Toyota Pick-ups, Land Cruiser, and 4 Runner 1997-00

Alternator

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All current trucks use a nominal 12-volt alternator. (Exact output should be slightly higher, generally 13.514.4 volts). Amperage ratings may vary according to the year, model and accessories. All have a transistorized, non-adjustable regulator, integrated with the alternator.

TESTING



If a battery/alternator tester is available, connect the tester to the charging circuit recommended by the manufacture's instructions.

If a tester is not available, connect a voltmeter and an ammeter to the charging circuit by doing the following:

  1. Disconnect the wire from terminal B of the alternator and attach to the negative () lead of the ammeter.
  2.  



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Fig. Attach the ammeter and voltmeter as shown to test the charging system



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Fig. With the engine running from idle to 2000 rpm, the readings should be as shown

  1. Connect the positive (+) lead of the ammeter to terminal B of the alternator.
  2.  
  3. Connect the positive (+) lead of the voltmeter to terminal B of the alternator.
  4.  
  5. Ground the negative () lead of the voltmeter.
  6.  
  7. With the engine running from idle to 2000 rpm, check the reading on the ammeter and voltmeter. The standard amperage should be 10 amps or less; standard voltage cold is 13.915.1 volts, and 13.514.3 volts hot. If the reading is greater than standard voltage, replace the regulator.
  8.  
  9. If the reading is less than the standard voltage, check the regulator and alternator:
  10.  
  11. With terminal F grounded, start the engine and check the voltmeter reading of terminal B .
  12.  



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Fig. With terminal F grounded, start the engine and check the voltmeter reading of terminal B



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Fig. Note whether the reading is above or below the standard voltage

  1. If the voltmeter reading is more than the standard voltage, replace the regulator.
  2.  
  3. If the voltmeter reading is less than standard voltage, the alternator may be faulty.
  4.  
  5. With the engine running at 2000 rpm turn on the high beam headlights and place the heater switch on high.
  6.  
  7. Check the reading on the ammeter. It should be 30 amps or more.
  8.  



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Fig. The ammeter reading should be above 30 amps

  1. If the ammeter reading is less than the standard amperage, replace the alternator.
  2.  



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Fig. If the ammeter reading is below the 30 amps, replace the alternator

If the battery is fully charged, the indication will sometimes be slightly less than the standard amperage.

REMOVAL & INSTALLATION



On some models, the alternator is mounted very low on the engine. On these models, it may be necessary to remove the gravel shield and work from beneath the truck in order to gain access to the alternator. Replacing the alternator while the engine is cold is recommended. A hot engine can result in personal injury.

2RZ-FE and 3RZ-FE Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the wiring at the back of the alternator. Lift the rubber boot, remove the nut from the external terminal and the wire.
  4.  



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Fig. Exploded view of the alternator and drive belt2RZ-FE and 3RZ-FE engines



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Fig. Locations of the adjusting, pivot and lockbolts

  1. Loosen the alternator lockbolt, pivot bolt, nut and adjusting bolt.
  2.  
  3. Push the alternator towards the engine and remove the belt.
  4.  
  5. Remove the wiring harness with the clip.
  6.  
  7. Remove the alternator lockbolt, pivot bolt, and nut.
  8.  
  9. Remove the alternator.
  10.  

To install:

  1. Place the alternator into position and loosely install the pivot and adjusting bolts.
  2.  
  3. Install the drive belt; adjust it to the proper tension. Tighten the lockbolt to 21 ft. lbs. (29 Nm) and the pivot bolt to 43 ft. lbs. (59 Nm).
  4.  
  5. Connect the wire harness with clip.
  6.  
  7. Connect the wire to the terminal. Install the nut and tighten to 7 ft. lbs. (10 Nm). Fit the rubber boot over the terminal. Attach the wire harness connector.
  8.  
  9. Connect the negative battery cable.
  10.  

5VZ-FE Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the wiring at the back of the alternator. Lift the rubber boot; remove the nut from the external terminal and the wire.
  4.  



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Fig. Exploded view of the alternator and drive belt5VZ-FE Engine



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Fig. Locations of the adjusting and pivot bolts and the locknut

  1. Loosen the alternator locknut, pivot bolt, nut and adjusting bolt.
  2.  
  3. Push the alternator towards the engine and remove the belt.
  4.  
  5. Remove the alternator lockbolt, pivot bolt, and nut.
  6.  
  7. Remove the alternator.
  8.  

To install:

  1. Place the alternator into position and loosely install the pivot and adjusting bolts.
  2.  
  3. Install the drive belt; adjust it to the proper tension. Tighten the locknut 25 ft. lbs. (33 Nm) and the pivot bolt 38 ft. lbs. (51 Nm).
  4.  
  5. Connect the wire to the terminal and install the nut and tighten. Fit the rubber boot over the terminal. Attach the wire harness connector.
  6.  
  7. Connect the negative battery cable.
  8.  

1FZ-FE Engine
  1. Disconnect the negative battery terminal.
  2.  
  3. Remove the battery and tray.
  4.  
  5. Disconnect the power steering reservoir tank.
  6.  
  7. Loosen the lock, pivot and adjusting bolts.
  8.  
  9. Remove the two drive belts.
  10.  
  11. Disconnect the wiring at the back of the alternator. Lift the rubber boot; remove the nut from the external terminal and the wire.
  12.  



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Fig. Exploded view of alternator, battery, belt and related components1FZ-FE Engine



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Fig. Lock, pivot and adjusting bolt locations



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Fig. The wiring clamp is mounted into the alternator as shown

  1. Remove the wire clamp from the alternator.
  2.  
  3. Remove the lockbolt, nut and drive belt adjusting bar.
  4.  
  5. Hold the alternator; remove the pivot bolt then the alternator.
  6.  

To install:

  1. Mount the alternator on the bracket with the pivot bolt. Do NOT tighten the bolt yet.
  2.  
  3. Install the drive belt adjusting bar with the bolt and nut. Tighten the bolt to 15 ft. lbs. (21 Nm).
  4.  
  5. Temporarily install the lockbolt. Connect the alternator wiring, nut and rubber cap.
  6.  
  7. Connect the wire clamp to the alternator.
  8.  
  9. Install the drive belts.
  10.  
  11. Tighten the pivot bolt to 43 ft. lbs. (59 Nm) and the lockbolt to 15 ft. lbs. (21 Nm).
  12.  
  13. Connect the power steering reservoir tank.
  14.  
  15. Install the battery tray and battery.
  16.  
  17. Start the vehicle and check the alternator operation.
  18.  

2UZ-FE Engine
  1. Disconnect the negative battery cable.
  2.  
  3. On the Land Cruiser, drain the coolant since the radiator must be removed.
  4.  
  5. On the Tundra and the Land Cruiser, remove the alternator drive belt. Loosen the belt tension by turning the tensioner counterclockwise. Note that the pulley bolt for the belt tensioner has a left-hand thread.
  6.  
  7. On the Land Cruiser, perform the following:
    1. Remove the engine under cover.
    2.  
    3. Remove the radiator assembly.
    4.  
    5. Remove the power steering pump pulley. Note that it is splined to the pump shaft and may take some careful coaxing for removal. Do NOT hammer on either the pump shaft or the pulley.
    6.  

  8.  
  9. On the Tundra, perform the following:
    1. Remove the power steering pump from the engine.
    2.  
    3. Remove the engine under cover.
    4.  
    5. Remove the No. 2 fan shroud, by removing the clips.
    6.  

  10.  
  11. Remove the alternator electrical connector. There will likely be a clip securing the wiring to the alternator body. Gently work this clip free. Unbolt the alternator.
  12.  

To install:

  1. Installation is the reverse of removal. Verify that all electrical connections are tight. On Land Cruiser, if the pump pulley has been removed, install with a new pulley nut and torque to 32 ft. lbs. (43 Nm).
  2.  

 
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