Toyota Camry

 XV30 (2002–2006) Service Manual

Starting & charging
Charging system (1MZ−FE/3MZ−FE)

PRECAUTION

CAUTION:

• 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 while the engine is running.

• Check that the charging cable is tightened on terminal B of the generator and the fuse box.

ON−VEHICLE INSPECTION

1. CHECK BATTERY CONDITION

1. Check the battery for damage and deformation. If severe damage, deformation or leakage is found, replace the battery.

2. Check the electrolyte quantity of each cell.

For batteries that are maintenance−free: If the electrolyte quantity is below the recommended amount, replace the battery.

For batteries that are not maintenance−free: If the electrolyte quantity is below the recommended amount, add distilled water.

CAUTION: If the battery has gone flat or if the engine cannot be started easily, the engine may not be recovered properly. Recharge the battery and perform inspections again before returning the vehicle to the customer.

2. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES

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

If the terminals are corroded, clean the terminals.

b. Check the fusible link, high−current fuses and fuses for continuity.

3. INSPECT DRIVE BELT

a. Check the belt for wear, cracks and other signs of damage.

If any defect is found, replace the drive belt.

HINT:

Replace the drive belt if the following defects are found:

• If the belt has worn out until the wire can be seen.

• If the cracks reach the wire more than one place.

• If the belt has chunks missing from the ribs.

b. Check that the belt fits properly in the ribbed grooves.

HINT: With your hand, confirm that the belt has not slipped out of the groove on the bottom of the pulley.

4. VISUALLY CHECK GENERATOR WIRING

a. Check that the wiring is in good condition.

5. LISTEN FOR ABNORMAL NOISES FROM GENERATOR

a. Check that there is no abnormal noise from the generator while the engine is running.

6. INSPECT CHARGE WARNING LAMP CIRCUIT

1. Turn the ignition switch ON. Check that the charge warning lamp turns on.

2. Start the engine and check that the lamp turns off.

If the lamp does not operate as specified, troubleshoot the charge warning lamp circuit.

7. INSPECT CHARGING CIRCUIT WITHOUT LOAD

HINT: If a battery/generator tester is available, connect the tester to the charging circuit according to the manufacturer’s instructions.

a. If a tester is not available, connect a voltmeter to the charging circuit as follows.

1. Disconnect the wire from terminal B of the generator and connect it to the negative (−) lead of the ammeter.

2. Connect the positive (+) lead of the ammeter to terminal B of the generator.

3. Connect the positive (+) lead of the voltmeter to terminal B of the generator.

4. Ground the negative (−) lead of the voltmeter.

b. Check the charging circuit.

1. Keep the engine speed at 2,000 rpm, check the reading on the ammeter and voltmeter.

Standard amperage: 10 A or less Standard voltage: 13.2 to 14.8 V

Inspect charging circuit without load

8. INSPECT CHARGING CIRCUIT WITH LOAD

1. With the engine running at 2,000 rpm, turn on the high−beam headlamps and turn the heater blower switch to the HI position.

2. Check the reading on the ammeter.

   Standard amperage: 30 A or more

HINT:

• If the ammeter reading is less than the standard amperage, repair the generator.

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

Starting system (2AZ−FE)(From July, 2003)

Charging system (2AZ−FE)(From July, 2003)

Generator assy (2AZ−FE)(From July, 2003)

Starting system (1MZ−FE/3MZ−FE)

Ignition or starter switch assy (1MZ−FE/3MZ−FE)

Starter assy (1MZ−FE/3MZ−FE)

Ignition or starter switch assy (2AZ−FE)(From July, 2003)

Starter assy (1MZ−FE/3MZ−FE)

Charging system (1MZ−FE/3MZ−FE)

Starter assy (2AZ−FE)(From July, 2003)

Generator assy (1MZ−FE/3MZ−FE)

Starter assy (2AZ−FE)(From July, 2003)