CHARGING SYSTEM Noise Occurs from V-ribbed Belt or Generator Assembly

PROCEDURE


  1. CONFIRM PROBLEM SYMPTOM


    1. Confirm the problem symptom.

      Result
      Symptom Proceed to
      Noise occurs from V-ribbed belt A
      Noise occurs from generator assembly B

    B

    CHECK FOR NOISE WHEN ROTOR IS TURNING FREELY Click here

    A

  2. CHECK V-RIBBED BELT FOR WEAR


    1. Check the V-ribbed belt for wear or damage.

      OK
      The V-ribbed belt is not worn or damaged.
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE V-RIBBED BELT Click here

    OK

  3. CHECK GENERATOR PULLEY WITH CLUTCH FOR WEAR


    1. Check the generator pulley with clutch grooves for wear or damage.

      OK
      The generator pulley with clutch grooves are not worn or damaged.
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE GENERATOR PULLEY WITH CLUTCH Generator assembly (for 150 A Type): Click here
    REPLACE GENERATOR PULLEY WITH CLUTCH Generator assembly (for 180 A Type): Click here

    OK

  4. CHECK FOR NOISE WHILE CLUTCH PULLEY IS OPERATING


    1. Start the engine and check the generator pulley with clutch for looseness.

      OK
      The generator pulley with clutch is not loose.
      Result
      Proceed to
      OK
      NG

    NG

    TIGHTEN GENERATOR PULLEY WITH CLUTCH TO SPECIFIED TORQUE

    OK

  5. INSPECT GENERATOR PULLEY WITH CLUTCH (UNIT INSPECTION)


    1. Remove the generator assembly.

      Generator assembly (for 150 A Type): Click here

      Generator assembly (for 180 A Type): Click here

    2. Check the installation condition of the generator pulley cap.

      OK
      The generator pulley cap is not loose or missing.

    3. Check for forming of particles due to friction (for dry type pulley) or grease leaks (for wet type pulley).

      OK
      There are no large amounts of particles (for dry type pulley) or grease leaks (for wet type pulley).

    4. Check the generator pulley with clutch for misalignment (interference with the generator assembly).

      OK
      The generator pulley with clutch is not misaligned (no interference with the generator assembly).
    5. B005LZP

      Turn the generator pulley with clutch clockwise and counterclockwise by hand and check for noise.

      OK
      Noise does not occur when turned in either direction.

    6. Turn the generator pulley with clutch clockwise and counterclockwise by hand and visually check for runout.

      OK
      The generator pulley with clutch does not have runout.
    7. B005M66C02
      *a Protective Tape

      Hold the generator rotor assembly (fan) in the generator assembly with a screwdriver with its tip wrapped with protective tape, and check that the generator pulley with clutch locks when turned clockwise and turns freely when turned counterclockwise.

      OK
      The generator pulley with clutch locks when turned clockwise and turns freely when turned counterclockwise.
      Result
      Proceed to
      OK
      NG

    OK

    INSPECT PULLEY OTHER THAN GENERATOR ASSEMBLY PULLEY

    NG

    REPLACE GENERATOR PULLEY WITH CLUTCH Generator assembly (for 150 A Type): Click here
    REPLACE GENERATOR PULLEY WITH CLUTCH Generator assembly (for 180 A Type): Click here

  6. CHECK FOR NOISE WHEN ROTOR IS TURNING FREELY


    1. Perform a road test and check that noise does not occur when decelerating.

      OK
      Noise does not occur.

    2. Stop the engine and check that generator pulley with clutch noise does not occur as the engine stops.

      OK
      Noise does not occur.
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE GENERATOR PULLEY WITH CLUTCH Generator assembly (for 150 A Type): Click here
    REPLACE GENERATOR PULLEY WITH CLUTCH Generator assembly (for 180 A Type): Click here

    OK

  7. CHECK ENGAGEMENT OF GENERATOR PULLEY WITH CLUTCH


    1. Remove the generator assembly.

      Generator assembly (for 150 A Type): Click here

      Generator assembly (for 180 A Type): Click here

    2. Hold the generator rotor assembly (fan) in the generator assembly with a screwdriver with its tip wrapped with protective tape, and check that the generator pulley with clutch locks when turned from counterclockwise (free turning direction) to clockwise (locking direction).

      OK
      The generator pulley with clutch locks.
      Result
      Proceed to
      OK
      NG

    OK

    REPAIR OR REPLACE GENERATOR ASSEMBLY Generator assembly (for 150 A Type): Click here
    REPAIR OR REPLACE GENERATOR ASSEMBLY Generator assembly (for 180 A Type): Click here

    NG

    REPLACE GENERATOR PULLEY WITH CLUTCH Generator assembly (for 150 A Type): Click here
    REPLACE GENERATOR PULLEY WITH CLUTCH Generator assembly (for 180 A Type): Click here