CHARGING SYSTEM ON-VEHICLE INSPECTION

CAUTION:

If the battery is weak or if the engine is difficult to start, recharge the battery and perform inspections again before returning the vehicle to the customer.


  1. CHECK BATTERY CONDITION


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

    2. A01CGZ7

      Check the volume of electrolyte in each cell (for maintenance-free batteries).


      1. If the electrolyte volume is below the lower line, replace the battery.

    3. A01CIQ8

      Check the volume of electrolyte in each cell (for non-maintenance-free batteries).


      1. If the electrolyte volume is below the lower line, add distilled water to each cell. Then, recharge the battery and check the electrolyte specific gravity.

        Standard electrolyte specific gravity
        1.25 to 1.29 at 20°C (68°F)

        If the result is not as specified, replace the battery.

    4. A01CHM9

      Measure the battery voltage.


      1. If it has been less than 20 minutes since you stopped driving the vehicle or since the engine was stopped, turn the ignition switch to ON and turn on the electrical systems (headlights, blower motor, rear defogger etc.) for 20 seconds. This will remove the surface charge on the batteries.

      2. Turn the ignition switch off.

      3. Turn the electrical systems off.

      4. Using a voltmeter, measure the battery voltage between the positive (+) and negative (-) terminals as shown in the illustration.

        Standard voltage
        24.0 to 25.0 V at 20°C (68°F)

        If the result is not as specified, recharge or replace the battery.

  2. CHECK FUSES


    1. Measure the resistance of each fuse for the charging system.

      Tech Tips

      The fuses shown in the System Diagram are related to the charging system.

      Standard resistance
      Below 1 Ω

      If any of the results is not as specified, replace the fuse(s) as necessary.

  3. CHECK DRIVE BELT


    1. A01CH6Z

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

      If any defects are found, replace the drive belts as a set.

    2. A01CHF1E04
      Text in Illustration
      *1 Clearance
      *2 CORRECT
      *3 INCORRECT

      Check that each belt does not touch the bottom of the pulley groove.

      If the result is not as specified, replace the drive belts as a set.

  4. VISUALLY CHECK GENERATOR WIRING


    1. Check that the generator wiring is in good condition.

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

  5. LISTEN FOR ABNORMAL NOISES FROM GENERATOR


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

      If there is abnormal noise, repair or replace the generator.

  6. CHECK CHARGE WARNING LIGHT CIRCUIT


    1. Turn the ignition switch to ON. Check that the charge warning light comes on.

    2. Start the engine and check that the light goes off.

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

  7. CHECK CHARGING CIRCUIT WITHOUT LOAD


    1. A01CILDE03
      Text in Illustration
      *1 Ammeter
      *2 Terminal B
      *3 Generator
      *4 Voltmeter
      *5 Battery

      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 the positive (+) terminal of the battery.

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

    2. Check the charging circuit.


      1. While keeping the engine speed at 2000 rpm, check the readings on the ammeter and voltmeter.

        Standard amperage
        10 A or less
        Standard voltage
        25.0 to 26.0 V

        If the results are not as specified, repair or replace the generator assembly.

        Tech Tips

        If the battery is not fully charged, the ammeter reading may be more than the standard amperage.

  8. CHECK CHARGING CIRCUIT WITH LOAD


    1. Keep the engine speed at 2000 rpm, turn on the high beam headlights, and turn the heater blower switch to the "HI" position.

    2. Check the reading on the ammeter.

      Standard amperage
      30 A or more

      If the ammeter reading is less than the standard amperage, repair or replace the generator assembly.

      Tech Tips

      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.