Toyota RAV4 2000-05

Alternator

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Diagnosis & Testing



Alternator Load Test
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. With the engine running, turn on the blower motor and the high beams (or other electrical accessories to place a load on the charging system).
  4.  
  5. Increase and hold engine speed to 2000 rpm.
  6.  
  7. Measure the voltage reading at the battery.
  8.  
  9. The voltage should increase at least 0.5 volts from the voltage test. If the voltage does not meet specifications, the charging system is malfunctioning.
    NOTE
    Usually under and overcharging is caused by a defective alternator, or its related parts (regulator), and replacement will fix the problem; however, faulty wiring and other problems can cause the charging system to malfunction. Further testing, which is not covered by this book, will reveal the exact component failure. 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.

  10.  

Alternator No-Load Test
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Connect a tachometer to the engine.
    CAUTION
    Ensure that the transmission is in Park and the emergency brake is set. Blocking a wheel is optional and an added safety measure.

  4.  
  5. Turn off all electrical loads (radio, blower motor, wipers, etc.)
  6.  
  7. Start the engine and increase engine speed to approximately 1500 rpm.
  8.  
  9. Measure the voltage reading at the battery with the engine holding a steady 1500 rpm. Voltage should have raised at least 0.5 volts, but no more than 2.5 volts.
  10.  
  11. If the voltage does not go up more than 0.5 volts, the alternator is not charging. If the voltage goes up more than 2.5 volts, the alternator is overcharging.
    NOTE
    Usually under and overcharging is caused by a defective alternator, or its related parts (regulator), and replacement will fix the problem; however, faulty wiring and other problems can cause the charging system to malfunction. Further testing, which is not covered by this book, will reveal the exact component failure. 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.

  12.  
  13. If the voltage is within specifications, proceed to the next test.
  14.  

Voltage Test
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Make sure the engine is OFF , and turn the headlights on for 15-20 seconds to remove any surface charge from the battery.
  4.  
  5. Using a DVOM set to volts DC, probe across the battery terminals.
  6.  
  7. Measure the battery voltage.
  8.  
  9. Write down the voltage reading and proceed to the next test.
  10.  

Installation



2.0L Engine
  1. Install or connect the following:

    Alternator
     
    Adjusting lockbolt and the pivot bolt
     
    Drive belt
     

  2.  
  3. Adjust the drive belt tension to:

    New belt with A/C: 140-190 lbs.
     
    Used belt with A/C: 100-120 lbs.
     
    New belt without A/C: 100-150 lbs.
     
    Used belt without A/C: 75-115 lbs.
     

  4.  
  5. Install or connect the following:

    Tighten the pivot bolt to 38 ft. lbs. (52 Nm).
     
    Tighten the adjusting lockbolt to 13 ft. lbs. (18 Nm).
     
    Electrical wiring to the alternator
     

  6.  

Removal



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 vehicle 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.

2.0L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    It may be necessary to remove other belts for access.



    Electrical wiring from the alternator
     
    Loosen the adjusting lockbolt and the pivot bolt.
     
    Loosen the adjusting bolt to relieve tension on the drive belt, if equipped with air conditioning
     
    Drive belt
     



    Pivot bolt and the adjusting lockbolt
     
    Alternator
     

  4.  

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 vehicle 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.

2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Electrical wiring from the alternator
     
    Loosen the adjusting lockbolt and the pivot bolt.
     
    Loosen the adjusting bolt to relieve tension on the drive belt, if equipped with air conditioning
     
    Drive belt
     

  4.  


NOTE
It may be necessary to remove other belts for access.



Pivot bolt and the adjusting lockbolt
 
Alternator
 

To install:

  1. Install or connect the following:

    Alternator
     
    Adjusting lockbolt and the pivot bolt
     
    Drive belt
     

  2.  
  3. Adjust the drive belt tension to:

    New belt with A/C: 140-190 lbs.
     
    Used belt with A/C: 100-120 lbs.
     
    New belt without A/C: 100-150 lbs.
     
    Used belt without A/C: 75-115 lbs.
     

  4.  
  5. Install or connect the following:

    Tighten the pivot bolt to 38 ft. lbs. (52 Nm).
     
    Tighten the adjusting lockbolt to 13 ft. lbs. (18 Nm).
     
    Electrical wiring to the alternator
     

  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove or disconnect the following:
    NOTE
    It may be necessary to remove other belts for access.



    Electrical wiring from the alternator
     
    Loosen the adjusting lockbolt and the pivot bolt.
     
    Loosen the adjusting bolt to relieve tension on the drive belt, if equipped with air conditioning
     
    Drive belt
     



    Pivot bolt and the adjusting lockbolt
     
    Alternator
     

  6.  

To install:

  1. Install or connect the following:

    Alternator
     
    Adjusting lockbolt and the pivot bolt
     
    Drive belt
     

  2.  
  3. Adjust the drive belt tension to:

    New belt with A/C: 140-190 lbs.
     
    Used belt with A/C: 100-120 lbs.
     
    New belt without A/C: 100-150 lbs.
     
    Used belt without A/C: 75-115 lbs.
     

  4.  
  5. Install or connect the following:

    Tighten the pivot bolt to 38 ft. lbs. (52 Nm).
     
    Tighten the adjusting lockbolt to 13 ft. lbs. (18 Nm).
     
    Electrical wiring to the alternator
     

  6.  

 
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