Toyota Avalon (XX50): Charging System

Charging Failure

PROCEDURE

(a) Start the engine and visually check that the generator rotor assembly (fan) in the generator assembly is operating.

OK:

The generator rotor assembly (fan) is operating.

NG

REPLACE GENERATOR PULLEY WITH CLUTCH

OK

(a) Remove the generator assembly.

Click here

(b) Check the installation condition of the generator pulley cap.

OK:

The generator pulley cap is not loose or missing.

(c) Check for forming of particles due to friction (for dry type pulley) or grease leaks (for wet type pulley).

OK:

There are no large amounts of particles (for dry type pulley) or grease leaks (for wet type pulley).

(d) Check the generator pulley with clutch for misalignment (interference with the generator assembly).

OK:

The generator pulley with clutch is not misaligned (no interference with the generator assembly).

(e) Turn the generator pulley with clutch clockwise and counterclockwise by hand and check for noise. OK: Noise does not occur when turned in either direction.

(f) Turn the generator pulley with clutch clockwise and counterclockwise by hand and visually check for runout.

OK:

The generator pulley with clutch does not have runout.

(g) Inspect generator pulley with clutch.

Click here

OK

REPAIR OR REPLACE GENERATOR ASSEMBLY

NG

REPLACE GENERATOR PULLEY WITH CLUTCH

Data List / Active Test

DATA LIST / ACTIVE TEST

DATA LIST

HINT:

Using the Techstream to read the Data List allows the values or states of switches, sensors, actuators and other items to be read without removing any parts. This non-intrusive inspection can be very useful because intermittent conditions or signals may be discovered before parts or wiring is disturbed. Reading the Data List information early in troubleshooting is one way to save diagnostic time.

NOTICE:

In the table below, the values listed under Normal Condition are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not.

(a) Warm up the engine.

(b) Turn the A/C switch off.

(c) Turn the engine switch off.

(d) Connect the Techstream to the DLC3.

(e) Turn the engine switch on (IG).

(f) Turn the Techstream on.

(g) Enter the following menus: Powertrain / Engine / Data List.

(h) According to the display on the Techstream, read the Data List.

HINT:

Normal Condition: If no idling conditions are specified, the shift lever should be in N or P, and the A/C switch and all accessory switches should be off.

ACTIVE TEST

HINT:

Using the Techstream to perform Active Tests allows relays, VSVs, actuators and other items to be operated without removing any parts. This non-intrusive functional inspection can be very useful because intermittent operation may be discovered before parts or wiring is disturbed. Performing Active Tests early in troubleshooting is one way to save diagnostic time. Data List information can be displayed while performing Active Tests.

(a) Connect the Techstream to the DLC3.

(b) Turn the engine switch on (IG).

(c) Turn the Techstream on.

(d) Enter the following menus: Powertrain / Engine / Active Test.

(e) According to the display on the Techstream, perform the Active Test.

Diagnosis System

DIAGNOSIS SYSTEM

DLC3 (Data Link Connector 3)

(a) Check the DLC3.

Click here

BATTERY VOLTAGE

Standard Voltage:

11 to 14 V

If the voltage is below 11 V, replace or recharge the battery.

Diagnostic Trouble Code Chart

DIAGNOSTIC TROUBLE CODE CHART

Dtc Check / Clear

DTC CHECK / CLEAR

CHECK DTC

(a) Connect the Techstream to the DLC3.

(b) Turn the engine switch on (IG).

(c) Turn the Techstream on.

(d) Enter the following menus: Powertrain / Engine / Trouble Codes.

(e) Check the details of the DTCs.

Click here

CLEAR DTC

(a) Connect the Techstream to the DLC3.

(b) Turn the engine switch on (IG).

(c) Turn the Techstream on.

(d) Enter the following menus: Powertrain / Engine / Trouble Codes.

(e) Clear the DTCs.

Fail-safe Chart

FAIL-SAFE CHART

If the following DTC is stored, the ECM enters fail-safe mode to allow the vehicle to be driven temporarily.

Freeze Frame Data

FREEZE FRAME DATA

DESCRIPTION

The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was moving or stationary, whether the engine was warmed up or not, whether the air fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction.

HINT:

• If it is impossible to reproduce the symptoms even though a DTC is stored, confirm the freeze frame data.
• Freeze frame data is available in long and short forms.

LIST OF FREEZE FRAME DATA

How To Proceed With Troubleshooting

CAUTION / NOTICE / HINT

HINT:

*: Use the Techstream.

PROCEDURE

NEXT

HINT:

• In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred.
• Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases.
• The following 5 items are important points for problem analysis:

  What	Vehicle model, system name
  When	Date, time, occurrence frequency
  Where	Road conditions
  Under what conditions?	Running conditions, driving conditions, weather conditions
  How did it happen?	Problem symptoms

NEXT

(a) Measure the battery voltage.

Standard Voltage:

11 to 14 V

If the voltage is below 11 V, recharge or replace the battery before proceeding to the next step.

NEXT

(a) Check if CAN communication DTCs are output.

Click here

B

GO TO CAN COMMUNICATION SYSTEM

A

HINT:

Refer to DTC Check / Clear.

Click here

B

GO TO DTC CHART

A

HINT:

Refer to Problem Symptoms Table.

Click here

B

GO TO STEP 12

A

HINT:

Refer to Data List / Active Test.

Click here

B

GO TO STEP 12

A

HINT:

Refer to Terminals of ECM.

Click here

NG

GO TO STEP 12

OK

HINT:

Refer to Symptom Simulation.

Click here

NEXT

NEXT

NEXT

NEXT

NEXT

END

Noise Occurs from V-ribbed Belt or Generator Assembly

PROCEDURE

(a) Confirm the problem symptom.

B

GO TO STEP 6

A

(a) Check the V-ribbed belt for wear or damage.

OK:

The V-ribbed belt is not worn or damaged.

NG

REPLACE V-RIBBED BELT

OK

(a) Check the grooves of the generator pulley with clutch for wear or damage.

OK:

The grooves of the generator pulley with clutch are not worn or damaged.

NG

REPLACE GENERATOR PULLEY WITH CLUTCH

OK

(a) Start the engine and check the generator pulley with clutch for looseness.

OK:

The generator pulley with clutch is not loose.

NG

TIGHTEN GENERATOR PULLEY WITH CLUTCH TO SPECIFIED TORQUE

OK

(a) Remove the generator assembly.

Click here

(b) Check the installation condition of the generator pulley cap.

OK:

The generator pulley cap is not loose or missing.

(c) Check for forming of particles due to friction (for dry type pulley) or grease leaks (for wet type pulley).

OK:

There are no large amounts of particles (for dry type pulley) or grease leaks (for wet type pulley).

(d) Check the generator pulley with clutch for misalignment (interference with the generator assembly).

OK:

The generator pulley with clutch is not misaligned (no interference with the generator assembly).

(e) Turn the generator pulley with clutch clockwise and counterclockwise by hand and check for noise. OK: Noise does not occur when turned in either direction.

(f) Turn the generator pulley with clutch clockwise and counterclockwise by hand and visually check for runout.

OK:

The generator pulley with clutch does not have runout.

(g) Inspect generator pulley with clutch.

Click here

OK

INSPECT PULLEY OTHER THAN GENERATOR ASSEMBLY PULLEY

NG

REPLACE GENERATOR PULLEY WITH CLUTCH

(a) Perform a road test and check that noise does not occur when decelerating.

OK:

Noise does not occur.

(b) Stop the engine and check that generator pulley with clutch noise does not occur as the engine stops.

OK:

Noise does not occur.

NG

REPLACE GENERATOR PULLEY WITH CLUTCH

OK

(a) Inspect generator pulley with clutch.

Click here

OK

REPAIR OR REPLACE GENERATOR ASSEMBLY

NG

REPLACE GENERATOR PULLEY WITH CLUTCH

On-vehicle Inspection

ON-VEHICLE INSPECTION

CAUTION / NOTICE / HINT

CAUTION:

• To prevent injury due to contact with an operating V-ribbed belt or cooling fan, keep your hands and clothing away from the V-ribbed belt and cooling fans when working in the engine compartment with the engine running or the engine switch on (IG).
• To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

PROCEDURE

1. CHECK BATTERY CONDITION

NOTICE:

If the battery is weak or if the engine is difficult to start, recharge the battery and perform inspections again before returning the vehicle to the customer.

(a) Check the battery for damage or deformation. If severe damage, deformation or leakage is found, replace the battery.

(b) Check the electrolyte level in each cell.

(1) For maintenance-free batteries:

• If the electrolyte level is below the lower line, replace the battery.
• If the electrolyte level is above the lower line, check the battery voltage when cranking the engine. If the voltage is less than 11 V, recharge or replace the battery.

  HINT:

  Before checking the battery voltage, turn off all the electrical systems (headlights, blower motor, rear window defogger, etc.).

(2) For non-maintenance-free batteries: If the electrolyte level is below the lower line, add distilled water to each cell. Then, recharge the battery and check the electrolyte specific gravity. Standard Specific Gravity: 1.25 or higher at 20°C (68°F) If the electrolyte level is above the lower line, check the battery voltage when cranking the engine. If the battery voltage is less than 11 V, recharge or replace the battery. HINT: Before checking the battery voltage, turn off all the electrical systems (headlights, blower motor, rear window defogger, etc.).

(c) Check the voltage.

(1) Turn the engine switch off and turn on the headlights for 20 to 30 seconds. This will remove the surface charge from the battery.

(2) Measure the battery voltage according to the value(s) in the table below.

Standard Voltage:

If the voltage is not as specified, recharge or replace the battery.

2. INSPECT BATTERY TERMINAL AND FUSE

(a) Check that the battery terminals are not loose or corroded.

If the terminal is corroded, clean the terminal.

Torque:

Positive (+) Battery Terminal :

5.4 N·m {55 kgf·cm, 48 in·lbf}

Negative (-) Battery Terminal :

5.4 N·m {55 kgf·cm, 48 in·lbf}

(b) Measure the resistance of the fuses.

Standard Resistance:

Below 1 Ω

If the result is not as specified, replace the fuse.

3. INSPECT V-RIBBED BELT

Click here

4. INSPECT GENERATOR WIRING

(a) Visually check the generator wiring.

(1) Check that the wiring is in good condition.

5. CHECK FOR ABNORMAL NOISE

(a) Check for abnormal noises from the generator assembly.

(1) Check that no abnormal noises are heard from the generator assembly while the engine is running.

If noise occurs, refer to Problem Symptoms Table.

Click here

6. INSPECT CHARGING CIRCUIT WITHOUT LOAD

CAUTION:

• To prevent injury due to contact with an operating V-ribbed belt or cooling fan, keep your hands and clothing away from the V-ribbed belt and cooling fans when working in the engine compartment with the engine running or the engine switch on (IG).
• To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

(a) Connect a voltmeter and an ammeter to the charging circuit as follows. HINT: If a battery/generator assembly tester is available, connect the tester to the charging circuit in accordance with the manufacturer's instructions. (1) Disconnect the wire from terminal B of the generator assembly and connect it to the negative (-) lead of the ammeter. (2) Connect the ammeter positive (+) lead to terminal B of the generator assembly. (3) Connect the voltmeter positive (+) lead to the positive (+) terminal of the battery. (4) Ground the voltmeter negative (-) lead.

*1 Battery *2 Generator Assembly *a Terminal B

(b) Check the charging circuit.

(1) Maintain the engine speed at 2000 rpm and check the readings on the ammeter and voltmeter.

Standard Current:

10 A or more

Standard Voltage:

13.5 to 14.4 V

If the result is not as specified, repair or replace the generator assembly.

7. INSPECT CHARGING CIRCUIT WITH LOAD

CAUTION:

• To prevent injury due to contact with an operating V-ribbed belt or cooling fan, keep your hands and clothing away from the V-ribbed belt and cooling fans when working in the engine compartment with the engine running or the engine switch on (IG).
• To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

(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:

30 A or more

If the result is not as specified, repair or replace the generator assembly.

HINT:

If the battery is fully charged, the reading will sometimes be less than the standard. If this is the case, add more electrical load (operate the wipers, rear window defogger, etc.) and check the reading on the ammeter again.

Lost Communication with Alternator Missing Message (P161A87)

DESCRIPTION

The ECM communicates with the generator assembly via LIN communication. If a LIN communication error is detected, the ECM stores this DTC.

WIRING DIAGRAM

PROCEDURE

(a) Check the charging system.

Click here

NG

REPAIR OR REPLACE CHARGING SYSTEM

OK

(a) Disconnect the C56 ECM connector.

(b) Disconnect the C57 generator assembly connector.

(c) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

OK

REPLACE GENERATOR ASSEMBLY

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

Parts Location

PARTS LOCATION

ILLUSTRATION

ILLUSTRATION

Precaution

PRECAUTION

INITIALIZATION

NOTICE:

• When the cable is disconnected from the negative (-) battery terminal, initialize the following system(s) after the cable is reconnected.

  Click here

CHARGING SYSTEM PRECAUTION

NOTICE:

• Check that the battery cables are connected to the correct terminals.
• Disconnect the battery cables when the battery is given a quick charge.
• Do not perform tests with a high voltage insulation resistance tester.
• Never disconnect the battery cables while the engine is running.
• Check that the charging cable nuts are tightened on terminal B of the generator assembly and on the engine room relay block and junction block assembly.

Problem Symptoms Table

PROBLEM SYMPTOMS TABLE

HINT:

• Use the table below to help determine the cause of problem symptoms. If multiple suspected areas are listed, the potential causes of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary.
• Inspect the fuses and relays related to this system before inspecting the suspected areas below.

System Diagram

SYSTEM DIAGRAM

Terminals Of Ecm

TERMINALS OF ECM

HINT:

The standard normal voltage and resistance between each pair of ECM terminals is shown in the table below. The appropriate conditions for checking each pair of terminals are also indicated. The result of checks should be compared with the standard normal voltage and resistance for that pair of terminals, displayed in the Specified Condition column. The illustration above can be used as a reference to identify the ECM terminal locations.