Charging System - Low Battery/No Start Condition
ELECTRICALEL013-03
REVISED
September 26, 2003
Title:
CHARGING IMPROVEMENT AT IDLE
Models:
'98 - '03 Sienna
TSB REVISION NOTICE:
November 4, 2003: New note and graphic have been added. The previous version of this TSB should be discarded.
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
Warranty Information
Applicable Warranty:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
*Warranty application is limited to correction of a problem based upon a customer's specific complaint.
Repair Procedure
NOTE:
Confirm that the vehicle does not have an unusual parasitic load on the battery with key off and doors locked. Parasitic load should be less than 40 mA.
1. Disconnect negative terminal from the vehicle battery.
2. Disconnect the alternator wire and connector.
3. Remove the drive belt and original alternator.
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.
4. 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.
5. Install the 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.
6. Install the drive belt.
A. Install the drive belt and adjust belt tension.
Drive Belt Tension: 175 +/- 5 lbf
B. Tighten the adjusting lock bolt and the pivot bolt.