Charging System - Delco Remy Alternators

91toyota03

REF.: ELECTRICAL


NO.: EL91-002


DATE: MAY 10, 1991


MODEL: SV


DELCO REMY ALTERNATORS ON 1991 CAMRYS


1991 4-cylinder TMC produced Camrys (SV) are equipped with either a Delco Remy or Nippondenso alternator. These alternators are not interchangeable. When replacing an alternator, the original production brand alternator must be used.

Please note that the lengths of the alternator belts are different between the two brands and are therefore interchangeable.

All 1991 TMM produced Camrys will be equipped with Nippondenso alternators.





ILLUSTRATION:


PART NUMBER INFORMATION:


Manufacturer Alternator Alternator belt
P/N Belt Type P/N

with A/C 90916-02327
Delco Remy 27060-74200
without A/C 90916-02329

with A/C 99365-51110
Nippondenso 27060-74020
without A/C 90916-02295

* These alternators are not interchangeable.





CAUTION LABEL:

A caution label has been installed on vehicles with Delco Remy Alternators as shown in illustration:


SERVICE PROCEDURE FOR DELCO REMY ALTERNATOR:

The Delco Remy Alternator is not a serviceable unit. If the following diagnostic procedure indicates a problem in the alternator, do not disassemble. Replace the alternator as a complete assembly.

NOTE: The Delco Remy Alternator cannot be full fielded.

1. Test the battery to make sure it is fully charged. This is critical since a battery with a low state of charge will affect your test results.

2. Measure the belt tension using the following specifications:

New Used

with A/C 175 +/- 5 130 +/- 10

without A/C 125 +/-25 95 +/- 20

GROUND TERMINAL # 2:

3. Check the charge warning lamp function:

A) The charge warning lamp should be "ON" with the key "ON" and the engine "OFF". This checks the following functions:


^ Bulb and related circuits.

^ Regulator lamp driver function and connector adapter IC function.

^ Terminal # 2 connections (see Wiring Diagram of Delco Alternator).

If the charge warning lamp is "OFF", disconnect the harness at the alternator, ground harness terminal # 2 with a fused jumper lead and check the charge warning lamp.





If the lamp is now "ON", check the grounding screw for the lamp driver circuit (see Wiring Diagram of Delco Remy Alternator) for continuity. If the grounding screw is secure, replace the alternator.


If the lamp remains "OFF", check the charge warning lamp circuit including the Ignition, Charge and Engine fuses.

Disconnect the three pin connector:

3. Check the charge warning lamp function (Cont'd):

B) The charge warning lamp should be "OFF" with the engine running at 2500 rpm which indicates normal operation.

If the charge warning lamp stays "ON", disconnect the three pin connector between the engine room wire harness and the alternator assembly.


^ If the charge warning lamp stays "ON" with the connector disconnected, a short to ground in terminal # 2 is indicated.

^ If the charge warning light goes "OFF", replace the alternator.

4. Check the voltage regulator output. Normal regulated voltage is between 13.5 and 15.1 volts depending on temperature.

5. Check the battery voltage. The harness voltage at terminal # 1 should be the same voltage across the battery. It not there is a voltage drop in the "S" circuit.

1991 TOYOTA/DELCO CHARGING SYSTEM:

WIRING DIAGRAM OF DELCO REMY ALTERNATOR:

The following is a wiring diagram of the Delco Remy Alternator and associated parts.


TERMINAL IDENTIFICATION AND PURPOSE:

Terminal # 1 Monitors voltage at the battery to control alternator output. If this line open circuits, the
(Sense) alternator will switch to an internal sensing line. The charge warning lamp will not illuminate
when this condition occurs.

Terminal # 2 Illuminates charge warning indicator lamp. If this line open circuits, this system will not shut
(Lamp Driver) down but the charge warning lamp will not illuminate (lamp will not illuminate at initial key
"ON"). The lamp driver circuit uses the connector mounting screws as a ground source.
Make sure that there is a good ground.


Terminal # 3 Generates a "high" signal causing the field circuit to go to 30% duty cycle when the key is
(Enable) "ON" It this open circuits, the system will shut down but charge warning lamp will not
illuminate when this condition occurs.


FEATURES OF DELCO REMY ALTERNATOR:

Delco Remy Alternators have the following features:


1. Charge warning indicator lamp will illuminate when the alternator is overcharging or undercharging.


2. The alternator is rated 74 amperes.


3. The alternator uses a small pulley which provides good current output characteristics at low engine speeds and a delta wound stator which provides good current output characteristic at high engine speeds.


4. Dual cooling fans are used. The internal rotor mounted cooling fan improves heat dissipation from alternator.


5. The alternator uses sealed drive frame/end frame bearings.


6. THE ALTERNATOR CANNOT BE FULL FIELDED.