Toyota RAV4 Service Manual: Inspection

1. Inspect generator brush holder assembly

1. Using a vernier caliper, measure the brush length.

Standard length: 9.5 To 11.5 Mm (0.374 To 0.453 In.)

Minimum length: 4.5 Mm (0.177 In.)

If the brush length is less than the minimum, replace the generator brush holder assembly.

2. Inspect generator rotor assembly

1. Check the resistance.

1. Measure the resistance between the slip rings.

Standard resistance: 2.3 To 2.7 Ù at 20°c (68°f)

If the result is not as specified, replace the generator rotor assembly.

2. Measure the resistance between the slip ring and rotor core.

Standard resistance: 1 m  or higher

If the result is not as specified, replace the generator rotor assembly.

2. Check the slip ring diameter.

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

Standard diameter: 14.2 To 14.4 Mm (0.559 To 0.567 In.)

Minimum diameter: 14 mm (0.551 In.)

If the diameter is less than the minimum, replace the generator rotor assembly.

3. Check the appearance.

1. Check that the bearing is not rough or worn.

Ok: the bearing rotates smoothly.

If the result is not as specified, replace the generator rotor assembly.

3. Inspect generator drive end frame bearing

1. Check that the bearing is not rough or worn.

Ok: the bearing rotates smoothly.

If the bearing does not rotate smoothly, replace the bearing.

4. Inspect generator pulley with clutch

1. Hold the center of the pulley, and confirm that the outer ring turns counterclockwise and does not turn clockwise.

   If the result is not as specified, replace the generator pulley with clutch.