain cover.

A097394E02
 CH–16 2AZ-FE CHARGING – GENERATOR

(b) Install the generator with the 2 bolts.

Torque: 21 N*m (215 kgf*cm, 16 ft.*lbf) for bolt A
52 N*m (530 kgf*cm, 38 ft.*lbf) for bolt B

A A122810E01

(c) Install the wire harness clamp.

(d) Install the wire harness clamp bracket with the bolt.
Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf)
(e) Connect the generator wire with the nut.
Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf)
(f) Install the terminal cap.
(g) Connect the generator connector.
2. INSTALL FAN AND GENERATOR V BELT
(a) Install the belt (see page EM-7).
A122809

3. CONNECT CABLE TO NEGATIVE BATTERY

TERMINAL

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 2AZ-FE CHARGING – BATTERY CURRENT SENSOR CH–17

BATTERY CURRENT SENSOR

ON-VEHICLE INSPECTION
1. CHECK BATTERY CURRENT SENSOR ASSEMBLY
(a) Measure the resistance of the sensor.
Standard resistance
Tester Connection Specified Condition
2 (VC5) - 4 (E2) 3 to 10 kΩ
2 (VC5) - 3 (IB) Below 0.5 kΩ
VC5 3 (IB) - 4 (E2) 3 to 10 kΩ
2 1
4 3 If the result is not as specified, replace the sensor
E2 IB
assembly.
A124656E01

(b) Measure the resistance of the sensor.

Standard resistance
Tester Connection Condition Specified Condition
THB
1 (THB) - 4 (E2) 20 to 30°C (68 to 86°F) 1.5 to 2.5 kΩ
2 1
If the result is not as specified, replace the sensor
4 3
assembly.
E2

Resistance kΩ
6
5
4
3
2
1
0
10 20 30 40 50 60 70 °C
50 68 86 104 122 144 158 °F
Temperature
A125629E01

CH