DIY Toyota generator repair

In detail: DIY repair of a Toyota generator from a real master for the site my.housecope.com.

A special device is used to convert mechanical energy into an electrical form. Generators Toyota Corolla versions with a body 110, 120 and 150 three-phase type, with electric excitation, with a built-in rectifier unit. The voltage regulators included in them have an electronic principle of operation.

The operation of the generator on the Toyota Corolla is necessary to ensure uninterrupted and timely supply of current with a certain power. In addition, during operation, it must also provide charging of the battery.

This unit must have a sufficiently high strength, the required power reserve (for E120 models it ranges from 60 A / h to 82 A / h, depending on the engine size, and is selected for a specific model, taking into account the year of manufacture), small dimensions and weight, and Tot - differ in a low noise level and created radio interference.

Malfunctions in the operation of the Toyota Corolla 120 generator of the body and all other models can be eliminated both with their own hands and with the help of the experience of service station specialists. Usually, with a low mileage on models starting from the E11 version, which is about 50 thousand kilometers, you will have to replace the alternator belt or tighten it, make other repairs to ensure normal and efficient operation of the unit.

The operation of the Toyota Corolla E150 generator, like other units of this brand, begins immediately after the engine is started, and during operation it constantly recharges the engine battery, preventing it from being completely discharged. Its operation is based on the well-known principle of electromagnetic induction, according to which the magnetic flux, passing through the winding of a copper coil, at its terminals provokes the formation of a voltage, in magnitude directly proportional to the speed of rotation.

Video (click to play).

The generator set of the Corolla 120, as well as models with a different body (for example, the Fielder 14, Corolla 121 models), is located in the front of the engine and is activated by the crankshaft. Closed bearings, on which the shaft is installed, are designed for the entire period of operation of the car, without additional lubrication.

With a high mileage Toyota Corolla E150, as well as older versions of the car, it is recommended to check and, if necessary, repair or replace the unit. The fact that there is a malfunction on the generator may be indicated by:

Battery discharge lamp that does not go out after starting the engine. This indicates that the belt has weakened (should be tightened) or the reason is in the unit itself (replacement of worn brushes is required, a breakdown in the winding, it is necessary to change the diode kit).
No power is supplied to the battery, the cause may be an oxidized terminal, a loose belt, an inoperative battery.
The battery is being recharged - any of the faulty elements of the mechanism may be the cause.
The appearance of a characteristic whistle in the area of \ u200b \ u200bthe generator is most often due to a strong degree of belt tension and a high load on the bearing.

Any repair and replacement must be carried out only after the vehicle is completely de-energized with all the terminals disconnected from the battery.

In situations where it is not possible to repair the device, it is replaced.

If the performance check showed the need for replacement, then in order to do this, the old generator should be removed. This will require tools such as a flat head screwdriver, 10 and 12 wrenches, and special tools to remove the motor mud flaps.For the Corolla after 2007, it is necessary to first remove the front wheel on the right, as well as the mud flaps (lower and right). Then you should remove the decorative cover from the motor along with the front lining. A wire with a negative terminal is disconnected from the battery. The block is disconnected from the harness. Next, you need to clamp the clips on the cap and remove its cover. Unscrew the power cable retainer and disconnect it. Loosen the belt to the required level by removing it from the pulley. Loosen the lower and upper bolts that secure the unit and remove it.

After removing and carrying out repair work, install the parts in the reverse order, while tightening the belt of the device to the required degree of tension and adjusting the remaining units.

Repair of the Toyota Corolla generator is carried out after its dismantling, and for any repair work you need such tools as: a 12 key and a 10 head, a Phillips screwdriver, a screw puller, a hammer, as well as a vernier caliper and a tester to check the parameters.

First, a revision of the rotor performance is performed. It is checked for the integrity of the windings using a tester. If there is a break, then the rotor itself must be replaced. The designations on the tester, when the test is carried out, should be from 2.3 ohms to 2.7 ohms, and the presence of an infinity value indicates damage to the winding. To make measurements, three nuts are unscrewed on the removed generator, the back cover and the insulation sleeve are removed.

Next, the operation of the rectifier diodes is checked. To do this, control their ability to transmit current in only one direction. If the chain runs in both directions, replace the block.

Read also: DIY kia preggio repair

The technical condition of the generator can be checked using the following measuring instruments:

The rotor speed is measured using a tachometer (usually located next to the speedometer on the dashboard). During normal operation of the generator, the indicators of this device should not be less than 2000 rpm, while the norm is 5000 rpm.

Let's consider the reasons that can cause generator breakdown. So, if the generator does not generate a charge, then the following phenomena may be the reasons for this:

Fuse or contacts blown.
Broken or worn out generator brushes.
The regulator relay is out of order.
Due to the short circuit of the winding, an open circuit occurred in the stator or rotor circuit.

In order to fix the first three malfunctions from the list, you just need to replace the worn out parts of the generator, having previously, of course, disassembled it.

First of all, remove the brush holder along with the voltage regulator, carefully unscrewing all fasteners.
Remove the tensioning bolts and then the cover with the stator.
Remove the cover from the stator by first disconnecting the phase windings from the output wires on the rectifier unit.
Next, remove the pulley from the shaft and the front cover of the generator using a special puller.

The assembly of the generator is carried out in reverse order.

In the event of a short circuit in the winding, you will need more serious action than a simple replacement of the part. So, a broken winding can either be repaired or replaced with new wires. Often the winding breaks off near the slip rings. In addition, breakdown can occur due to unsoldering of any of the ends of the winding. Such a malfunction can be repaired by rewinding the coil in the area of the gap back from the rotor winding. Further, the broken end of the winding must be removed (evaporated) from the slip ring and the previously unwound wire must be soldered there. The wiring is very easy to repair by re-soldering the wiring.

A weak or too strong generator charge is indicated by a damaged relay, which must be replaced when the generator is repaired.

If the generator voltage check showed that the device is working, but the indicator is flashing on the instrument panel, then, most likely, one of the diodes that are responsible for powering the light in the indicator has failed. These diodes are located in the generator itself, and replacement is carried out after disassembling the device.

Noise unusual for a generator may be indicated by wear of the rotor bearing. If an inspection reveals that the generator bearing is worn out, it will need to be replaced. If the incomprehensible sounds of the generator are associated with the absence of play in the bearing, then it can be simply filled with oil, having previously washed it in gasoline. Extraneous sounds will then disappear.

Thus, you can even repair the generator on your own in your garage (as well as overhaul of the engine, in fact). When checking and replacing parts of the device, observe safety precautions and be careful, because the electrical system should not be damaged in this case.

Three-phase alternators with electromagnetic excitation are installed on Toyota Corolla cars, with a built-in rectifier unit and an electronic voltage regulator. The generator shaft is mounted on sealed bearings that do not require additional lubrication throughout the entire service life. The generator wag is driven from the crankshaft pulley by a poly V-belt. To reduce belt wear when sharpBy decreasing the speed of the engine crankshaft, the generator rotor rotates by inertia, the generator pulley is equipped with a freewheel that transmits rotation in only one direction.Recently, many firms have appeared, specializing in the repair of imported generators and starters. There you can diagnose a faulty unit, purchase spare parts for any generator (starter) model, and get expert advice.If you are not sure that you can repair the generator (starter) yourself, it makes sense to contact a company where the repair of these units will be done quickly, efficiently and, as a rule, at an affordable price. However, on high-mileage vehicles, it is often more profitable to replace a complete assembly with a new one than to replace broken parts. You will need: all tools for removing the engine mudguards, as well as keys "10", "12", a flat-blade screwdriver.1. Remove the right front wheel2. Remove the lower and right side engine mudguards3. Remove the decorative engine cover4. Remove the front lining of the engine compartment 5. Disconnect the wire from the negative terminal of the storage battery.6. Press out the clamp of the connector of the harness of the probes.7.. and disconnect the block from the generator. 8. Press the retaining clips of the protective cap.9. . and remove the generator outlet protective cap.10. Unscrew the nut securing the power cable lug. eleven. . and disconnect the power lead from the generator.12. Loosen the tension of the accessory drive belt and remove the belt from the alternator pulley.14. . and the lower alternator mounting bolts (arrow) and remove the alternator from the vehicle.15. Install the generator in the reverse order of removal, and adjust the tension of the accessory drive beltComplete disassembly of the generator is not recommended, so it is best to contact a workshop that specializes in generator repair. This subsection only shows the replacement of the brush assembly and rectifier unit.

You will need: keys "10", "22", socket "10", a screwdriver with a cross-shaped blade, a screw puller, a hammer, a vernier caliper, a tester.1. Remove the generator from the vehicle3.. and remove the back cover of the generator.4. Remove the generator power contact insulating sleeve.5. Check the resistance of the rotor winding by connecting a tester to the slip rings. The resistance should be approximately 2.3-2.7 ohms. If the tester shows infinity, then there is an open circuit in the windings and the rotor needs to be replaced.6. Check the diodes of the rectifier unit. Connect one wire to the "mass" of the rectifier unit, the other - to the diode terminal.7.. and then swap the wires. The diode should only pass current in one direction. If the diode passes current in both directions, then it is faulty. 8. Check the rest of the diodes in the same way.9. To replace the rectifier unit, remove the five screws and remove the rectifier unit.10. Remove the two screws securing the brush holder.12. Check the ease of movement of the brushes in the brush holder and their protrusion in a free state. If the brushes protrude less than 4.5 mm, replace the brush holder assembly.13. Check the short circuit of the rotor winding to ground. To do this, connect the tester probes to the rotor pole and alternately to the slip rings. The measured resistance must be infinitely large, otherwise replace the rotor.14. Measure the diameter of the rotor slip rings. If any of the rings are less than 14 mm in diameter, replace the rotor.15. Assemble the generator in the reverse order of removal.Do-it-yourself generator repairs are not done by many motorists. Nevertheless, having some experience in auto repair and "straight" hands, a simple generator repair can be done on your own. This article will focus on the repair of generators for cars of the VAZ family, which you can do on your own.We have previously written about some of the symptoms of generator malfunction. This time we will dwell in more detail on simple ways to check and repair car generators, which we can do with our own hands.What to do if the battery charging indicator lamp on the instrument panel lights up, and the voltmeter needle goes into the “red zone”?The first step is to inspect the alternator belt for damage.Then check the belt tension by trying to turn the alternator pulley:

If the pulley slips against the belt, tighten it urgently.

If the belt is stretched and not stretched, it is useless to repair it - replace the belt.

The belt is tensioned by moving the generator along the tensioning bar (position 1 in the figure below), having previously loosened the fastening nut. The easiest way to move the generator is with a pry bar.A weak alternator belt tension in most cases is accompanied by an unpleasant whistle. You can learn more about this from our article "Why does the alternator belt whistle and how to eliminate the whistle?"If the drive is working properly, you should continue troubleshooting in the generator itself. To test the performance of a car generator do not remove the terminals from the battery while the engine is running... This can lead to damage caused by a sudden power surge - even if the generator was serviceable, after that it will definitely need to be repaired.The simplest way to check the generator's performance is to connect a voltmeter to the poles of the battery (as in the photo above):

Start the engine. At start-up, the voltage at the battery terminals must not fall below 8 V (at an ambient temperature of 20 ° C).

Raise the engine speed to 3000 rpm. If the terminals are less than 12.5 V, then the generator will most likely need repair - dismantle the voltage regulator assembly with the brush assembly.

For example, let's take a generator from a VAZ 2109 car.Before starting the generator repair, disconnect the ground terminal from the battery. Remove the positive terminal from the voltage regulator, then use a Phillips screwdriver to unscrew the two screws securing the regulator and carefully pull it out.The scheme for removing the generator from the car is shown in the figure above. After removal and disassembly, we proceed to inspect the generator.

Visual inspection can show such a malfunction as wear of brushes, the length of which should be at least 5 mm.

A failure of the voltage regulator is also possible - in any case, when repairing a generator, it would be better to replace it with a new one.

It is advisable to inspect the condition and wear of the alternator slip rings. If carbon deposits are present, they should be sanded and polished with a fine sandpaper.

Check the ease of movement of the brushes in the brush holder of the new voltage regulator, then carefully insert the regulator into the generator socket, secure it first with one screw by hand, then carefully press it into the installation position and tighten the screws with a screwdriver.

This completes our generator repair, you can start checking it.

Connect the positive terminal to the voltage regulator and connect the ground to the battery.

After that, connect a voltmeter to the battery poles and start the engine.

Boost your engine RPM to 3000 rpm. If the device reads from 13.5 V to 14.5 V, then everything is in order and the generator is working properly. The voltage of the on-board network must be higher than the battery rating in order to ensure a full charge of the battery while driving.

Now let's check the voltage regulation. To do this, turn on the high beam headlights and repeat the measurement at 3000 rpm - the voltmeter reading should not differ from the previously measured by more than 0.4 V.

Of course, we talked about the simplest generator repair, which does not require special skills and high qualifications. Such a repair is quite capable of doing it yourself. In case of more serious malfunctions, we recommend contacting specialists for repairs (such as in the video below).After repairing the generator, special attention should be paid to maintaining the battery. We recommend reading about how to properly charge and take care of your battery.