Toyota 1.8L1ZZ-FED (ZZW30) Engine Service & Repair Manual

CH021–01 – CHARGING CHARGING SYSTEM CH–1 778 AuthorĂ: DateĂ: 2000 MR2 (RM760U) CHARGING SYSTEM PRECAUTION S Check that the battery cables are connected to the correct terminals. S Disconnect the battery cables when the battery is given a quick charge. S Do not perform tests with a high voltage insulation resistance tester. S Never disconnect the battery while the engine is running.

CH0DG–01 Z11577 Except Maintenance–Free Battery Z11556 Voltmeter Maintenance–Free Battery Z11580 White Red OK Blue Insufficient Water Charging Necessary CH–2 – CHARGING CHARGING SYSTEM 779 AuthorĂ: DateĂ: 2000 MR2 (RM760U) ON–VEHICLE INSPECTION 1. CHECK BATTERY ELECTROLYTE LEVEL Check the electrolyte quantity of each cell. Maintenance–Free Battery: If under the lower level, replace the battery (or add distilled water if possible) and check the charging system. Except Maintenance–Free Battery: If under the lower level, add distilled water. 2. Except Maintenance–Free Battery: CHECK BATTERY SPECIFIC GRAVITY Check the specific gravity of each cell. Standard specific gravity: 1.25 – 1.29 at 20°C (68 °F) If the specific gravity is less than specification, charge the battery. 3. Maintenance–Free Battery: CHECK BATTERY VOLTAGE (a) After having driven the vehicle and in the case that 20 minutes have not passed after having stopped the engine, turn the ignition switch ON and turn on the electrical system (headlight, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge. (b) Turn the ignition switch OFF and turn off the electrical sys- tems. (c) Measure the battery voltage between the negative (–) and positive (+) terminals of the battery. Standard voltage: 12.5 – 12.9 V at 20°C (68°F) If the voltage is less than specification, charge the battery. HINT: Check the indicator as shown in illustration. 4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES (a) Check that the battery terminals are not loose or cor- roded. (b) Check the fusible link, H–fuses and fuses for continuity.

B00543 B00145 B00146 B00540 CORRECT WRONG WRONG – CHARGING CHARGING SYSTEM CH–3 780 AuthorĂ: DateĂ: 2000 MR2 (RM760U) 5. INSPECT DRIVE BELT (a) Visually check the belt for excessive wear, frayed cords etc. If any defect has been found, replace the drive belt. HINT: Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be re- placed. HINT: The drive belt tension can be released by turning the belt tensioner clockwise. (b) Check the belt tensioner operation. S Check that belt tensioner moves downward when the drive belt is pressed down at the points indi- cated in the illustration with approx. 98 N (10 kgf, 22.0 lbf) of force. S Check the alighment of the belt tensioner pulley to make sure the drive belt will not slip off the pulley. If necessary, replace the belt tensioner. HINT: S After installing a belt, check that it fits properly in the ribbed grooves. S Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley. S After installing a new belts, run the engine for about 5 minutes and check the belt tension existing. 6. VISUALLY CHECK GENERATOR WIRING AND LIS- TEN FOR ABNORMAL NOISES (a) Check that the wiring is in good condition. (b) Check that there is no abnormal noise from the generator while the engine is running. 7. INSPECT DISCHARGE WARNING LIGHT CIRCUIT (a) Turn the ignition switch ”ON”. Check that the discharge warning light comes on. (b) Start the engine. Check that the light goes off. If the light does not operate as specified, troubleshoot the discharge warning light circuit.

CH0732 Disconnect Wire from Terminal B Generator Voltmeter Battery Ammeter B09163 Terminal F CH–4 – CHARGING CHARGING SYSTEM 781 AuthorĂ: DateĂ: 2000 MR2 (RM760U) 8. INSPECT CHARGING CIRCUIT WITHOUT LOAD HINT: If a battery/generator tester is available, connect the tester to the charging circuit as permanufacturer’s instructions. (a) If a tester is not available, connect a voltmeter to the charging circuit as follows: S Disconnect to the wire from terminal B of the generator and connect it to the negative (–) lead of the ammeter. S Connect the positive (+) lead of the ammeter to terminal B of the generator. S Connect the positive (+) lead of the voltmeter to terminal B of the generator. S Ground the negative (–) lead of the voltmeter. (b) Check the charging circuit as follows: With the engine running from idle to 2,000 rpm, check the reading on the ammeter and voltmeter. Standard amperage: 10A or less Standard voltage: 13.2 – 14.0 V If the voltmeter reading is more than standard voltage, replace the voltage regulator. If the voltmeter reading is less than the standard voltage, check the voltage regulator and generator as follows: S With terminal F grounded, start the engine and check the voltmeter reading of terminal B. S If the voltmeter reading is more than standard voltage, replace the voltage regulator. S If the voltmeter reading is less than standard voltage, check the generator. 9. INSPECT CHARGING CIRCUIT WITH LOAD (a) With the engine running at 2,000 rpm, turn on the high beam headlights and place the heater blower switch at ”H”. (b) Check the reading on the ammeter. Standard amperage: 30 A or more If the ammeter reading is less than standard amperage, repair the generator. HINT: If the battery is fully charged, the indication will sometimes be less than standard amperage.

CH023–04 B10240 Generator Generator Connector Generator Wire Wire Clamp 25 (255, 18) 54 (550, 40) Drive Belt 52 (530, 38) 52 (530, 38) RH Engine Mounting Insulator N·m (kgf·cm, ft·lbf) : Specified torque – CHARGING GENERATOR CH–5 782 AuthorĂ: DateĂ: 2000 MR2 (RM760U) GENERATOR COMPONENTS

B07729 111 (1,125, 81) Drive End Flame z Front Bearing Retainer Pulley Rotor Bearing Cover z Rear Bearing Generator Washer Rectifire End Frame Rubber Insulator Rectifire Holder Voltage Regulator Seal Plate Brush Holder Brush Holder Cover Terminal Insulator Rear End Cover Plate Terminal N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part Wire Clip CH–6 – CHARGING GENERATOR 783 AuthorĂ: DateĂ: 2000 MR2 (RM760U)

B00145 CH024–03 B07730 (a) (b) (c) B07731 – CHARGING GENERATOR CH–7 784 AuthorĂ: DateĂ: 2000 MR2 (RM760U) REMOVAL 1. REMOVE DRIVE BELT Turn the drive belt tensioner slowly clockwise and loosen it. Then, remove the drive belt and replace the drive belt tensioner little by little and fix it quietly. 2. REMOVE RH ENGINE MOUNTING INSULATOR (See page EM–54) 3. REMOVE GENERATOR (a) Disconnect the wire clamp from the wire clip on the rectifier end frame. (b) Remove the cap and nut, and disconnect the generator wire. (c) Disconnect the generator connector. (d) Remove the 2 bolts and generator.

B07732 Plate Terminal CH025–03 B07733 B07734 B00210 Turn SST (B) SST (A) B00224 SST (B) Insert SST (C) CH–8 – CHARGING GENERATOR 785 AuthorĂ: DateĂ: 2000 MR2 (RM760U) DISASSEMBLY 1. REMOVE REAR END COVER (a) Remove the nut and terminal insulator. (b) Remove the bolt, 3 nuts, plate terminal and end cover. 2. REMOVE BRUSH HOLDER AND VOLTAGE REGULA- TOR (a) Remove the brush holder cover from the brush holder. (b) Remove the 5 screws, brush holder and voltage regulator. (c) Remove the seal plate from the rectifier end frame. 3. REMOVE RECTIFIER HOLDER (a) Remove the 4 screws and rectifier holder. (b) Remove the 4 rubber insulators. 4. REMOVE PULLEY (a) Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820–63010 Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) (b) Check that SST (A) is secured to the rotor shaft. (c) Mount SST (C) in a vise. (d) Insert SST (B) into SST (C), and attach the pulley nut to SST (C).

B00237 SST (A) SST (C) Turn B00322 Turn SST (A) SST (B) B07735 Wire Clip B09160 SST – CHARGING GENERATOR CH–9 786 AuthorĂ: DateĂ: 2000 MR2 (RM760U) (e) To loosen the pulley nut, turn SST (A) in the direction shown in the illustration. NOTICE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one–half of a turn. (f) Remove the generator from SST (C). (g) Turn SST (B), and remove SST (A and B). (h) Remove the pulley nut and pulley. 5. REMOVE RECTIFIER END FRAME (a) Remove the 4 nuts and wire clip. (b) Using SST, remove the rectifier end frame. SST 09286–46011 (c) Remove the generator washer from the rotor 6. REMOVE ROTOR FROM DRIVE END FRAME

CH0784 Ohmmeter Continuity CH0DH–01 B02105 No Continuity Ohmmeter CH1023 B00240 Ohmmeter Continuity B00102 No Continuity Ohmmeter CH–10 – CHARGING GENERATOR 787 AuthorĂ: DateĂ: 2000 MR2 (RM760U) INSPECTION 1. INSPECT ROTOR (a) Check the rotor for open circuit. Using an ohmmeter, check that there is continuity between the slip rings. Standard resistance: 2.1 – 2.5 Ω at 20°C (68°F) If there is no continuity, replace the rotor. (b) Check the rotor for ground. Using an ohmmeter, check that there is no continuity between the slip ring and rotor. If there is continuity, replace the rotor. (c) Check that the slip rings are not rough or scored. If rough or scored, replace the rotor. (d) Using a vernier caliper, 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.) If the diameter is less than minimum, replace the rotor. 2. INSPECT STATOR (DRIVE END FRAME) (a) Check the stator for open circuit. Using an ohmmeter, check that there is continuity between the coil leads. If there is no continuity, replace the drive end frame assembly. (b) Check the stator for ground. Using an ohmmeter, check that there is no continuity between the coil lead and drive end frame. If there is continuity, replace the drive end frame assembly.

Toyota 1.8L1ZZ-FED (ZZW30) Engine Service & Repair Manual

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