Toyota Camry 2007-2009 Service Manual - 2GR-FE_Charging

2GR-FE CHARGING – CHARGING SYSTEM

CHARGING SYSTEM

PRECAUTION

1. Check that the battery cables are connected to the
correct terminals.

2. Disconnect the battery cables when the battery is
given a quick charge.

3. Do not perform tests with a high voltage insulation
resistance tester.

4. Never disconnect the battery while the engine is
running.

5. Check that the charging cable nut is tightened on
terminal B of the generator and the engine room R/B.

CH–1

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CH–2

PARTS LOCATION

GENERATOR

2GR-FE CHARGING – CHARGING SYSTEM

COMBINATION METER

-CHARGE WARNING LIGHT

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ENGINE ROOM R/B

-ALT-S FUSE

-ALT FUSE

INSTRUMENT PANEL J/B

-GAUGE NO. 1 FUSE

-GAUGE NO. 2 FUSE

A135521E01

From Battery

From IG1 Relay

2GR-FE CHARGING – CHARGING SYSTEM

SYSTEM DIAGRAM

ALT-S

GAUGE No. 1

Combination Meter

CH–3

From IG2 Relay

ALT

FL MAIN

GAUGE No. 2

Generator

1

B

C19

13
F1

IG+

IG+

Charge

IC
Regulator

CHG-

IG

23

F1

4

L

C18

2

C18

1

S

C18

Battery

A138773E01

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CH–4

2GR-FE CHARGING – CHARGING SYSTEM

Result

Symptom Suspected area See page

Charge Warning Light Comes ON while Driving

Noise Occurs from Generator while Engine is Running

PROBLEM SYMPTOMS TABLE

1. Clutch pulley

2. Generator assembly

1. V-ribbed belt

3. Generator assembly

CH-7

CH-82. Clutch pulley

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Green

Dark

2GR-FE CHARGING – CHARGING SYSTEM

ON-VEHICLE INSPECTION

1. CHECK BATTERY ELECTROLYTE LEVEL

(a) Check the electrolyte level.

(1) If the electrolyte level is low , replace the battery

(or add distilled water) and check the charging
system.

2. CHECK BATTERY SPECIFIC GRAVITY

(a) Check the color of the indicator.

Clear or Light Yellow

3. CHECK BATTERY VOLTAGE

A115815E01

Result

Indicator color Condition

Green Good

Dark Charging necessary

Clear or light yellow Replacement necessary

(a) If it has not been 20 minutes since you drove the

vehicle or since the engine was stopped, turn the
ignition switch on (IG) and turn on the electrical
systems (headlight, blower motor, rear defogger,
etc.) for 60 seconds. This will remove the surface
charge from the battery.

(b) Turn off the ignition switch and the electrical

systems.

CH–5

A081052E01

B000543

(c) Measure the battery voltage between the negative (-

) and positive (+) terminals of the battery.

Standard voltage:

12.5 to 12.9 V at 20°C (68°F)

HINT:
If the voltage is below the specification, charge the
battery.

4. CHECK BATTERY TERMINAL

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

corroded.
If the terminals are corroded, clean them.

5. CHECK FUSES

(a) Measure the resistance of the ALT fuse, ALT -S fuse,

GAUGE No. 1 fuse and GAUGE No. 2 fuse.

Standard resistance:

Below 1 Ω

If the result is not as specified, replace the fuses as
necessary.

6. CHECK V-RIBBED BELT

(a) Check the belt for wear, cracks or other signs of

damage.
If any of the following defects is found, replace the
V-ribbed belt.

• The belt is worn out, cracked, or the cords are
exposed.

• The cracks reach the cords in more than one
place.

• The belt has chunks missing from the ribs.

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CH–6

CORRECT INCORRECT

2GR-FE CHARGING – CHARGING SYSTEM

(b) Check that the belt fits properly in the ribbed

grooves.
HINT:
Check with your hand to confirm that the belt has
not slipped out of the groove on the bottom of the
pulley.
If it has slipped out, replace the V -ribbed belt. Insta ll
a new V-ribbed belt correctly.

CH

Disconnect
Wire from
Terminal B

Battery

Battery

Ammeter

A





Generator

Voltmeter

V





B000540E03

A110265E04

7. VISUALLY CHECK GENERATOR WIRING

(a) Check that the generator wiring is in good condition.

If the condition is not good, repair or replace the
generator wire.

8. LISTEN FOR ABNORMAL NOISES FROM
GENERATOR

(a) Check that there is no abnormal noise from the

generator while the engine is running.
If there is abnormal noise, replace the pulley or
generator.

9. CHECK CHARGE WARNING LIGHT CIRCUIT

(a) Turn the ignition switch on (IG). Check that the

charge warning light comes on.

(b) Start the engine and check that the light goes off.

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

10. CHECK CHARGING CIRCUIT WITHOUT LOAD

(a) According to the following procedure, connect an

ammeter and voltmeter as shown in the illustration.
(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

positive (+) terminal of the battery.

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

(b) Check the charging circuit.

(1) While keeping the engine speed at 2,000 rpm,

check the readings on the ammeter and
voltmeter.

Standard amperage:

10 A or less

Standard voltage:

13.2 to 14.8 V

If the results are not as specified, replace the
generator assembly.
HINT:

• If the battery is not fully charged, the
ammeter reading may be more than the
standard amperage. In this case, increase
electrical load by operating devices such as
the wiper motor and rear window defogger.
Then, recheck the reading on the ammeter.

2GR-FE CHARGING – CHARGING SYSTEM

11. CHECK CHARGING CIRCUIT WITH LOAD

(a) Keep the engine speed at 2,000 rpm, turn on the

high beam headlights, and turn the heater blower
switch to the "HI" position.

(b) Check the reading on the ammeter.

Standard amperage:

30 A or more

If the ammeter reading is less than the standard
amperage, replace the generator assembly.
HINT:

• If the battery is fully charged, the ammeter
reading may be less than the standard
amperage. In this case, increase electrical load
by operating devices such as the wiper motor
and rear window defogger. Then, recheck the
reading on the ammeter.

CH–7

CH

CH–8

2GR-FE CHARGING – CHARGING SYSTEM

Charge Warning Light Comes ON while Driving

INSPECTION PROCEDURE

CHECK LOCK FUNCTION OF CLUTCH PULLEY

1

(a) Check the lock function with the pulley installed in the

vehicle.
(1) Visually check that the rotor in the generator

operates with the engine started.

(b) Check the lock function with the pulley removed from the

vehicle.
(1) Remove the generator pulley cap. Using SST, hold

the generator rotor.

(2) Turn the clutch pulley clockwise and check that the

outer ring locks.

OK:

Free Lock

SST 09820-63020

The outer ring locks.

A128078E01

OK

CHECK LOCK OF CLUTCH PULLEY

2

OK

REPLACE GENERATOR ASSEMBLY

NG

(a) Start the engine and visually check looseness of the

clutch pulley.

OK:

NG

REPLACE CLUTCH PULLEY

The clutch pulley is not loose.

TIGHTEN CLUTCH PULLEY TO THE
SPECIFIED TORQUE

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