GENERATOR INSPECTION[ZJ, ZY, Z6]

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Caution

•  Do not apply direct battery positive voltage to the 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 deflection/tension is correct. (See DRIVE BELT INSPECTION[ZJ, ZY, Z6].)

3.  With the ignition switch at ON, 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 off after the engine is started.

•  If it does not go out, inspect if any one of the following DTCs in the on-board diagnostic system are displayed: P0112, P0113, P2502, P2503, P2504. (See DTC TABLE[ZJ, ZY, Z6].)

Generator

Voltage

1.  Verify that the battery is fully charged.

2.  Verify that the drive belt deflection/tension is correct. (See DRIVE BELT INSPECTION[ZJ, ZY, Z6].)

3.  Turn off all electrical loads.

4.  Start the engine and verify that the generator rotates smoothly without any noise while the engine is running.

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

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•  Headlights

•  Blower motor

•  Rear defroster

Current

Note

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

•  If the accelerator pedal is depressed continuously for a specified time, the engine speed may decrease to the idle speed. This is due to the fuel cut control operation, which prevents overheating, and it does not indicate a malfunction.

1.  Verify that the battery is fully charged.

2.  Verify that the drive belt deflection/tension is correct. (See DRIVE BELT INSPECTION[ZJ, ZY, Z6].)

3.  Disconnect the negative battery cable.

4.  Connect a tester capable of reading 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 of the vehicle is low, specified current will not be verified although the generator is normal. In this case, increase the electrical load (by turning on the headlight and leave it for a while, then discharge the battery or by similar methods) and recheck.

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

9.  Turn the following electrical loads on and verify that the current reading increases more than the minimum value indicated below.

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

•  Headlights (high-beam)

•  Blower motor (high)

•  Rear window defroster

•  Stop lamp

PCM and generator shearing inspection

1.  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 ALTTV PID using M-MDS, or measure the voltage of PCM terminal 2AR (without throttle valve actuator), 2AE (with throttle valve actuator) using a tester. Is the voltage between 13 and 15 V ?		Yes	Go to Step 4.
			No	PCM input error.
3	Monitor the ALTTV PID using M-MDS, or measure the voltage of PCM terminal 2AR (without throttle valve actuator), 2AE (with throttle valve actuator) using a tester. Is the voltage between 13 and 15 V ?		Yes	Go to Step 5.
			No	PCM input error.
4	Monitor the ALTF PID using M-MDS, or calculate the duty value of the PCM terminal 2AN (without throttle valve actuator), 2AF (with throttle valve actuator) using oscilloscope. Is the duty value 100% ?		Yes	PCM input error.
			No	PCM, generator, or both are not normal.
5	Monitor the ALTF PID using M-MDS, or calculate the duty value of the PCM terminal 2AN using oscilloscope. Is the duty value 0% ?		Yes	PCM input error.
			No	PCM, generator, or both are not normal.

Generator Inner Parts

Rotor

1.  Measure the resistance between the slip rings using an ohmmeter.

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•  If not as specified, replace the rotor.

2.  Verify that there is no continuity between the slip ring and core using an ohmmeter.

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•  If there is continuity, replace the rotor.

3.  Inspect the slip ring surface condition.

•  If the slip ring surface is rough, use a lathe or fine sandpaper to repair it.

Stator coil

1.  Inspect for continuity between the stator coil leads using an ohmmeter.

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•  If there is no continuity, replace the stator.

2.  Verify that there is no continuity between the stator coil leads and the core using an ohmmeter.

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•  If there is continuity, replace the stator coil.

Brush

1.  Inspect brushes for wear.

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•  If any brush is worn almost to or beyond the limit, replace all of the brushes.

Brush spring

1.  Measure the force of the brush spring using a spring pressure gauge.

2.  Read the spring pressure gauge at the brush tip projection of 2 mm {0.079 in}.

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•  Replace the brush spring if necessary.

Rectifier (without throttle valve actuator)

1.  Inspect for continuity of the diodes using an ohmmeter.

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•  If not as specified, replace the rectifier.

Specification

Rectifier (with throttle valve actuator)

1.  Inspect for continuity of the diodes using an ohmmeter.

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•  If not as specified, replace the rectifier.

Specification

Bearing

1.  Inspect for abnormal noise, looseness, and sticking.

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•  Replace the bearing if necessary.