GENERATOR INSPECTION[LF, L3]

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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[LF, L3].)

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[MTX, LF ATX (FS5A-EL)].) (See DTC TABLE[LF ATX (FN4A-EL), L3 ATX].)

Generator

Voltage

1. Verify that the battery is fully charged.

2. Verify that the drive belt deflection/tension is correct. (See DRIVE BELT INSPECTION[LF, L3].)

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.

European (L.H.D. U.K.) specs.

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Except for European (L.H.D. U.K.) specs.

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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—8V

Terminal D: Turn the electrical loads (headlights, blower motor, rear window defroster) 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 deflection/tension is correct. (See DRIVE BELT INSPECTION[LF, L3].)

3. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION[LF, L3].)

4. Disconnect the negative battery cable.

5. Connect a tester capable of reading 120 A or more between generator terminal B and the wiring harness.

6. Connect the negative battery cable.

7. Turn off all electrical loads.

8. Start the engine.

9. 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.

10. 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

Generator generated current minimum value (European (L.H.D. U.K.) specs.)

70 % of the nominal output current (nominal output current: 110 A)

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

Generator generated current minimum value (Except for European (L.H.D. U.K.) specs.)

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. 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 M-MDS, or measure the voltage of PCM terminal 2AJ^*3, 2AM^*4 using a tester. Is the voltage between 13 and 15 V ?

Yes

Go to Step 4.

No

PCM input error.

3

Monitor the ALTT V PID using M-MDS, or measure the voltage of PCM terminal 2AJ^*3, 2AM^*4 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 2AI^*3, 2AQ^*4 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 2AI^*3, 2AQ^*4 using 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 M-MDS, or measure the voltage of PCM terminal 2AJ^3, 2AM^4 using a tester. Is the voltage between 13 and 15 V ?	Yes	Go to Step 4.
No	PCM input error.
3	Monitor the ALTT V PID using M-MDS, or measure the voltage of PCM terminal 2AJ^3, 2AM^4 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 2AI^3, 2AQ^4 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 2AI^3, 2AQ^4 using 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, and stop lamp.

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

*3 :MTX, LF ATX (FS5A-EL)

*4 :LF ATX (FN4A-EL), L3 ATX

Generator Inner Parts (European (L.H.D. U.K.) specs.)

Rotor

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

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• If not within the specification, replace the rotor.

Generator rotor resistance (between slip rings) [20 °C {68 °F}]

• 1.8—2.2 ohm

2. Verify that there is no continuity between the slip ring and core using a tester.

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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 smooth it.

Stator coil

1. Verify that the continuity is as indicated in the table.

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• If there is any malfunction, replace the stator.

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

• If there is continuity, replace the stator coil.

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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.

Generator brush length

Standard: 22.5 mm {0.89 in}

Minimum: 5.0 mm {0.20 in}

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.

Generator brush spring force

• Standard: 4.1—5.3 N {0.42—0.54 kgf, 0.92—1.19 lbf}

• Minimum: 1.7 N {0.17 kgf, 0.38 lbf}

Rectifier (Using an analog circuit tester)

1. Inspect for continuity of the diodes using an analog circuit tester.

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• If not as specified, replace the rectifier.

Specification

Negative	Positive	Continuity
E	P1, P2, P3, P4, P5, P6	Yes
B	P1, P2, P3, P4, P5, P6	No
P1, P2, P3, P4, P5, P6	E	No
P1, P2, P3, P4, P5, P6	B	Yes

Rectifier (Using a digital circuit tester)

1. Inspect for continuity of the diodes using a digital circuit tester.

• If not as specified, replace the rectifier.

Specification

Negative	Positive	Continuity
E	P1, P2, P3, P4, P5, P6	No
B	P1, P2, P3, P4, P5, P6	Yes
P1, P2, P3, P4, P5, P6	E	Yes
P1, P2, P3, P4, P5, P6	B	No

Bearing

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

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• Replace the bearing if necessary.

Generator Inner Parts (Except for European (L.H.D. U.K.) specs.)

Rotor

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

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• If not within the specification, replace the rotor.

Resistance [20 °C {68 °F}]

1.8—2.2 ohms

2. Verify that there is no continuity between the slip ring and core using a tester.

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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 smooth it.

Stator coil

1. Inspect for continuity between the stator coil leads using a tester.

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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 a tester.

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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.

Standard brush length

18.5 mm {0.73 in}

Minimum brush length

5.0 mm {0.2 in}

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.

Standard spring force

4.8—6.0 N {0.49—0.61 kgf, 1.08—1.34 lbf}

Minimum spring force

2.16 N {0.22 kgf, 0.49 lbf}

Rectifier

1. Inspect for continuity of the diodes using a tester.

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• If not as specified, replace the rectifier.

Specification

Tester		Continuity
Negative	Positive	Continuity
E	P1, P2, P3, P4	Yes
B	P1, P2, P3, P4	No
P1, P2, P3, P4	E	No
P1, P2, P3, P4	B	Yes

Bearing

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

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• Replace the bearing if necessary.