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Canada - Charging System - System Inoperative





T-TCI-3746

April 2, 2012

CHARGING SYSTEM INOPERATIVE

Service Category
Power Source/Network

Section
Battery/Charging

Market
Canada





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 TSB applies to vehicles produced BEFORE the Production Change Effective VIN 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-8150C). 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, refer to the GR8 Battery Diagnostic Station Instruction Manual located on ETAS/TIS library > Tools > tools and equipment > GR8 Battery Diagnostic Station Instruction Manual.

^ For details on how to use the Digital Battery System Analyzer, refer to the Digital Battery System Analyzer Instruction Manual located on ETAS/TIS library > Tools > tools and equipment > NVS-8150C Digital Battery System Analyzer 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 the repair manual or EWD in the ETAS/TIS library to diagnose the circuit.

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 the 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 the lock function of the 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 the ETAS/TIS library, applicable model and model year Repair Manual:

^ 2011 Avalon:
Power Source/Network - Battery/Charging - "2GR-FE Charging: Generator: Removal"

^ 2011 Camry:
Power Source/Network - Battery/Charging - "2AR-FE/2GR-FE Charging: Generator: Removal"

^ 2O12 Camry:
Power Source/Network - Battery/Charging - "2AR-FE/2GR-FE Battery/Charging: Generator: Removal"

^ 2011 / 2012 Highlander:
Power Source/Network - Battery/Charging - "2GR-FE Charging: Generator: Removal"

^ 2011 RAV4:
Power Source/Network - Battery/Charging - "2AR-FE/2GR-FE Charging: Generator: Removal"

^ 2011 / 2012 Sienna:
Power Source/Network - Battery/Charging - "2GR-FE Battery/Charging: Generator: Removal"

^ 2011 Venza:
Power Source/Network - Battery/Charging - "2GR-FE Battery/Charging: Generator: Removal"

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: 09820-63020-02

^ 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: 09820-63020-02





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 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: 09820-63020-02





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)

NOTICE

^ Check that the drive end frame is secured in the vise tightly.

^ Hold SST (A) tightly during the operation.

E. Remove 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 the ETAS/TIS library, applicable model and model year Repair Manual:

^ 2011 Avalon:
Power Source/Network - Battery/Charging - "2GR-FE / Battery/Charging: Generator: Installation"

^ 2011 Camry:
Power Source/Network - Battery/Charging - "2AR-FE/2GR-FE Charging: Generator: Installation"

^ 2O12 Camry:
Power Source/Network - Battery/Charging - "2AR-FE/2GR-FE Battery/Charging: Generator: Installation"

^ 2011 / 2012 Highlander:
Power Source/Network - Battery/Charging - "2GR-FE Charging: Generator:Installation"

^ 2011 RAV4:
Power Source/Network - Battery/Charging - "2AR-FE/2GR-FE Charging: Generator: Installation"

^ 2011 / 2012 Sienna:
Power Source/Network - Battery/Charging - "2GR-FE Battery/Charging: Generator: Installation"

^ 2011 Venza:
Power Source/Network - Battery/Charging - "2GR-FE Battery/Charging: Generator: Installation"

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 ETAS/TIS library, applicable model and model year Repair Manual:

^ 2011 Avalon:
General - Introduction - "Introduction: Repair Instruction: Initialization"

^ 2011 Camry:
Re-initialization not necessary.

^ 2012 Camry:
General - Introduction - "Introduction: Repair Instruction: Initialization"

^ 2011 / 2012 Highlander:
General - Introduction - "Introduction: Repair Instruction: Initialization"

^ 2011 RAV4:
Re-initialization not necessary.

^ 2011/2012 Sienna:
General - Introduction - "Introduction: Repair Instruction: Initialization"

^ 2011 Venza:
General - Introduction - "Introduction: Repair Instruction: Initialization"

NOTE:
Issue of the 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.

© 2012 Toyota Motor Sales, Canada
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