Charging System - Inoperative
T-SB-0055-12March 13, 2012
Charging System Inoperative
Service Category
Power Source/Network
Section
Battery/Charging
Market
USA
Applicability
Introduction
Some 2011 - 2012 model year vehicles with 2AR or 2GR engines may exhibit insufficient charging performance from the alternator. An updated pulley assembly is available to address this condition.
Parts Information
Production Change Information
This bulletin applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Warranty Information
Required Tools & Equipment
TSB Overview
Before replacing the pulley this TSB will lead you through standard charging system diagnostic steps to ensure that the low charge condition is not caused by some other component.
1. Check battery condition.
2. Check fuses belts and alternator wiring.
3. Check alternator warning light and charging circuit under load.
4. Check alternator clutch pulley function and replace if needed.
Repair Procedure
1. Check the battery condition.
A. Check the battery for damage and deformation. If severe damage deformation or leakage is found replace the battery.
B. Check the battery using the GR8 Battery Diagnostic Station or the Digital Battery System Analyzer (NVS-8150). If the battery diagnostics fail replace the battery and continue with the next step.
NOTE
For details on how to use the GR8 Battery Diagnostic Station or the Digital Battery System Analyzer, refer to the instruction manual on the Technical Information System (TIS), Diagnostics - Tools & Equipment - Battery Diagnostics -
^ GR8 Instruction Manual
^ NVS-8150 Instruction Manual
C. Inspect the battery terminal and check that the battery terminals are not loose or corroded.
2. Check fuses.
A. Measure the resistance of each fuse for the charging system.
HINT
The fuses shown in the Charging System Diagram are related to the charging system.
Standard Resistance: Below 1 ohm
If any of the results are not as specified replace the fuse(s) as necessary.
3. Check the V-ribbed belt.
A. Check the belt for wear cracks or other signs of damage. If any of the following conditions are found replace the V-ribbed belt.
^ The belt is cracked.
^ The belt is worn out to the extent that the cords are exposed.
^ The belt has chunks missing from the ribs.
B. Check that the belt fits properly in the ribbed grooves.
4. Inspect the alternator wiring.
A. Visually check that the alternator wiring is in good condition.
B. Check voltage at IG and at IG and S/RLO* terminals.
* RLO = RAV4 S = All Except RAV4
(1) Disconnect the appropriate connector at the alternator:
(2) Turn ignition (IG) to the ON position.
(3) Measure the voltage according to the value(s) in the table.
If voltage is not as specified refer to TIS to diagnose the circuit:
^ Reference Information - Technician Group - Quick Reference: Body Electrical Diagnosis
5. Check for noises from the alternator.
Listen and check that NO abnormal noises are heard from the alternator while the engine is running.
6. Inspect the charge warning light circuit.
A. Turn the engine switch (IG) ON. Check that the charge warning light comes on.
B. Start the engine and check that the light goes OFF.
If the light does NOT operate as specified troubleshoot the charge warning light circuit.
7. Inspect the charging circuit without load.
A. Connect a voltmeter and an ammeter to the charging circuit as follows.
(1) Disconnect the wire from terminal B of the alternator and connect it to the negative (-) lead of the ammeter.
(2) Connect the ammeter positive (+) lead to terminal B of the alternator.
(3) Connect the voltmeter positive (+) lead to the positive (+) terminal of the battery.
(4) Ground the voltmeter negative (-) lead.
B. Check the charging circuit.
Keep the engine speed at 2000 rpm and check the reading on the ammeter and voltmeter.
Standard Current: 10 A or less
Standard Voltage: 13.2 to 14.8 V
^ If the result is NOT as specified go to step 9.
^ If the results are as specified go to step 8.
HINT
If the battery is not fully charged, the ammeter reading will sometimes be more than the standard current.
8. Inspect charging circuit with load.
A. With the engine running at 2000 rpm turn the high beam headlights on and turn the heater blower switch to the "HI" position.
B. Check the reading on the ammeter.
Standard Current: 30A or more
^ If the ammeter reading is less than the standard current go to step 9.
^ If the current is 30A or more STOP - This TSB does NOT apply the charging system is operating normally.
HINT
If the battery is fully charged, the indication will sometimes be less than the standard current. If this is the case, add more electrical load (operate the wipers, rear window defogger, etc.) and check the reading on the ammeter again.
9. Check lock function of alternator clutch pulley.
A. Check the lock function with the pulley installed in the vehicle. Visually check that the rotor in the alternator operates with the engine running.
^ If the pulley does NOT operate with the engine running go to step 10.
^ If the pulley operates with the engine running go to step B (remove alternator).
B. Remove the alternator.
Refer to TIS applicable model and model year Repair Manual:
C. Check the lock function with the pulley removed from the vehicle.
(1) Remove the alternator pulley cap.
Using a screwdriver puncture the center of the alternator pulley cap and pry it off.
NOTE
Do NOT reuse the alternator pulley cap.
(2) Hold the alternator rotor using the SST, and turn the clutch pulley clockwise to check that the outer ring locks.
SST: 09820-63021
^ OK: The outer ring locks.
If OK STOP - This TSB does NOT apply replace the alternator.
^ NG: The outer ring does NOT lock replace the alternator clutch pulley.
10. Remove the alternator clutch pulley.
A. Mount the alternator drive end frame in a vise tightly.
SST: 09820-63021
B. Place the rotor shaft end into SST (A).
C. Attach SST (B) to the clutch pulley.
D. Loosen the pulley by turning SST (B) in the direction shown in the illustration.
E. Remove the SST from the alternator assembly.
F. Remove the clutch pulley from the rotor shaft.
11. Install the alternator clutch pulley.
A. Temporarily install the clutch pulley onto the rotor shaft.
B. Place the rotor shaft end into SST (A).
SST: 09820-63021
C. Attach SST (B) to the clutch pulley.
D. Tighten the pulley by turning SST (B) in the direction shown in the illustration.
Torque: 64 N*m (653 kgf*cm, 47 ft*lbf)
E. Remove the SST from the alternator assembly.
F. Check that the clutch pulley rotates smoothly.
G. Install a new alternator pulley cap to the clutch pulley.
12. Install the alternator.
Refer to TIS applicable model and model year Repair Manual:
13. Confirm the charge indicator lamp is NOT illuminated and the charging system is operating properly as described in steps 7 and 8.
14. Re-initialize affected electrical systems.
Refer to TIS applicable model and model year Repair Manual: