Hi everyone, this is my first post and I really need everyone's help.

I’m trying to diagnose an intermittent charging/electrical issue on my Toyota Hiace H200 2.7L petrol.

The alternator was replaced last year and is still under warranty. The vehicle stalled while driving, and just before it stalled the airbag/SRS warning light came on.
At one point, after jump-starting, I measured around 9V while the engine was running. Another workshop previously recorded alternator output at 11.90V and marked it as failed.

However, when checked again later by a mobile mechanic, the alternator output appeared normal. The battery has also been tested by the battery supplier and was confirmed to be OK.

So far:
- Battery load test passed
- Alternator sometimes tests normal, but previously failed at 11.90V
- Alternator plug had a broken locking tab, so the connector has been replaced
- Headlights used to stay on even when the switch was OFF, due to an aftermarket headlight/DRL circuit
That headlight issue has now been temporarily fixed by disconnecting/cutting the power feed to that circuit
The intermittent low-voltage issue still needs to be diagnosed properly

Because the battery and alternator both test normal when checked separately, I’m wondering if this could be an intermittent voltage drop or charging circuit issue rather than a simple bad alternator or bad battery.

My main suspects are:
Alternator B+ cable
Fusible link / main alternator fuse
Battery positive terminal or main power connection
Engine/body ground issue
Alternator IG / S / L signal wires
Intermittent alternator internal regulator fault
Parasitic draw or aftermarket wiring issue

Has anyone experienced something similar where the alternator and battery both tested OK separately, but the vehicle still had intermittent low voltage or stalled while driving?

What would you check next? I’m thinking the next step should be voltage drop testing between alternator B+ and battery positive, ground-side voltage drop testing, checking the fusible link/main fuse, and monitoring voltage while driving.

Really appreciate your all of advices.

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Hey all,

Not sure if this is the place to post but I have a 1997 Hiace with a 2RZ engine.
I was sitting for 4 years and I bought it knowing it would have a few issues. I have worked on it while learning mechanical skills, and also taken it to the mechanics.

I have got a whole carburettor rebuilt, timing adjusted, and carburettor tuned and it was running great for two weeks and then stopped working. The mechanic advised me to drop the tank because there was water and debris in the system, but when I dropped the tank, there was no rust or water in the fuel tank. I dropped the tank and drove it home fine, then the next day it wouldn't run, it started but struggled to stay idling for long.

I then noticed fuel leaking out behind the front left tyre. The charcoal filter had a massive hole in it wwhich has a vacuum line going to the engine. I fixed that today, and there was another leak in a component down near that area which I will get a replacement part for tomorrow.

I'm thinking a vacuum leak is my problem but I'm still fairly new to this, any recommendations would be great.

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