GENERATOR INSPECTION [ZJ, ZY]

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Caution

• Do not apply direct battery positive voltage to generator terminal D, otherwise it could cause damage to the internal parts (power transistor) of the generator.

Generator Warning Light

1. Verify that the battery is fully charged.

2. Verify that the drive belt is correct. (See DRIVE BELT INSPECTION [ZJ, ZY].)

3. With the ignition switch turned to the ON position, verify that the generator warning light illuminates.

• If it does not illuminate, inspect the generator warning light and the wiring harness.

― If the generator warning light and the wiring harness are normal, inspect the PCM.

4. Verify that the generator warning light goes out after the engine is started.

• If the generator warning light does not go out, perform the DTC inspection, then perform troubleshooting according to the corresponding diagnostic procedure. (See ON-BOARD DIAGNOSTIC TEST [ZJ, ZY].) (See DTC TABLE [ZJ, ZY].)

Generator

Voltage

1. Verify that the battery is fully charged.

2. Verify that the drive belt is correct. (See DRIVE BELT INSPECTION [ZJ, ZY].)

3. Turn off all electrical loads.

4. Start the engine.

5. Verify that the generator rotates smoothly without any noise while the engine is running.

• If there is any noise, find the cause and repair or replace the generator.

6. Measure the voltage at each terminal using a tester.

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• If it is not as specified, find the cause and repair or replace the applicable part.

Generator standard voltage [IG-ON]

Terminal B: B+

Terminal P: Approx. 1 V or less

Terminal D: Approx. 0 V

Generator standard voltage [Idle, 20 °C {68 °F}]

Terminal B: 13—15 V

Terminal P: Approx. 3—8 V

Terminal D: Turn the electrical loads (headlights, blower motor, rear window defroster, brake light, etc.) on and verify that the voltage reading increases.

Current

Note

• Since the charging current decreases rapidly after starting the engine, carry out the following procedure quickly, and read the maximum current value.

1. Verify that the battery is fully charged.

2. Verify that the drive belt is correct. (See DRIVE BELT INSPECTION [ZJ, ZY].)

3. Disconnect the negative battery cable.

4. Connect a tester, which can read 120 A or more, between generator terminal B and the wiring harness.

5. Connect the negative battery cable.

6. Turn off all electrical loads.

7. Start the engine.

8. Increase engine speed to 2,500 rpm.

Note

• When the electrical load on the vehicle is low, the specified current cannot be verified although the generator is normal. In this case, increase the electrical load (Leave the headlights turned on for a while, then discharge the battery, or use a similar method.) and recheck.

• When the generator itself or the ambient temperature are too high, the specified current also cannot be verified. In this case, cool down the generator and recheck.

9. Turn the electrical loads (headlights, blower motor, rear window defroster, brake lights, etc.) on and verify that the current reading increases more than the minimum value indicated below.

― If it is not as specified, go to the PCM and generator shearing inspection. (See PCM and generator shearing inspection.)

Generator generated current minimum value

70% of the nominal output current (nominal output current: 90 A)

[Ambient temp. 20 °C {68 °F}, voltage 13.0—15.0 V, both engine and generator are hot]

PCM and generator shearing inspection

1. Connect the M-MDS to the DLC-2.

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2. Inspect as follows:

Step

Inspection

Action

1

Measure the generator terminal B voltage when the electrical loads^*1 are on and off.

15 V or more

Go to Step 2.

13—15 V

Normal^*2

13 V or less

Go to Step 3.

2

Monitor the ALTT V PID using the M-MDS, or measure the voltage of PCM terminal 2AE using a tester. Is the voltage between 13—15 V?

Yes

Go to Step 4.

No

PCM input error.

3

Monitor the ALTT V PID using the M-MDS, or measure the voltage of PCM terminal 2AE using a tester. Is the voltage between 13—15 V?

Yes

Go to Step 5.

No

PCM input error.

4

Monitor the ALTF PID using the M-MDS, or calculate the duty value of the PCM terminal 2AF using an oscilloscope. Is the duty value 100%?

Yes

PCM input error.

No

PCM, generator, or both are not normal.

5

Monitor the ALTF PID using the M-MDS, or calculate the duty value of the PCM terminal 2AF using an oscilloscope. Is the duty value 0%?

Yes

PCM input error.

No

PCM, generator, or both are not normal.

Step	Inspection	Action
1	Measure the generator terminal B voltage when the electrical loads^*1 are on and off.	15 V or more	Go to Step 2.
13—15 V	Normal^*2
13 V or less	Go to Step 3.
2	Monitor the ALTT V PID using the M-MDS, or measure the voltage of PCM terminal 2AE using a tester. Is the voltage between 13—15 V?	Yes	Go to Step 4.
No	PCM input error.
3	Monitor the ALTT V PID using the M-MDS, or measure the voltage of PCM terminal 2AE using a tester. Is the voltage between 13—15 V?	Yes	Go to Step 5.
No	PCM input error.
4	Monitor the ALTF PID using the M-MDS, or calculate the duty value of the PCM terminal 2AF using an oscilloscope. Is the duty value 100%?	Yes	PCM input error.
No	PCM, generator, or both are not normal.

5	Monitor the ALTF PID using the M-MDS, or calculate the duty value of the PCM terminal 2AF using an oscilloscope. Is the duty value 0%?	Yes	PCM input error.
No	PCM, generator, or both are not normal.

*1 :Headlights, blower motor, rear window defroster, brake lights, etc.

*2 :If the generator field coil duty value does not change when electrical loads (such as headlights, blower motor, rear window defroster, brake lights) are on or off, inspection with discharged battery is needed.

Generator Inner Parts

Rotor

1. Measure the resistance between the slip rings using a tester.

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