CH–1

CHARGING (5VZ–FE) – CHARGING SYSTEM

CHARGING SYSTEM CH0J3–02

ON–VEHICLE INSPECTION
CAUTION:

Check that the battery cables are connected to the
correct terminals.

Disconnect the battery cables when the battery is giv-
en a quick charge.

Do not perform tests with a high voltage insulation re-
sistance tester.

Never disconnect the battery while the engine is run-
ning.

Check that the charging cable is tightened on termi-
nal B of the alternator generates or not with connect-
ing terminal F to the other terminal.

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1. CHECK BATTERY ELECTROLYTE LEVEL
Check the electrolyte quantity of each cell.
Upper Level Maintenance–free Battery:
If under the lower level, replace the battery (or add distilled wa-
ter if possible) and check the charging system.
Except Maintenance–free Battery:
If under the lower level, add distilled water.
Lower Level

B07241

Except Maintenance–free Battery 2. Except Maintenance–free Battery:

CHECK BATTERY SPECIFIC GRAVITY
Check the specific gravity of each cell.
Standard specific gravity: 1.25 – 1.29 at 20°C (68°F)
If the specific gravity is less than specification, charge the bat-
tery.
3. Maintenance–free Battery:
CHECK BATTERY VOLTAGE
B07242 (a) After having driven the vehicle and in the case that 20
minutes have not passed after having stopped the en-
gine, turn the ignition switch ON and turn on the electrical
system (headlight, blower motor, rear defogger etc.) for
60 seconds to remove the surface charge.
(b) Turn the ignition switch OFF and turn off the electrical sys-
tems.

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1463

CH–2
CHARGING (5VZ–FE) – CHARGING SYSTEM

Maintenance–free Battery (c) Measure the battery voltage between the negative (–)
Voltmeter and positive (+) terminals of the battery.
Standard voltage: 12.5 – 12.9 V at 20°C (68°F)
If the voltage is less than specification, charge the battery.

B07243

Maintenance–free Battery HINT:

Check the indicator as shown in the illustration.
CLEAR EYE or
GREEN EYE DARK EYE LIGHT YELLOW
4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND
FUSES
CHARGED DISCHARGED ADD WATER
(a) Check that the battery terminals are not loose or cor-
roded.
(b) Check the fusible link and fuses for continuity.

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P14937

5. INSPECT DRIVE BELT

(a) Visually check the belt for excessive wear, frayed cords
etc.
HINT:
Cracks on the ribbed side of the belt are considered acceptable.
If the belt has chunks missing from the ribs, it should be re-
placed.

P06717

DENSO Boroughs (b) Using a belt tension gauge, check the drive belt tension.
Belt tension gauge:
DENSO BTG 20 (95506–00020) or
Boroughs No. BT–33–73F
Drive belt tension:
New belt 160 ± 25 lbf
Used belt 100 ± 20 lbf
If necessary, adjust the drive belt tension.
Z00038

HINT:

”New belt” refers to a belt which has been used less than
5 minutes on a running engine.

”Used belt” refers to a belt which has been used on a run-
ning engine for 5 minutes or more.
CORRECT WRONG WRONG
After installing the drive belt, check that it fits properly in
the ribbed grooves. Check with your hand to confirm that
the belt has not slipped out of the groove on the bottom
P06723 of the crank pulley.

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1464

 CH–3
CHARGING (5VZ–FE) – CHARGING SYSTEM

After installing a new belt, run the engine for approx. 5

minutes and then recheck the tension.
6. VISUALLY CHECK GENERATOR WIRING AND LIS-
TEN FOR ABNORMAL NOISES
(a) Check that the wiring is in good condition.
(b) Check that there is no abnormal noise from the generator
while the engine is running.

Ammeter 7. CHECK CHARGING CIRCUIT WITHOUT LOAD

Disconnect Wire HINT:
from Terminal B If a battery/generator tester is available, connect the tester to
the charging circuit as per manufacturer’s instructions.
Battery (a) If a tester is not available, connect a voltmeter and amme-
ter to the charging circuit as follows:
B

Disconnect the wire from terminal B of the generator
Generator

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Voltmeter
and connect the wire to the negative (–) terminal of
Z10324 the ammeter.

Connect the test lead from the positive (+) terminal
of the ammeter to terminal B of the generator.

Connect the positive (+) lead of the voltmeter to ter-
minal B of the generator.

Ground the negative (–) lead of the voltmeter.
(b) Check the charging circuit as follows:
With the engine running from idling to 2,000 rpm, check
the reading on the ammeter and voltmeter.
Standard amperage: 10 A or less
Standard voltage: 13.2 – 14.8 V
If the voltage reading is greater than the standard voltage, re-
place the voltage regulator.
8. INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn on the high
beam headlights and place the heater blower switch at HI.
(b) Check the reading on the ammeter.
Standard amperage: 30 A or more
If the ammeter reading is less than standard amperage, repair
the generator.
HINT:
If the battery is fully charged, the indication will sometimes be
less than standard amperage.

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1465

CH–4
CHARGING (5VZ–FE) – GENERATOR

GENERATOR
CH02J–06

COMPONENTS
Generator Connector

Wire
Adjusting
Clamp
Bolt

Adjusting
Slider Generator Wire
Pivot Bolt
51.0 (520, 38)

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Drive Belt Generator

Lock Nut
18.5 (185, 14)
N·m (kgf·cm, ft·lbf) : Specified torque B16501

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1466

 CH–5
CHARGING (5VZ–FE) – GENERATOR

Rotor

Drive End Frame (Stator)

Pulley

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110.5 (1,125, 81)

Rear End Cover

Brush Holder

Voltage Regulator
Terminal Insulator

Rectifier End Frame

Plate Terminal
Brush Holder Cover

Seal Plate

Rectifier Holder
Generator Washer
Rubber Insulator

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

Non–reusable part B16589

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1467

CH–6
CHARGING (5VZ–FE) – GENERATOR
CH02K–04

REMOVAL
1. DISCONNECT WIRING FROM GENERATOR
(a) Disconnect the connector from the generator.
(b) Remove the nut and disconnect the wire from the genera-
tor.
(c) Disconnect the wire clamp from the generator.

2. REMOVE GENERATOR DRIVE BELT

Pivot Bolt (a) Loosen the adjust lock nut, bolt and pivot bolt.
(b) Loosen the adjusting belt, and remove the drive belt.
3. REMOVE GENERATOR
Remove the pivot bolt, adjusting lock nut, adjusting bolt, adjust-
ing slider and generator.
Adjusting Bolt

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Adjusting
Lock Nut P20342

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1468

 CH–7
CHARGING (5VZ–FE) – GENERATOR
CH0LJ–01

DISASSEMBLY
1. REMOVE REAR END COVER
(a) Remove the nut and terminal insulator.
(b) Remove the bolt 3 nuts, plate terminal and end cover.
(c) Remove the brush holder cover from the brush holder.

B16503

2. REMOVE BRUSH HOLDER

(a) Remove the 2 screws and brush holder.
(b) Remove the seal plate from the rectifier end frame.

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B16504

3. REMOVE VOLTAGE REGULATOR

Remove the 3 screws and voltage regulator.

B16505

4. REMOVE RECTIFIER HOLDER

(a) Remove the 4 screws and rectifier holder.
(b) Remove the 4 rubber insulators.

B12759

5. REMOVE PULLEY
(a) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
SST 09820–63011
Turn SST (A) Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Check that SST (A) is secured to the rotor shaft.

SST (B)
P13597

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1469

CH–8
CHARGING (5VZ–FE) – GENERATOR

(c) Mount SST (C) in a vise.

(d) Insert SST (B) into SST (C), and attach the pulley nut to
SST (C).
SST (B)

SST (C) Insert

P10834

(e) To loosen the pulley nut, turn SST (A) in the direction
shown in the illustration.
NOTICE:
SST (C)
To prevent damage to the rotor shaft, do not loosen the
SST (A) pulley nut more than one–half of a turn.
(f) Remove the generator from SST (C).

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Turn P10827

Turn (g) Turn SST (B), and remove SST (A and B).
(h) Remove the pulley nut and pulley.

SST (A)

SST (B)
P13598

6. REMOVE RECTIFIER END FRAME

(a) Remove the 4 nuts.

B12749

(b) Using SST, remove the rectifier end frame.

SST 09286–46011
(c) Remove the generator washer.
7. REMOVE ROTOR FROM DRIVE END FRAME

SST

CH0335

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1470

 CH–9
CHARGING (5VZ–FE) – GENERATOR
CH0J4–02

INSPECTION
1. INSPECT VOLTAGE REGULATOR
(a) Using an ohmmeter, check the continuity between termi-
nals F and B.
Standard:
When the positive and negative poles between termi-
nals F and B are exchanged, there is continuity in one
way but no continuity in another way.
B16396
If the continuity is not as specified, replace the regulator.

(b) Using an ohmmeter, check the continuity between termi-

nals F and E.
Standard:
When the positive and negative poles between termi-
nals F and E are exchanged, there is continuity in one
way but no continuity in another way.
If the continuity is not as specified, replace the regulator.

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B16505

2. INSPECT ROTOR FOR OPEN CIRCUIT

(a) Check the rotor for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the slip rings.
Ohmmeter Standard resistance: 2.1 – 2.5 Ω at 20°C (68°F)
If there is no continuity, replace the rotor.

Continuity
CH0784

(b) Check the rotor for ground.

Using an ohmmeter, check that there is no continuity be-
tween the slip ring and rotor.
If there is continuity, replace the rotor.
Ohmmeter

No Continuity
B02105

(c) Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor.
(d) Using vernier calipers, measure the slip ring diameters.
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.

CH1023

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1471

CH–10
CHARGING (5VZ–FE) – GENERATOR

3. INSPECT STATOR FOR OPEN CIRCUIT

(a) Check the stator for open circuit.
Using an ohmmeter, check that there is continuity be-
Continuity tween the coil leads.
Ohmmeter If there is no continuity, replace the drive end frame assembly.

CH0806

Ohmmeter (b) Check the stator for ground.

Using an ohmmeter, check that there is no continuity be-
No Continuity
tween the coil lead and drive end frame.
If there is continuity, replace the drive end frame assembly.

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B00102

Ohmmeter
4. INSPECT POSITIVE RECTIFIER
(a) Check the positive (+) rectifire.
(1) Using an ohmmeter, connect one tester probe to the
positive (+) terminal and the other to each rectifier
terminal.
Positive (+)
Terminal (2) Reverse the polarity of the tester probes and repeat
Rectifier step (a).
Terminal (3) Check that one shows continuity and the other
B05819 shows no continuity.
If continuity is not as specified, replace the rectifier holder.
(b) Check the negative (–) rectifire.
Ohmmeter Negative (–)
(1) Using an ohmmeter, connect one tester probe to
Terminal
each negative (–) terminal and the other to each
rectifier terminal.
(2) Reverse the polarity of the tester probes and repeat
step (a).
(3) Check that one shows continuity and the other
shows no continuity.
P13566 If continuity is not as specified, replace the rectifier holder.

5. INSPECT EXPOSED BRUSH LENGTH

Using vernier calipers, measure the exposed brush length.
Standard exposed length:
9.5 – 11.5 mm (0.374 – 0.453 in.)
Minimum exposed length: 1.5 mm (0.059 in.)
If the exposed length is less than minimum, replace the brush
holder assembly.

P13535

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1472

 CH–11
CHARGING (5VZ–FE) – GENERATOR

6. INSPECT BEARINGS
Check that the bearing is not rough or worn.
If necessary, replace the drive end frame assembly (front bear-
ing) or rotor assembly (rear bearing).

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2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1473

CH–12
CHARGING (5VZ–FE) – GENERATOR
CH0LK–01

REASSEMBLY
1. PLACE RECTIFIER END FRAME ON PULLEY
2. INSTALL ROTOR TO DRIVE END FRAME

P13486

3. INSTALL RECTIFIER END FRAME

(a) Place the generator washer on the rotor.

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P03794

(b) Using a 29 mm socket wrench and press, slowly press in

29 mm
Socket
the rectifier end frame.
Wrench (c) Install the 4 nuts.
Torque: 4.5 N·m (46 kgf·cm, 39 in.·lbf)

P13487

4. INSTALL PULLEY
(a) Install the pulley to the rotor shaft by tightening the pulley
nut by hand.
Turn
(b) Hold SST (A) with a torque wrench, and tighten SST (B)
SST (A) clockwise to the specified torque.
SST 09820–63011
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(c) Check that SST (A) is secured to the pulley shaft.
SST (B)
P13597

(d) Mount SST (C) in a vise.

(e) Insert SST (B) into SST (C), and attach the pulley nut to
SST (C).

SST (C)

P04210

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1474

 CH–13
CHARGING (5VZ–FE) – GENERATOR

(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)
SST (C)
(g) Remove the generator from SST (C).

Turn
SST (A)

P04395

Turn (h) Turn SST (B), and remove SST (A and B).

SST (A)

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SST (B)
P13598

5. INSTALL RECTIFIER HOLDER

Inside (a) Install the 4 rubber insulators on the lead wires.
NOTICE:
Be careful of the rubber insulators installation direction.

B05821

(b) Install the rectifier while pushing it with the 4 screws.

Push Torque: 2.94 N·m (30 kgf·cm, 26 in.·lbf)

B12754

6. INSTALL BRUSH HOLDER AND VOLTAGE REGULA-

TOR
(a) Place the seal plate on the rectifier end frame.

B05823

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1475

CH–14
CHARGING (5VZ–FE) – GENERATOR

(b) Place the voltage regulator and brush holder on the recti-
Upward
fier end frame.
NOTICE:
Be careful of the brush holder installation direction.
(c) Install the 5 screws.
Torque: 1.96 N·m (20 kgf·cm, 17in.·lbf)

B16508

7. INSTALL REAR END COVER

(a) Place the brush holder cover on the brush holder.

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B16509

(b) Install the end cover and plate terminal with the bolt and
3 nuts.
Torque:
Bolt: 3.85 N·m (39 kgf·cm, 34 in.·lbf)
Nut: 4.4 N·m (46 kgf·cm, 39 in.·lbf)

B16510

(c) Install the terminal insulator with the nut.

Torque: 4.1 N·m (41.5 kgf·cm, 36 in.·lbf)
8. CHECK THAT ROTOR ROTATES SMOOTHLY

B16511

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1476

 CH–15
CHARGING (5VZ–FE) – GENERATOR
CH0BI–02

INSTALLATION
Pivot Bolt
1. INSTALL GENERATOR
Temporarily install the generator with the pivot bolt,adjusting
slider,adjusting bolt and adjusting lock nut.
2. INSTALL AND ADJUST GENERATOR DRIVE BELT
(a) Install the generator drive belt.
Adjusting Bolt (b) Adjust the drive belt tension with the adjusting bolt (See
Adjusting page CH–1).
Lock Nut P20342
(c) Tighten the pivot bolt and adjusting lock nut.
Torque:
Pivot bolt: 51 N·m (520 kgf·cm, 38 ft·lbf)
Lock nut: 18.5 N·m (185 kgf·cm, 14 ft·lbf)
3. CONNECT WIRING TO GENERATOR
(a) Connect the wire clamp to the generator.
(b) Connect the wire to the generator with the nut.
(c) Connect the connector to the generator.

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2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1477