Canada - Charging System - Low Battery/No Start Condition

Bulletin
1286

Issue Date
2003-10-28

Reference
EE-03-005

Model
Sienna

Year Range
1998 ~ 2003

Market
Canada

Component
EE

Subject:
CHARGING IMPROVEMENT AT IDLE

INTRODUCTION:
Some customers may complain of a low battery or no start condition after running the engine at idle or low RPM for extended periods of time with several accessories on (for example, front and rear air conditioning) during high temperature conditions. A new alternator has been developed to improve charging performance at idle.

NOTE:
This new alternator will not prevent dead batteries or no start conditions on vehicles that are stored for long periods of time or on vehicles that are driven very infrequently.

APPLICABLE VEHICLES:
- 1998 - 2003 model year Sienna vehicles.







PARTS INFORMATION:

REPAIR PROCEDURE:







1. Disconnect negative terminal from the vehicle battery.
2. Disconnect the alternator female connector from the vehicle wire harness.







3. Remove original alternator and drive belt.







4. Remove the terminal out from original connector.
a) Pull up retainer in waterproof connector to disengage the secondary lock.







b) Release the locking lug from terminal and pull the terminal out from backside of connector.
c) Remove connector cover from vehicle wire harness.







5. Install new connector onto alternator harness.
a) Remove locking ring from face of new connector.
b) Install terminals into back of connector as shown.
c) Install black rubber plug included with alternator kit into location shown. This step is critical.

NOTE:
Do not return this vehicle to the customer unless the unused terminal location is sealed off from possible water intrusion.







6. Install new alternator.
a) Install the alternator, adjusting lock bolt, plate washer and pivot bolt.
b) Install wiring harness clamp bracket with bolt contained in kit.
c) Connect the alternator wire and install the nut.
d) Connect the alternator connector.
e) Connect the wire harness to the clamp.







7. Install drive belt.

a) Install the drive belt and adjust belt tension.
Drive Belt Tension: 175 +/-- 5 lbf

b) Tighten adjusting lock bolt and the pivot bolt.







WARRANTY INFORMATION:


NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.