Toyota Previa 1991-1997 Repair Information

Alternator

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TESTING



See Figure 1

A voltmeter and ammeter are necessary for testing.



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Fig. Fig. 1: Alternator, voltmeter and ammeter test connections

  1. Make sure the battery terminals are not loose or corroded. Check the fusible link for continuity.
  2.  
  3. Inspect the drive belt for excessive wear. Check the drive belt tension. If necessary adjust the drive belt.
  4.  
  5. Check the following fuses for continuity: ENGINE, CHARGE, IGN fuses.
  6.  
  7. Visually check alternator wiring and listen for abnormal noises.
  8.  
  9. Check that the discharge warning light comes ON when the ignition switch is turned ON . Start the engine. Check that the warning light goes out.
  10.  
  11. Check the charging circuit WITHOUT A LOAD.
    1. Disconnect the wire from terminal B of the alternator and attach it to the negative lead of the ammeter.
    2.  
    3. Connect the positive lead 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. Ground the negative lead of the voltmeter.
    8.  
    9. To check the charging circuit, run the engine from idle to 2000 rpms and check the reading on the ammeter and voltmeter. Standard amperage is 10 amps or less. Standard voltage is as follows:

      77°F (25°C)-14.0-15.0 volts
       
      239°F (115°C)-13.5-14.3 volts
       

    10.  
    11. If the voltmeter reading is more than standard voltage, replace the voltage regulator. If the voltmeter reading is less than standard, check the alternator.
    12.  

  12.  
  13. Check the charging circuit WITH A LOAD.
    1. With the engine running at 2000 rpm, turn on high beams and heater fan to HI.
    2.  
    3. Check the standard amperage, it should be 30 amps or more. If the ammeter is less than standard, replace the alternator.
    4.  

  14.  
  15. Replace the necessary parts. Recheck the charging system.
  16.  

If a battery is fully charged, sometimes the indication will be less than 30 amps.

REMOVAL & INSTALLATION



2TZ-FE Engine

See Figures 2 through 8

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the No. 1 engine undercover.
  4.  



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Fig. Fig. 2: Alternator mounting-2TZ-FE engine

  1. Lower the vehicle.
  2.  
  3. Disconnect the alternator wire from the adjusting bar.
  4.  
  5. Detach the alternator connector.
  6.  



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Fig. Fig. 3: Some of the wiring is hard to access

  1. Remove the nut, and disconnect the alternator wire.
  2.  



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Fig. Fig. 4: Remove the wire from the shaft on the top of the alternator

  1. Loosen the lock bolt, adjusting bolt and pivot bolt then remove the drive belt.
  2.  



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Fig. Fig. 5: Loosen the bolts on the alternator to remove the drive belt

  1. Remove the pivot bolt and lock bolt.
  2.  



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Fig. Fig. 6: The adjuster bracket and bolt are located on the side of the alternator



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Fig. Fig. 7: Pull the lock bolt from the lower portion of the alternator

  1. Hold the alternator and extract it from the vehicle.
  2.  



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Fig. Fig. 8: Extract the alternator from the bottom of the vehicle

To install:

Mount the alternator on the bracket with the pivot bolt and lock bolt. Do not tighten them yet.

  1. Install and adjust the drive belt with the adjusting bolt. Tighten the lock bolt to 13 ft. lbs. (18 Nm) and the pivot bolt to 37 ft. lbs. (50 Nm).
  2.  
  3. Attach the alternator connector.
  4.  
  5. Connect the alternator wire with the nut.
  6.  
  7. Connect the alternator wore to the adjusting bar with the bolt.
  8.  
  9. Rasie and support the vehicle and install the No. 1 engine undercover.
  10.  
  11. Perform the on vehicle testing inspection.
  12.  

2TZ-FZE Engine

See Figures 9, 10 and 11

  1. Remove the air duct.
  2.  



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Fig. Fig. 9: Exploded view of the alternator and related components-2TZ-FZE engine

  1. Remove the engine coolant reservoir.
  2.  
  3. Remove the battery. Be sure to disconnect the negative battery cable first.
  4.  
  5. Loosen the No. 1 idler pulley nut and adjusting bolt, then extract the drive belt.
  6.  



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Fig. Fig. 10: Loosen the No. 1 idler pulley nut and adjusting bolt-2TZ-FZE engine

  1. Disconnect the alternator wires and connector from the unit and stay.
  2.  
  3. Remove the 3 bolts and extract the alternator. One bolt is strictly for the alternator, the other two retain the stay to the alternator.
  4.  



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Fig. Fig. 11: Remove the 2 stay bolts and 1 alternator bolt

To install:

Position the alternator with the 3 bolts and tighten the alternator bolt to 37 ft. lbs. (50 Nm). Tighten the stay bolts to 20 ft. lbs. (26 Nm).

  1. Attach the alternator wires and connector to the unit and stay.
  2.  
  3. Install and adjust the drive belt with the adjusting bolt and No. 1 idler pulley nut.
  4.  
  5. Install the battery.
  6.  
  7. Install the engine coolant reservoir and air duct.
  8.  
  9. Perform the on vehicle testing inspection.
  10.  

 
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