2004 Toyota RAV4

2004 STARTING & CHARGING SYSTEMS Generators & Regulators - RAV4

2004 STARTING & CHARGING SYSTEMS

Generators & Regulators - RAV4

DESCRIPTION & OPERATION

The generator is a small, high RPM, high performance type with an internal Integrated Circuit (IC) voltage
regulator which controls charging system voltage. A transistor inside IC regulator controls generator voltage
output to maintain a constant voltage. Charging system voltage is maintained within an operating range of 13.2-
14.8 volts.

When ignition is turned on, battery voltage flows from generator terminal "L" through IC regulator to ground,
causing discharge warning light to come on. When engine starts, generator RPM increases, which increases
generator output voltage. When generator output voltage is greater than battery voltage, voltage to recharge
battery flows from terminal "B". At the same time, voltage at terminal "L" increases and the potential difference
between battery and terminal "L" ceases, causing discharge warning light to go off.

ADJUSTMENTS

NOTE: New belt refers to a belt which has been used 5 minutes or less on a running
engine. Used belt refers to a belt which has been used more than 5 minutes on
a running engine. After installing new belt, run engine for at least 5 minutes and
recheck tension.

BELT TENSION

4-Cylinder

Engine uses a serpentine drive belt. Serpentine drive belt uses an automatic belt tensioner. No adjustment is
necessary, but must be properly installed. For belt routing, see Fig. 1 .

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Fig. 1: Serpentine Drive Belt Routing (2.4L)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TROUBLE SHOOTING

NOTE: See CHARGING SYSTEM - GENERAL TROUBLE SHOOTING article in GENERAL

INFORMATION.

Check all fuses, fusible links, ignition switch and appropriate relays (if equipped). Check generator output. See
NO-LOAD TEST under ON-VEHICLE TESTING.

ON-VEHICLE TESTING
NO-LOAD TEST

1. Disconnect battery-to-generator terminal "B" wire. See Fig. 2 . Using an ammeter and voltmeter, connect
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2004 STARTING & CHARGING SYSTEMS Generators & Regulators - RAV4

negative ammeter lead to disconnected generator terminal "B" wire end, and connect positive ammeter
lead to generator terminal "B".
2. Connect voltmeter positive lead to generator terminal "B" and negative lead to ground. See Fig. 2 . Start
engine and increase engine speed to 2000 RPM. Both meters should read within specification. See
GENERATOR SPECIFICATIONS . If voltage is more than specified, replace voltage regulator. If
voltage reading is less than specified, check voltage regulator. See VOLTAGE REGULATOR .

Fig. 2: Testing Charging Circuit

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

LOAD TEST

NOTE: If battery is fully charged, generator load test results may be less than 30 amps.

1. Connect an ammeter as described in NO-LOAD TEST , step 1 . See Fig. 2 . Start engine. Turn on high
beam headlights and place heater blower control on H. Increase engine speed to 2000 RPM.
2. Check ammeter reading. See GENERATOR SPECIFICATIONS . If amperage is less than specified,
repair or replace generator.

BENCH TESTING
BRUSHES
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2004 STARTING & CHARGING SYSTEMS Generators & Regulators - RAV4

1. Brushes should slide smoothly in holders. Replace brushes if damaged or worn. See GENERATOR
SPECIFICATIONS .
2. If exposed brush length is less than minimum, replace brush holder assembly.

DIODES

NOTE: Procedure given, applies to 90-amp generator only. Information not available for
100-amp generator.

1. With diode/rectifier assembly removed and on bench, contact positive diode plate terminal with one
ohmmeter probe. Using other ohmmeter probe, contact each diode lead in same plate. Note ohmmeter
reading. Reverse ohmmeter probes, and repeat tests for all diodes.
2. All diodes should show continuity in one direction and no continuity in opposite direction. If any diode is
defective, replace diode/rectifier assembly.

ROTOR

1. Check rotor for open field windings by using an ohmmeter across slip rings. Rotor resistance should be
within specification. See GENERATOR SPECIFICATIONS .
2. Check rotor for shorts to ground by connecting ohmmeter between slip ring and rotor shaft. Ohmmeter
should indicate no continuity. Check slip rings for wear or pitting. See GENERATOR
SPECIFICATIONS . If slip rings are rough or scored, replace rotor.

STATOR

NOTE: Procedure given, applies for 90-amp generator only. Information not available
for 100-amp generator.

Connect ohmmeter between stator leads. Continuity should exist between all stator leads. Connect ohmmeter
between each stator lead and drive end frame. Continuity should not exist. If stator does not test as indicated,
replace drive end frame assembly.

VOLTAGE REGULATOR

NOTE: When positive and negative probes between terminals are exchanged, there is
continuity in one direction but not in the other direction.

Using ohmmeter, check for continuity between following:

 Terminals "F" and "B"

 Terminals "F" and "E"

If continuity is not as specified, replace voltage regulator. See Fig. 3 or Fig. 4 .

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Fig. 3: Testing Voltage Regulator (W/90-Amp Generator)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 4: Testing Voltage Regulator (W/100-Amp Generator)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL & INSTALLATION

GENERATOR

Removal & Installation

Disconnect negative battery cable. Use Torque Wrench Adaptor (SST 09249-63010) to aid in removing
serpentine drive belt. See Fig. 5 . Disconnect generator wire harness connector. Remove battery nut and wire
from back of generator. Remove generator mounting bolts. Remove generator. To install, reverse removal
procedure. Tighten generator bolts to specification. See TORQUE SPECIFICATIONS . Install serpentine
drive belt.

Fig. 5: Identifying Torque Wrench Adapter

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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2004 STARTING & CHARGING SYSTEMS Generators & Regulators - RAV4

OVERHAUL
GENERATOR

Disassembly (90-Amp)

1. Use generator Pulley Set Nut Wrench Set (SST 09820-63011) to remove generator pulley. Install SST
"A" and "B" to rotor shaft and tighten SST "B" clockwise to 29 ft. lbs. (39 N.m). See Fig. 6 . Place SST
"C" securely into a vise. Verify that SST "A" is secured to rotor shaft and install SST "A" and "B" and
generator into SST "C". Turn SST "A" in correct direction to loosen pulley nut. To prevent damage to
rotor shaft, DO NOT loosen pulley nut more than 1/2 turn. Remove generator from SST "C". Turn SST
"A" and "B", remove pulley nut and pulley.
2. Remove nut and terminal insulator. Remove bolt, 3 nuts, plated terminal and rear end cover. See Fig. 7 .
Remove 2 screws and brush holder. Remove 3 screws and voltage regulator. Remove 4 screws and diode
(rectifier) holder. Remove 4 rubber insulators.
3. Remove 4 nuts and wire clip. Using Bearing Puller (SST 09286-46011), remove rectifier end frame.
Remove generator washer from rotor. Remove rotor from drive end frame.

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Fig. 6: Removing Generator Pulley

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 7: Exploded View Of Generator (90-Amp)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Disassembly (100-Amp)

1. Use generator Pulley Set Nut Wrench Set (SST 09820-63011) to remove generator pulley. Install SST
"A" and "B" to rotor shaft and tighten SST "B" clockwise to 29 ft. lbs. (39 N.m). See Fig. 6 . Place SST
"C" securely into a vise. Verify that SST "A" is secured to rotor shaft and install SST "A" and "B" and
generator into SST "C". Turn SST "A" in correct direction to loosen pulley nut. To prevent damage to
rotor shaft, DO NOT loosen pulley nut more than 1/2 turn. Remove generator from SST "C". Turn SST
"A" and "B", remove pulley nut and pulley.
2. Remove 3 nuts and rear end cover. See Fig. 8 . Remove nut and terminal insulator. Remove 2 screws and
brush holder.
3. Remove bolt and cord clip. Remove 4 bolts and rectifier end frame. Remove coil assembly using Puller
(SST 09950-40011). See Fig. 9 . Remove generator washer from rotor. Remove rotor from drive end
frame.

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Fig. 8: Exploded View Of Generator (100-Amp)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 9: Removing Rectifier End Frame

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Assembly (90-Amp)

Place drive end frame on pulley and install rotor in drive end frame. Place generator washer on rotor and
position rectifier end frame on rotor. Using 29 mm socket, slowly press in rectifier end frame. Use generator
Pulley Set Nut Wrench Set (SST 09820-63011) to install generator pulley. Place SST "C" securely into a vise.
Install SST "A" and "B" and generator into SST "C". See Fig. 6 . Tighten pulley nut in the opposite direction of
disassembly. See TORQUE SPECIFICATIONS . To complete reassembly, reverse disassembly procedure.
After completing assembly, verify rotor turns smoothly.

Assembly (100-Amp)

Place drive end frame on pulley and install rotor in drive end frame. Place generator washer on rotor and
position rectifier end frame on rotor. Using 29 mm socket, slowly press in rectifier end frame. Use generator
Pulley Set Nut Wrench Set (SST 09820-63011) to install generator pulley. Place SST "C" securely into a vise.
Install SST "A" and "B" and generator into SST "C". See Fig. 6 . Before installing brush holder, push brushes
back into holder and install .039" (1 mm) pin into brush holder hole. See Fig. 10 . Tighten pulley nut in the
opposite direction of disassembly. See TORQUE SPECIFICATIONS . To complete reassembly, reverse
disassembly procedure. After completing assembly, verify rotor turns smoothly.

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Fig. 10: Securing Brushes In Brush Holder

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

GENERATOR SPECIFICATIONS
GENERATOR SPECIFICATIONS
Application Specification
Brush Length
Standard .374-.453 Inch (9.5-11.5 mm)
Limit (Minimum) More Than .059 Inch (1.5 mm)
Rotor
Resistance (1)
90-Amp 2.1-2.5 Ohms
100-Amp 2.3-2.7 Ohms
Slip Ring Diameter
Standard .551-.567 Inch (14.0-14.4 mm)
Minimum
90-Amp .504 Inch (12.8 mm)
100-Amp .551 Inch (14.0 mm)
Generator Regulated Output
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Amperage
Without Load 10 Or Less Amps
With Load 30 Or More Amps
Voltage 13.2-14.8 Volts
(1) Measured @ 68°F (20°C).

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Generator Mounting Bolt
8-mm 15 (21)
10-mm 38 (52)
Pulley Nut 81 (111)
INCH Lbs. (N.m)
Battery Wire Terminal Nut 36 (4.1)
Bearing Retainer Bolt
90 amp 27 (3.0)
100 amp 20 (2.3)
Brush Holder Screw 16 (1.8)
Drive End Frame Bolt/Nut
With Cord Clip 40 (4.5)
Without Cord Clip 51 (5.8)
Generator Holder With Rectifier 26 (2.9)
Generator Rear End Cover
Screw 35 (3.9)
Nut 41 (4.6)
Regulator Assembly 18 (2.0)

WIRING DIAGRAMS
Refer to CHARGING CIRCUIT under STARTING/CHARGING in SYSTEM WIRING DIAGRAMS article
in ELECTRICAL.

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