Toyota Camry 1983-1996 Repair Guide

Alternator

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TESTING



Gasoline Engines

The easiest way to test the performance of the alternator is to perform a regulated voltage test.

  1. Start the engine and allow it to reach operating temperature.
  2.  
  3. Connect a voltmeter between the positive and negative terminals of the battery.
  4.  
  5. Voltage should be 14.1-14.7 volts.
  6.  
  7. If voltage is higher or lower than specification, connect a voltmeter between the battery positive (B+) voltage output terminal of the alternator and a good engine ground.
  8.  
  9. Voltage should be 14.1-14.7 volts.
  10.  
  11. If voltage is still out of specification, a problem exists in the alternator or voltage regulator.
  12.  
  13. If voltage is now within specification, a problem exists in the wiring to the battery or in the battery itself.
  14.  

Many automotive parts stores have alternator bench testers available for use by customers. An alternator bench test is the most definitive way to determine the condition of your alternator.

Diesel Engines

See Figures 1, 2, 3 and 4

  1. If a battery/alternator tester is available, connect the tester to the charging circuit as per manufactures instructions.
  2.  



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Fig. Fig. 1: Inspecting a charging system without load-diesel engines

  1. If a tester is not available, connect a voltmeter and ammeter to the charging circuit as follows:
    1. Disconnect the wire from terminal B of the alternator and connect the wire to the negative terminal of the ammeter.
    2.  
    3. connect the test lead from the positive terminal of the ammeter to terminal B of the alternator.
    4.  
    5. Connect the positive lead of the voltmeter to terminal B of the alternator.
    6.  
    7. Connect the negative lead of the voltmeter to ground.
    8.  

  2.  
  3. Check the charging circuit as follows:
    1. With the engine running at 2000 rpm, check the reading on the ammeter and voltmeter.

      Standard amperage-less than 10 amps
       
      Standard voltage-13.8-14.4 volts
       

    2.  
    3. If the voltage reading is greater than 14.4 volts, replace the IC regulator.
    4.  

  4.  



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Fig. Fig. 2: Voltage readings for amperage and voltage on the alternator testing-diesel engines

There is always battery current at terminal B, so disconnect the battery terminal before beginning work.

  1. If the voltage reading is less than 13.8 volts, check the alternator as follows:
    1. Remove the brush holder cover and attach terminal B wire in the original position.
    2.  
    3. With terminal F grounded, start the engine and check the voltage reading of terminal B.
    4.  
    5. If the voltage reading is greater than 14.4 volts, replace the IC regulator. If the voltage reading is less than 13.8 volts, replace the alternator.
    6.  

  2.  



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Fig. Fig. 3: Remove the brush holder cover and connect the terminal B wire in its original position-diesel engines



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Fig. Fig. 4: With terminal F grounded, start the engine and check the voltage reading of terminal B-diesel engines

REMOVAL & INSTALLATION



Gasoline Engines

See Figure 5 thru 11

  1. Turn the ignition key to the OFF position. Disconnect the negative battery cable. Wait at least 90 seconds from the time the negative battery was disconnected to start work.
  2.  


CAUTION
On models with an airbag, wait at least 90 seconds from the time that the ignition switch is turned to the LOCK position and the battery is disconnected before performing any further work.

  1. Remove the two bolts and the No. 3 right hand engine mounting stay on the 3VZ-FE. Remove the bolt and nut and then remove the No. 2 right hand engine mounting stay on 2VZ-FE and 3VZ-FE engines.
  2.  
  3. Disconnect the electrical harness and wire (and nut) from the alternator.
  4.  



Click image to see an enlarged view

Fig. Fig. 5: Exploded view of the alternator assembly-2S-ELC, 3S-FE and 2VZ-FE engines shown, others similar

  1. Remove the air cleaner (2S-E), if necessary, to gain access to the alternator.
  2.  
  3. Unfasten the bolts which attach the adjusting link to the alternator.
  4.  
  5. Remove the alternator drive belt from the pulley.
  6.  



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Fig. Fig. 6: Remove the rubber cover over the wiring harness attached to the alternator



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Fig. Fig. 7: Remove the pivot bolt first ...



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Fig. Fig. 8: ... then remove the two adjusting bolts



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Fig. Fig. 9: Remove the drive belt from around the alternator pulley



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Fig. Fig. 10: Disconnect the wiring by pushing the clip in and pulling out the harness



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Fig. Fig. 11: Once all components are disconnected, remove the unit form the engine

  1. Unfasten the alternator attaching bolt and then withdraw the alternator from its bracket.
  2.  

To install:
  1. Mount the alternator on the alternator brackets with the pivot and adjusting bolts. Do not tighten the bolts at this time.
  2.  
  3. Install the drive belt onto the pulley making sure that the grooves on the belt and the grooves on the pulley are properly aligned.
  4.  
  5. Adjust the drive belt tension and properly tighten the pivot and adjusting bolts.
  6.  
  7. Attach the wire (and nut) and harness to the alternator.
  8.  
  9. Connect the negative and starter battery cables.
  10.  
  11. Start the engine and allow it warm to warm up. Visually inspect the drive belt and listen for any abnormal vibration. Stop the engine and recheck the belt tension.
  12.  

Diesel Engines

See Figure 12

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the harness from the alternator.
  4.  



Click image to see an enlarged view

Fig. Fig. 12: Exploded view of the alternator assembly-diesel engines

  1. Remove the nut and detach the wire from the alternator.
  2.  
  3. Disconnect the vacuum hoses. Disconnect vacuum pump oil inlet and outlet hoses.
  4.  
  5. Loposen the alternator pivot bolt, adjusting lock bolt and adjusting nut. Remove the drive belt.
  6.  
  7. Carefully raise the engine with a jack up enough to remove the pivot bolt.
  8.  
  9. Remove the pivot bolt and adjusting bolts. Separate the alternator from the engine.
  10.  

To install:

Raise the engine slightly and install the pivot bolt.

  1. Mount the alternator on the engine bracket with the pivot bolt and adjusting lock bolts. Do not tighten them at this time.
  2.  
  3. Install the drive belt. Using a tension gage, check the drive belt tension. A new belt should be 75-125 lb. and a used belts tension should be 70-110 lb. Tighten the pivot and adjusting lock nuts.
  4.  

A new belt is one that has not been used for more than 5 minuets on a running engine.

  1. Connect the oil inlet and outlet hoses for the vacuum pump. Connect the vacuum hoses.
  2.  
  3. Attach the wire to the alternator with the nut.
  4.  
  5. Connect the harness to the alternator.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Start the engine and allow it warm to warm up. Visually inspect the drive belt and listen for any abnormal vibration. Stop the engine and recheck the belt tension.
  10.  

 
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