Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Charging Systems: Charging: Generator: Disassembly
- REMOVE GENERATOR REAR END COVER
- Remove the 3 nuts and end cover.
- Remove the terminal insulator.
- REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
- Remove the rear seal plate from the brush holder.
- Remove the 2 screws and brush holder.
- Remove the front seal plate from the coil.
- REMOVE GENERATOR PULLEY
- Hold SST (A) with a torque wrench and tighten SST (B) clockwise to the specified torque.
SST 09820-63011
Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
- Check that SST (A) is secured to the rotor shaft.
- Mount SST (C) in a vise.
- Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
- To loosen the pulley nut, turn SST (A) in the direction shown in the illustration.NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a turn.
- Remove the generator from SST (C).
- Turn SST (B) and remove SST (A and B).
- Remove the pulley nut and pulley.
- Hold SST (A) with a torque wrench and tighten SST (B) clockwise to the specified torque.
- REMOVE GENERATOR COIL ASSEMBLY
- Remove the 4 bolts.
- Using SST, remove the coil.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09958-04011)
- Remove the generator washer.
- REMOVE GENERATOR ROTOR ASSEMBLY
- INSPECT GENERATOR ROTOR ASSEMBLY
- Check the rotor for an open circuit.
- Using an ohmmeter, measure the resistance between the slip rings.
Standard resistance:
2.1 to 2.5 Ω at 20°C (68°F)
If the result is not as specified, replace the generator rotor.
- Using an ohmmeter, measure the resistance between the slip rings.
- Check if the rotor is grounded.
- Using an ohmmeter, measure the resistance between the slip ring and the rotor core.
Standard resistance:
10 kΩ or higher
If the result is not as specified, replace the generator rotor.
- Using an ohmmeter, measure the resistance between the slip ring and the rotor core.
- Inspect the slip rings.
- Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor assembly.
- Check that the slip rings are not rough or scored.
- Using a vernier caliper, measure the slip ring diameter.
Standard diameter:
12.8 to 14.4 mm (0.504 to 0.567 in.)
If the diameter is less than the minimum, replace the rotor assembly.
- Check the rotor for an open circuit.
- INSPECT GENERATOR BRUSH HOLDER ASSEMBLY
- Using a vernier caliper, measure the exposed brush length.
Standard exposed length:
1.5 to 11.5 mm (0.059 to 0.453 in.)
If the length is less than the minimum, replace the brush holder assembly.
- Using a vernier caliper, measure the exposed brush length.
- INSPECT BEARING
- Check that the bearing is not rough or worn. If necessary, replace the bearing.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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