SECTION 6D - CHARGING SYSTEM (6VD1 MODELS)
Service Precaution
Charging System
General Description
General On-Vehicle Inspection
Generator
Removal
Inspection
Installation
Disassembled View
Disassembly
Inspection and Repair
Reassembly
Bench Test
Main Data and Specifications
Service Precaut ion
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LO CATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener , use
ONLY the exact part number for that application.
HOLDEN will call out those fasteners that require
replacement after removal HOLDEN will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Pa ints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener join t interf ac es. Gen eral l y , such coating s
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener . When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
Charging System
General Description
The IC integral regulator charging system and its main
components are connected as shown in illustration.
The regulator is a solid state type and it is mounted along
with the brush holder assembly inside the generator
installed on the rear end cover.
The generator does not require particular maintenance
such as voltage adjustment.
The rectifier connected to the stator coil has eight diodes
to transform AC voltage into DC voltage.
This DC voltage is connected to the output terminal of
generator.
General On–Vehicle Inspection
The operating condition of charging system is indicated
by the charge warning lamp. The warning lamp comes on
when the starter switch is turned to “ON” position. The
charging system operates normally if the lamp goes off
when the engine starts.
If the warning lamp shows abnormality or if undercharged
or overcharged battery condition is suspected, perform
diagnosis by checking the charging system as follows:
1.Check visually the belt and wiring connector.
2. With the engine stopped, turn the stator switch to
“ON” position and observe the warning lamp.
If lamp does not come on:
Disconnect wiring connector from generator, and
ground the terminal “L” on connector side.
If lamp comes on:
Repair or replace the generator.
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Generator
Removal
1.Disconnect battery ground cable.
2.Move drive belt tensioner to loose side using wrench
then remove drive belt (1).
3.Disconnect the wire from terminal “B” and disconnect
the connector (4).
4.Remove generator fixing bolt (3).
5.Remove generator assembly (2).
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Inspection
1.Disconnect the wiring connector from generator.
2.With the engine stopped, turn starter switch to “ON”
and connect a voltmeter between connector terminal
L (2) and ground or between terminal IG (1) and
ground.
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If voltage is not present, the line between battery and
connector is disconnected and so requires repair.
3.Reconnect the wiring connector to the generator, run
the engine at middle speed, and turn off all electrical
devices other than engine.
4.Measure battery voltage. If it exceeds 16V, repair or
replace the generator.
5.Connect an ammeter to output terminal of generator,
and measure output current under load by turning on
the other electrical devices (eg., headlights). At this
time, the voltage must not be less than 13V.
Installation
1.Install generator assembly to the position to be
installed.
2.Install generator assembly and tighten the fixing bolts
to the specified torque.
Torque:
M10 bolt: 41 N·m (4.2 kg·m/30 lb ft)
M8 bolt: 21 N·m (2.1 kg·m/15 lb ft)
3.Connect wiring harness connector and direct terminal
“B”.
4.Move drive belt tensioner to loose side using wrench,
then install drive belt to normal position.
5.Reconnect battery ground cable.
Disassembled View
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Legend
(1)Pulley Nut
(2)Pulley
(3)Front Cover Assembly
(4)Rotor Assembly
(5)Rear End Cover
(6)Rectifier
(7)Terminal Insulator and Nut
(8)Regulator Assembly
(9)Brush Holder Assembly
(10)Rear Cover
Disassembly
1.Terminal insulator and nut(2).
2.Remove three nuts(1) on the rear cover and a nut on
terminal B and insulator, then remove the rear
cover(3).
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3.Remove two screws that fix the brush holder(5) and
rectifier, then remove the brush holder assembly(4).
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4.Remove three screws on the IC regulator , then the IC
regulator assembly(6).
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5. Remove four screws that fix rectifier(7) and stator
lead wires.
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6. Secure the pulley directly in the vise between two
copper plates, and remove the nut and pulley.
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7.Remove four nuts(8) that secure the front cover
assembly and rear end cover, and an insulator(9).
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8.Use the puller to remove the rear end cover.
9.Rotor assembly
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10.Pull the rotor assembly(10) off the front cover
assembly(12) using a bench press(11).
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Inspection and Repair
Repair or replace necessary parts if extreme wear or
damage is found during inspection.
Rotor Assembly
1.Check the rotor slip ring surfaces for contamination
and roughness. If rough, polish with #500—600
sandpaper.
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2.Measure the slip ring diameter, and replace if it
exceeds the limit.
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3.Check resistance between slip rings, and replace if
there is no continuity.
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4.Check for continuity between slip ring and rotor core.
In case of continuity, replace the rotor assembly.
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Stator Coil
1.Measure resistance between respective phases.
2.Measure insulation resistance between stator coil
and core with a mega–ohmmeter.
If less than standard, replace the coil.
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Brush
Measure the brush length.
If more than limit, replace the brush.
Standard: 10.mm (0.4134 in)
Limit: 8.4.mm (0.3307 in)
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Rectifier Assembly
Check for continuity across “P” and “E” in the × 100W
range of multimeter.
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Change polarity , and make sure that there is continuity in
one direction, and not in the reverse direction. In case of
continuity in both directions, replace the rectifier
assembly.
IC Regulator Assembly
Check for continuity across “B” and “F” in the × 100W
range of multimeter.
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Change polarity , and make sure that there is continuity in
one direction, and not in the reverse direction. In case of
continuity in both directions, replace the IC regulator
assembly.
Reassembly
To reassemble, follow the disassembly steps in the
reverse order, noting the following points:
1.Using a press with a socket wrench attached,
reassemble rotor and rear end cover assembly in the
front cover.
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2.Install pulley on the rotor.
Secure the pulley directly in the vise between two
copper plates, and tighten nut to the specified torque.
Torque: 111 N·m (11.3 kg·m/82 lb ft)
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Bench Test
Conduct a bench test of the generator.
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Preparation
Remove generator from the vehicle (see “Generator
removal”).
1.Secure generator to the bench test equipment and
connect wires.
Terminal “IG” for energization
Terminal “L” for neutral (warning lamp)
Terminal “B” for output
2.Conduct the generator characteristic test.
Characteristics of generator are shown in illustration.
Repair or replace the generator if its outputs are
abnormal.
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Main Data and Specifications
General Specifications
Parts Number (Nippon denso) 102211—5140
Model ACHD04
Rated voltage 12 V
Rated output 75 A
Rotating direction (As viewed from pulled) Clockwise
Pulley effective diameter 50 mm (1.97 in)
Weight 44 N (4.5 kg 33 lb)