Section 132 (Charging System (2GR-FE)): Generator: Inspection

WARNING: This page is about a different car, the 2007 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

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
1. 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.
    
    Fig 2: Measuring Resistance Between Slip Rings
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Measure the resistance between the slip ring and rotor core.
    Standard resistance:
    
    1 MΩ or higher
    
    If the result is not as specified, replace the generator rotor assembly.
    
    Fig 3: Measuring Resistance Between Slip Ring And Rotor Core
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. 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.
    
    Fig 4: Measuring Slip Ring Diameter
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. 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.
    
    Fig 5: Checking Condition Of Bearing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT GENERATOR DRIVE END FRAME BEARING
1. Check that the bearing is not rough or worn.
  OK: The bearing rotates smoothly.
  
  If the bearing does not rotate smoothly, replace the bearing.
  
  Fig 6: Inspecting Condition Of 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 Clutch Operation
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002