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Battery, alternator and starter Toyota Camry 3 (XV30)
Battery — general information
The vehicle covered in this manual has a 12V electrical system. The body ground is connected to the negative battery terminal. The battery is located in the engine compartment or under the rear seat (models with air...
The vehicle covered in this manual has a 12V electrical system. The body ground is connected to the negative battery terminal. The battery is located in the engine compartment or under the rear seat (models with air...
Charging the battery
A battery with a green dot indicates that charging is not needed until the battery is discharged, such as when starting a cold engine. When charging a battery with sealed terminals outside the vehicle, install an...
A battery with a green dot indicates that charging is not needed until the battery is discharged, such as when starting a cold engine. When charging a battery with sealed terminals outside the vehicle, install an...
Charging a fully discharged battery
Use the following procedure to recharge a completely discharged battery. Measure the voltage at the battery terminals with an accurate voltmeter. If the measured value is less than 10 V, the charging current will be...
Use the following procedure to recharge a completely discharged battery. Measure the voltage at the battery terminals with an accurate voltmeter. If the measured value is less than 10 V, the charging current will be...
Battery care
In order for the battery to last longer and maintain its maximum capacity, the following conditions must be met. Keep the battery and its surroundings clean. The surface of the battery must always be dry, otherwise...
In order for the battery to last longer and maintain its maximum capacity, the following conditions must be met. Keep the battery and its surroundings clean. The surface of the battery must always be dry, otherwise...
Checking a fully charged battery
Install on ammeter (with measuring range 0-5 mA and 0-5 A) the highest measurement limit. Connect an ammeter between the negative battery terminal and ground cable. Connect the positive wire of the ammeter to the...
Install on ammeter (with measuring range 0-5 mA and 0-5 A) the highest measurement limit. Connect an ammeter between the negative battery terminal and ground cable. Connect the positive wire of the ammeter to the...
Removing and installing the battery
When the battery is disconnected from the memory of the central unit of the engine and gearbox control system, the anti-lock brake system, as well as from the memory of a number of other electrical devices, such as a...
When the battery is disconnected from the memory of the central unit of the engine and gearbox control system, the anti-lock brake system, as well as from the memory of a number of other electrical devices, such as a...
Power supply system — general information
The power supply system consists of a generator, voltage regulator and storage battery. When these devices work together, power is provided to such consumers of electricity as ignition, headlights, radio, etc. The...
The power supply system consists of a generator, voltage regulator and storage battery. When these devices work together, power is provided to such consumers of electricity as ignition, headlights, radio, etc. The...
Generator — design description
Pic. 7.1. Segment Conductor Generator Components: 1 - pulley; 2 - front cover; 3 - rotor; 4 - slip ring; 5 - housing of the rectifier unit; 6 - rectifier block; 7 - output insulator; 8 - relay-voltage regulator...
Pic. 7.1. Segment Conductor Generator Components: 1 - pulley; 2 - front cover; 3 - rotor; 4 - slip ring; 5 - housing of the rectifier unit; 6 - rectifier block; 7 - output insulator; 8 - relay-voltage regulator...
Checking the generator on the car
Check the density and electrolyte level in each battery compartment. Pic. 7.2. Checking the degree of charge of the battery with a voltmeter Check the connection of the battery terminals and make sure there is no...
Check the density and electrolyte level in each battery compartment. Pic. 7.2. Checking the degree of charge of the battery with a voltmeter Check the connection of the battery terminals and make sure there is no...
Checking the accessory drive belt
Pic. 7.4. An example of accessory drive belt wear Check accessory drive belt for wear and damage. If defects are found, replace the belt (pic. 7.4). Note. Detachment of rubber from the cord on the inside is not allowed...
Pic. 7.4. An example of accessory drive belt wear Check accessory drive belt for wear and damage. If defects are found, replace the belt (pic. 7.4). Note. Detachment of rubber from the cord on the inside is not allowed...
Checking the electrical circuit of the generator at idle
Note. If you have a tester to check the alternator and battery, connect it in accordance with the manufacturer's instructions. If there is no tester, do the following: disconnect the wire from the generator output «IN»...
Note. If you have a tester to check the alternator and battery, connect it in accordance with the manufacturer's instructions. If there is no tester, do the following: disconnect the wire from the generator output «IN»...
Removing the generator (models with engine 1 and 2 AZ-FE)
Remove the drive belt by loosening the support, locking and adjusting bolts. Disconnect the alternator connector, remove the nut and disconnect the alternator wiring. Disconnect the wiring clamp from the generator. Pic....
Remove the drive belt by loosening the support, locking and adjusting bolts. Disconnect the alternator connector, remove the nut and disconnect the alternator wiring. Disconnect the wiring clamp from the generator. Pic....
Generator installation (models with engine 1 and 2 AZ-FE)
Install the generator on the bracket. Establish a basic and lock bolt of fastening of the generator, bait them, but do not twist completely. Pic. 7.10. Generator installation (models with engine 1 and 2 AZ-FE) Connect...
Install the generator on the bracket. Establish a basic and lock bolt of fastening of the generator, bait them, but do not twist completely. Pic. 7.10. Generator installation (models with engine 1 and 2 AZ-FE) Connect...
Removing the generator (models with 1MZ-FE engine)
Disconnect the generator wire connector. Remove the retaining nut and disconnect the lead wire from terminal B. Loosen bolts A and B. Loosen bolt C to reduce drive belt tension. Pic. 7.11. Removing the generator (models...
Disconnect the generator wire connector. Remove the retaining nut and disconnect the lead wire from terminal B. Loosen bolts A and B. Loosen bolt C to reduce drive belt tension. Pic. 7.11. Removing the generator (models...
Generator installation (models with 1MZ-FE engine)
Install the generator. Temporarily install bolts A and B. Connect the generator wire connector. Adjust the tension of the drive belt by tightening the adjusting bolt C. Tighten bolts A and B. Torque: bolt A - 58 Nm;...
Install the generator. Temporarily install bolts A and B. Connect the generator wire connector. Adjust the tension of the drive belt by tightening the adjusting bolt C. Tighten bolts A and B. Torque: bolt A - 58 Nm;...
Generator disassembly
Loosen the nut and remove the terminal insulator. Pic. 7.12. Removing the rectifier plate Remove the rectifier plate (pic. 7.12). Unscrew the three cover fastening nuts and remove the generator cover from the side of...
Loosen the nut and remove the terminal insulator. Pic. 7.12. Removing the rectifier plate Remove the rectifier plate (pic. 7.12). Unscrew the three cover fastening nuts and remove the generator cover from the side of...
Checking the voltage regulator relay
Pic. 7.22. Checking the voltage regulator relay Using an ohmmeter, check continuity between diodes F and B (pic. 7.22). Attention! When the positive and negative poles between terminals F and B are connected in a single...
Pic. 7.22. Checking the voltage regulator relay Using an ohmmeter, check continuity between diodes F and B (pic. 7.22). Attention! When the positive and negative poles between terminals F and B are connected in a single...
Checking the generator rotor
Check for an open in the field winding. Pic. 7.23. Checking resistance between slip rings Use an ohmmeter to measure the resistance between the slip rings (pic. 7.23). Rated resistance (V «cold» able): 2.7-3.1 ohm. If...
Check for an open in the field winding. Pic. 7.23. Checking resistance between slip rings Use an ohmmeter to measure the resistance between the slip rings (pic. 7.23). Rated resistance (V «cold» able): 2.7-3.1 ohm. If...
Checking the slip rings of the generator
Check the working surfaces of the slip rings. They should not have burrs or chips. Pic. 7.25. Measuring the diameter of slip rings Measure the diameter of the slip rings with a caliper (pic. 7.25). Standard diameter:...
Check the working surfaces of the slip rings. They should not have burrs or chips. Pic. 7.25. Measuring the diameter of slip rings Measure the diameter of the slip rings with a caliper (pic. 7.25). Standard diameter:...
Checking the generator rectifier unit
Check the positive valve. Pic. 7.26. Scheme for checking the conductivity of the contacts of the rectifier unit Connect the negative probe of an ohmmeter to the positive terminal of the rectifier unit, and connect the...
Check the positive valve. Pic. 7.26. Scheme for checking the conductivity of the contacts of the rectifier unit Connect the negative probe of an ohmmeter to the positive terminal of the rectifier unit, and connect the...
Checking the generator brushes
Pic. 7.27. Measuring the length of the protruding part of the brush Measure the length of the protruding part of the brushes (pic. 7.27). Standard length: 9.5-11.5 mm. Minimum allowable: 1.5 mm. If the brushes are less...
Pic. 7.27. Measuring the length of the protruding part of the brush Measure the length of the protruding part of the brushes (pic. 7.27). Standard length: 9.5-11.5 mm. Minimum allowable: 1.5 mm. If the brushes are less...
Alternator Bearing Check
Check the front bearing. Check that the front bearing runs smoothly without binding. Replace bearing if necessary. Loosen the four screws and remove the bearing holder. Pic. 7.28. Pressing out the front bearing With a...
Check the front bearing. Check that the front bearing runs smoothly without binding. Replace bearing if necessary. Loosen the four screws and remove the bearing holder. Pic. 7.28. Pressing out the front bearing With a...
Generator Assembly
Install the drive side generator cover onto the rotor. Install the washer. Install the rectifier housing with a plastic-headed hammer. Secure the housing with four nuts. Tightening torque: 4.5–5.4 Nm. Pic. 7.29....
Install the drive side generator cover onto the rotor. Install the washer. Install the rectifier housing with a plastic-headed hammer. Secure the housing with four nuts. Tightening torque: 4.5–5.4 Nm. Pic. 7.29....
Starter — general information
The starting system includes a battery-powered starter. The starter consists of a motor, a traction relay, an ignition switch, an interlock switch (only on vehicles with automatic transmission), connecting wires and...
The starting system includes a battery-powered starter. The starter consists of a motor, a traction relay, an ignition switch, an interlock switch (only on vehicles with automatic transmission), connecting wires and...
New Camry PS Starter
Pic. 7.33. Comparative block diagram of a conventional starter and a starter with a planetary gear PS starter is installed on Camry cars (electric motor with planetary gear see fig. 7.33). Since the PS starter has a...
Pic. 7.33. Comparative block diagram of a conventional starter and a starter with a planetary gear PS starter is installed on Camry cars (electric motor with planetary gear see fig. 7.33). Since the PS starter has a...
Removal and installation of a starter (models with engine 1 and 2 AZ-FE)
Disconnect the wires from the battery terminals. Remove the battery with support. Remove the air filter assembly with bracket. Disconnect the starter connector. Loosen the nut and disconnect terminal 30 of the starter...
Disconnect the wires from the battery terminals. Remove the battery with support. Remove the air filter assembly with bracket. Disconnect the starter connector. Loosen the nut and disconnect terminal 30 of the starter...
Removal and installation of a starter (models with 1MZ-FE engine)
Disconnect the wires from the battery terminals. Remove the battery with support. Remove the air filter assembly with bracket. Disconnect the starter connector. Loosen the nut and disconnect terminal 30 of the starter...
Disconnect the wires from the battery terminals. Remove the battery with support. Remove the air filter assembly with bracket. Disconnect the starter connector. Loosen the nut and disconnect terminal 30 of the starter...
Checking the operation of the starter
Attention! The check should be carried out in the interval of 3–5 s in order to avoid damage to the stator winding. Checking the retracting winding of the traction relay Disconnect the wire from the starter terminal...
Attention! The check should be carried out in the interval of 3–5 s in order to avoid damage to the stator winding. Checking the retracting winding of the traction relay Disconnect the wire from the starter terminal...
Checking the starter relay
Pic. 7.40. Starter relay outputs Using an ohmmeter, check for continuity between the terminals «1» and «2» (pic. 7.40). Using an ohmmeter, verify that there is no continuity between the leads «3» and «5». If signal...
Pic. 7.40. Starter relay outputs Using an ohmmeter, check for continuity between the terminals «1» and «2» (pic. 7.40). Using an ohmmeter, verify that there is no continuity between the leads «3» and «5». If signal...
Starter disassembly
Remove the starter housing assembly with the starter winding and armature from the traction relay housing. Pic. 7.41. Removing the wire terminal of the traction relay Unscrew the nut and disconnect the wire terminal...
Remove the starter housing assembly with the starter winding and armature from the traction relay housing. Pic. 7.41. Removing the wire terminal of the traction relay Unscrew the nut and disconnect the wire terminal...
Checking the starter armature
Pic. 7.47. Measuring the resistance between collector lamellas Using an ohmmeter, measure the resistance between the collector lamellae. The resistance should tend to 0, i.e. circuit must be closed (pic. 7.47). If the...
Pic. 7.47. Measuring the resistance between collector lamellas Using an ohmmeter, measure the resistance between the collector lamellae. The resistance should tend to 0, i.e. circuit must be closed (pic. 7.47). If the...
Checking the starter manifold
Inspect the working surfaces of the collector lamellas, if they are dirty and burnt, clean the working surfaces with sandpaper No. 400 or grind the collector on a lathe. Pic. 7.49. Collector beat measurement Set the...
Inspect the working surfaces of the collector lamellas, if they are dirty and burnt, clean the working surfaces with sandpaper No. 400 or grind the collector on a lathe. Pic. 7.49. Collector beat measurement Set the...
Checking the starter brush holder
Check brush holder insulation. Pic. 7.52. Checking the insulation of the brush holder Using an ohmmeter, check that the resistance between the positive «+» and negative «-» brush holder tends to infinity, i.e. open...
Check brush holder insulation. Pic. 7.52. Checking the insulation of the brush holder Using an ohmmeter, check that the resistance between the positive «+» and negative «-» brush holder tends to infinity, i.e. open...
Check of the traction relay of a starter
Pic. 7.53. Checking the traction relay Check for an open in the winding circuit. Measure the resistance between the terminals with an ohmmeter «50» and «WITH» (pic. 7.53). If the resistance tends to infinity, i.e....
Pic. 7.53. Checking the traction relay Check for an open in the winding circuit. Measure the resistance between the terminals with an ohmmeter «50» and «WITH» (pic. 7.53). If the resistance tends to infinity, i.e....
Starter Assembly
When assembling the starter, use high temperature grease to lubricate the bearings and gears. Lubricate the starter clutch shaft with grease. Install the circlip onto the clutch shaft using needle nose pliers. Pic....
When assembling the starter, use high temperature grease to lubricate the bearings and gears. Lubricate the starter clutch shaft with grease. Install the circlip onto the clutch shaft using needle nose pliers. Pic....
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- User manual
- Vehicle description
- Keys, locks and alarms
- Governing bodies
- Salon equipment
- Driving and operation
- Maintenance
- Power unit
- 4-cylinder engine
- Control system (I4)
- Engine overhaul (I4)
- 6-cylinder engine
- Control system (V6)
- Engine overhaul (V6)
- Transmission
- Clutch
- Mechanical gearbox
- Automatic gearbox
- Drive mechanism
- Chassis, running gear
- Wheels and tires
- Car suspension
- Steering
- Brake system
- Body and interior
- Exterior (external elements)
- Doors, locks and windows
- Air conditioning and heater
- Electrical equipment
- Equipment and devices
- Power devices
- Electrical circuits
- General information
- Controls and instruments
- Driving and operation
- Daily care
- Maintenance
- Power unit
- 4-cylinder engine
- 6-cylinder engine
- Engine overhaul
- Engine electrical equipment
- Cooling system
- Heating and ventilation
- Fuel system
- Exhaust system
- Transmission
- Mechanical gearbox
- Automatic gearbox
- Clutch
- Chassis, running gear
- Suspension and axle shafts
- Steering
- Brake system
- Body and interior
- Exterior (external elements)
- Interior (internal elements)
- Doors, locks and windows
- Electrical equipment
- Equipment and devices
- Electrical circuits
- General information
- User manual
- Maintenance
- Power unit
- 4-cylinder engine
- 6-cylinder engine
- Overhaul of engines
- Cooling and heating
- Fuel system
- Engine electrical equipment
- Control system
- Transmission
- Mechanical gearbox
- Automatic gearbox
- Clutch and drive shafts
- Chassis, running gear
- Brake system
- Car suspension
- Steering
- Body and interior
- Exterior (external elements)
- Interior (internal elements)
- Doors, locks and windows
- Electrical equipment
- Equipment and devices
- Headlights and lighting
- Electrical circuits
- General information
- User manual
- Maintenance
- Power unit
- Petrol engines
- Diesel engines
- Engine overhaul
- Cooling and lubrication system
- Fuel system (diesel)
- Fuel injection (petrol)
- Engine electrical equipment
- Transmission
- Clutch and cardan
- Automatic gearbox
- Chassis, running gear
- Front suspension
- Rear suspension
- Steering
- Brake system
- Body and interior
- Body elements
- Air conditioning and heater
- SRS security system
- Electrical equipment
- Equipment and devices
- Electrical circuits