Canada - Charging System - Alternator, Low Battery/No Start
BulletinTSB2044
Issue Date
November 02, 2004
Title
CHARGING IMPROVEMENT AT IDLE
Component
ENGINE ELECTRICAL
Models
'02 - '03 ES 300
Some customers may complain of a low battery or no start condition after running the engine at idle or low RPM for extended periods of time. A new alternator has been developed to improve charging performance at idle.
NOTE:
This new alternator will not prevent dead batteries or no start conditions on vehicles that are stored for long periods of time, vehicles with an electrical concern causing a high parasitic load on the battery, or on vehicles that are driven very infrequently.
PARTS INFORMATION:
APPLICABLE VEHICLES:
- 2002 - 2003 model year ES 300 vehicles.
WARRANTY INFORMATION:
REPAIR PROCEDURE:
NOTE:
Confirm that the vehicle does not have an unusual parasitic load on the battery with key off and doors locked. Parasitic load should be less than 40 mA.
1. Disconnect negative terminal from the vehicle battery.
2. Disconnect the alternator wire and connector.
3. Remove the drive belt and original alternator.
A. Pull out retainer from alternator's female connector to disengage the secondary lock.
B. Release the locking lug from terminal and pull the terminal out from backside of connector.
C. Remove connector cover from vehicle wire harness.
4. Install new connector onto alternator harness.
A. Remove locking ring from face of new connector.
B. Install terminals into back of connector as shown.
C. Install black rubber plug included with alternator kit into location shown.
This step is critical.
NOTE:
Do not return this vehicle to the customer unless the unused terminal location is sealed off from possible water intrusion.
5. Install new alternator.
A. Install the alternator, adjusting lock bolt, plate washer and pivot bolt.
B. Install wiring harness clamp bracket with bolt contained in kit.
C. Connect the alternator wire and install the nut.
D. Connect the alternator connector.
E. Connect the wire harness to the clamp.
6. Install drive belt.
A. Install the drive belt and adjust belt tension.
Drive Belt Tension: 175 +/- 5 lbf
B. Tighten adjusting lock bolt and the pivot bolt.
NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.