CHARGING SYSTEM (w/o DPF) ON-VEHICLE INSPECTION


  1. CHECK BATTERY CONDITION

    CAUTION:

    If the battery is weak or if the engine is difficult to start, perform the following procedures.


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

    2. Check the electrolyte level of each cell.


      1. For maintenance-free batteries:


        • If the electrolyte level is below the lower line, replace the battery.


        • If the electrolyte level is above the lower line, check the battery voltage when cranking the engine.


        • If the voltage is less than 9.6 V, recharge or replace the battery.

        Tech Tips

        Before checking the battery voltage, turn off all the electrical systems (headlights, blower motor, rear defogger, etc.).

      2. For non-maintenance-free batteries:


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

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

        If the electrolyte level is above the lower line, check the battery voltage when cranking the engine. If the voltage is less than 9.6 V, recharge or replace the battery.

        Tech Tips

        Before checking the battery voltage, turn off all electrical systems (headlights, blower motor, rear defogger, etc.).

  2. CHECK BATTERY TERMINAL AND FUSE


    1. Check that the battery terminals are not loose or corroded.

      If the terminals are corroded, clean the terminals.

    2. Measure the resistance of the ALT fuse and ALT-S (for Single Battery Type) fuse.

      Standard resistance
      Below 1 Ω

      If the results are not as specified, replace the fuse.

  3. CHECK V-RIBBED BELT


    1. A01KFSHE17
      Text in Illustration
      *a INCORRECT

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

      If any of the following defects are found, replace the drive belt.


      • The belt is worn and wire is exposed.


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


      • The belt has chunks missing from the ribs.

    2. A01KHV9E15
      Text in Illustration
      *a CORRECT
      *b INCORRECT

      Check that the belt fits properly in the ribbed grooves.

      Tech Tips

      Confirm by hand that the belt has not slipped out of the grooves on the bottom of the pulley.

  4. VISUALLY CHECK GENERATOR WIRING


    1. Check that the wiring is in good condition.

  5. LISTEN FOR ABNORMAL NOISE FROM GENERATOR


    1. Check that the generator does not emit any abnormal noise while the engine is running.

  6. CHECK CHARGE WARNING LIGHT CIRCUIT


    1. Turn the ignition switch to the ON position. 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. A01KI1IE03
      Text in Illustration
      *1 Battery
      *2 Terminal B
      *3 Generator
      *a Disconnect wire from terminal B
      *b Single battery type
      *c Double battery type

      Connect a voltmeter and ammeter to the charging circuit as follows:

      Tech Tips

      If a battery/generator tester is available, connect the tester to the charging circuit according to the manufacturer instructions.


      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 (for Single Battery Type).

      4. Connect the positive (+) lead of the voltmeter to the terminal B of the generator.

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

    2. Check the charging circuit.


      1. Keep the engine speed at 2,000 rpm. Check the reading on the ammeter and voltmeter.

        Standard current
        10 A or less
        Standard voltage
        13.2 to 14.8 V for Single Battery Type
        12.1 to 15.4 V for Two Battery Type

        If the results are not as specified, replace the generator.

        Tech Tips

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

  8. CHECK CHARGING CIRCUIT WITH LOAD


    1. With the engine running at 2,000 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 current
      30 A or more

      If the ammeter reading is less than the standard current, replace the generator.

      Tech Tips


      • If the battery is fully charged, the ammeter reading may be less than the standard current.

      • In this case, increase electrical load by operating such as the wiper motor. Then, recheck the reading on the ammeter.

  9. MATRIX FOR EACH PROBLEM SYMPTOM


    1. Confirm problem symptom.


      1. Confirm the problem symptom and perform inspection by following the corresponding chart.

        Result:
        Result Proceed to
        Problem in charging system (battery is dead and charging light comes on) Go to step (c)
        Belt noise and excessive slip Go to step (g)
        Noise from generator Go to next step

    2. Check lock of the generator with clutch pulley.


      1. Check the function with the pulley installed in the vehicle:


        1. Visually check that the rotor in the generator operates with the engine started.

      2. Check the function with the pulley removed from the vehicle:


        1. Remove the generator pulley cap. Using SST, fix the generator rotor.

        2. Turn the generator with clutch pulley clockwise and check that it does not operate.

        SST
        09820-63020
        Result:
        Result Proceed to
        NG Replace generator with clutch pulley
        OK Repair or replace generator

    3. Check the V belt for wear.


      1. Check the V belt for wear.

        Result:
        Result Proceed to
        NG Replace fan and generator V belt
        OK Go to next step

    4. Check the generator with clutch pulley for wear.


      1. Check the generator with clutch pulley groove for wear or other defects.

        Result:
        Result Proceed to
        NG Replace generator with clutch pulley
        OK Go to next step

    5. Check operation of the one-way clutch.


      1. Check that the generator with clutch pulley (outer ring) turns counterclockwise.

        Result:
        Result Proceed to
        NG Replace generator with clutch pulley
        OK Go to next step

    6. Check looseness of the generator with clutch pulley.


      1. Start the engine and check looseness of the generator with clutch pulley.

        Result:
        Result Proceed to
        NG

        Tighten generator with clutch pulley to the specified torque Click here

        OK Check other pulleys

    7. Check lock of the generator with clutch pulley.


      1. Remove the generator pulley cap. Using SST, secure the generator rotor.

        SST
        09820-63020

      2. Turn the generator with clutch pulley counterclockwise and check that it locks.

        Result:
        Result Proceed to
        NG Replace generator with clutch pulley
        OK Go to next step

    8. Check for noise while generator with clutch pulley is operating.


      1. Perform a driving test and check if noise occurs when decelerating.

        Result:
        Result Proceed to
        NG Replace generator with clutch pulley
        OK Repair or replace generator