Toyota Tacoma manuals

Toyota Corolla Repair Manual: Overhaul

1. Remove generator pulley

Sst 0982063010 (0982006010, 0982006020)

Sst 0982063010 (0982006010, 0982006020)

Hint:

  1. Hold sst 1 a with a torque wrench, and tighten sst 1 b clockwise to the specified torque.

    Torque: 39 nvm (398 Kgfcm, 29 ftlbf)

Notice

: check that sst is secured to the rotor shaft.

  1. Mount sst 2 in a vise.
  2.  insert sst 1 a, b into sst 2, and attach the pulley nut to sst 2.

  1. To loosen the pulley nut, turn sst 1 a in the direction shown in the illustration.

    Notice

    : to prevent damage to the rotor shaft, do not loosen the pulley nut more than onehalf of a turn.

  2.  remove the alternator form sst 2.

  1. Turn sst 1 b, and remove sst 1 a, b.
  2.  remove the pulley nut and pulley.

2. Remove generator brush holder assy

  1.  remove the nut and terminal insulator.
  2.  remove the screw, nut and terminal plate.
  3.  remove the 2 nuts and rear end cover.
  4. remove the brush cover from the brush holder.
  5.  remove the 2 screw and brush holder.
  6.  remove the plate seal.

3. Remove generator regulator assy

  1.  remove the 3 screws and regulator.

4. Remove generator holder w/rectifier

  1.  remove the 4 screws and holder w/ rectifier.

5. Remove generator rectifier end frame

  1. Remove the plate seal from the rectifier end frame.
  2.  remove the 4 terminal insulator, 4 nuts and cord clip.
  3.  using sst, remove the rectifier end frame.

    Sst 0928646011

6. Remove generator rotor assy

  1.  remove the washer from the rotor.
  2.  remove the rotor from drive end frame.

7. Inspect generator regulator assy

  1. Using an ohmmeter, check the continuity between terminals f and b.

Standard

: when the positive and negative poles between terminals f and b are exchanged, there is continuity in one way but no continuity in another way.

  1. Using an ohmmeter, check the continuity between terminals f and e.

Standard

: when the positive and negative poles between terminals f and e are exchanged, there is continuity in one way but no continuity in another way.

8. Inspect generator regulator assy

  1. Using an ohmmeter, check that there is continuity between the slip rings.

    Standard resistance: 2.1 2.5 W at 20 c (68 f)

  1. Using an ohmmeter, check that there is no continuity between the slip ring and rotor.

  1. Using a vernier calipers, measure the slip ring diameter.

    Standard diameter: 14.2 14.4 Mm (0.559 0.567 In.) Minimum diameter: 12.8 Mm (0.504 In.)

9. Inspect brush

  1. Using a 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.)

10. Install generator rotor assy

  1. Install the rotor to the drive end frame.
  2.  install the washer on the rotor.

  1. Using a socket wrench 29 and press, slowly press in the rectifier end frame.

  1. Install the cord clip and 4 nuts.

    Torque:
    nut a 4.5 Nvm (46 Kgfcm, 40 in.Vlbf) nut b 5.4 Nvm (55 Kgfcm, 48 in.Vlbf)

11. Install generator holder w/rectifier

  1.  install the holder w/ rectifier with 4 screws.

    Torque: 2.9 Nvm (30 Kgfcm, 26 in.Vlbf)

12. Install generator regulator assy

  1.  install the regulator with the 3 screw.

    Torque: 2.0 Nvm (20 Kgfcm, 18 in.Vlbf)

13. Install generator brush holder assy

  1. Place the plate seal on the brush holder.
  2. install the brush holder with the 2 screws.

    Torque: 2.0 Nvm (20 Kgfcm, 18 in.Vlbf)

Notice

: pay attention to the holder installation direction.

  1.  place the brush cover on the brush holder.
  2.  install the rear end cover with the 2 nuts.

    Torque: 4.4 Nvm (45 Kgfcm, 39 in.Vlbf)

  3.  install the terminal plate with the screw and nut.

    Torque:
    bolt 3.9 Nvm (40 Kgfcm, 35 in.Vlbf) nut 4.4 Nvm (45 Kgfcm, 39 in.Vlbf)

  4.  install the terminal insulator withe the nut.

    Torque: 4.1 Nvm (42 Kgfcm, 36 in.Vlbf)

14. Install generator pulley

Sst 0982063010 (0982006010, 0982006020)

Sst 0982063010 (0982006010, 0982006020)

Hint:

  1. Install the pulley to the rotor shaft by tightening the pulley nut by hand.
  2.  hold sst 1 a with a torque wrench, and tighten sst 1 b clockwise to the specified torque.

    Torque: 39 nvm (398 Kgfcm, 29 ftlbf)

Notice

: check that sst is secured to the pulley shaft.

  1. Mount sst 2 in a vise.
  2.  insert sst 1 a, b into sst 2, and attach the pulley nut to sst 2.

  1. Tighten the pulley nut, turn sst 1 a in the direction shown in the illustration.

    Torque: 111 nvm (1,132 Kgfcm, 82 ftlbf)

  2.  remove the alternator form sst 2.

  1. Turn sst 1 b, and remove sst 1 a, b.
  2.  turn the pulley, and check that the pulley moves smoothly.
Components
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Front suspension
...

Other materials:

Replacement
Hint: installation is in the reverse order of the removal. But the installation is indicated only when it has a point. In the lh side, work in the same procedure as in the rh side. 1. Disconnect battery negative terminal 2. Remove front seat assembly rh 3. Remove front seat inner be ...

Inspection procedure
1 Check low pitched horn assy Connect the positive (+) lead from the battery to the terminal and negative () lead to the horn body, and check that the horn blows. 2 Check relay (marking: horn) Remove the relay from the engine room j/b.  check the horn relay continu ...

Inspection procedure
1 Prepare for inspection Disconnect the negative () terminal cable from the battery, and wait at least for 90 seconds.  remove the horn button assy .  disconnect the connector of the instrument panel passenger airbag assy .  disconnect the connector of the front seat ...

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