CHARGING SYSTEM ON-VEHICLE INSPECTION


  1. CHECK AUXILIARY BATTERY


    1. Check that the auxiliary battery cables are connected to the correct terminals.

      If they are not, connect them properly.

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

  2. CHECK AUXILIARY BATTERY VOLTAGE


    1. Turn the power switch off and turn on the high beam headlights for 30 seconds. This will remove the surface charge from the auxiliary battery.

    2. Measure the auxiliary battery voltage according to the value(s) in the table below.

      Result
      Tester Connection Condition Specified Condition Result
      Positive (+) auxiliary battery terminal - Negative (-) auxiliary battery terminal 20°C (68°F), Power switch off 12.5 V or higher Auxiliary battery is OK
      11.0 to 12.5 V Recharge auxiliary battery
      Below 11.0 V Replace auxiliary battery

  3. RECHARGE AUXILIARY BATTERY


    1. Recharge the auxiliary battery.

      Tech Tips


      • Recharge the auxiliary battery according to the charger's instructions.

      • Apply the appropriate charging current according to the type of auxiliary battery as shown in the table below.

      Auxiliary Battery Type Charging Current

      S65D26R

      S55D23R

      		 4 to 5 A

    2. Turn the power switch off and turn on the high beam headlights for 30 seconds. This will remove the surface charge from the auxiliary battery.

    3. Measure the auxiliary battery voltage according to the value(s) in the table below.

      Result
      Tester Connection Condition Specified Condition Result
      Positive (+) auxiliary battery terminal - Negative (-) auxiliary battery terminal 20°C (68°F), Power switch off 12.5 V or higher Auxiliary battery is OK
      11.0 to 12.5 V Recharge auxiliary battery
      Below 11.5 V Replace auxiliary battery

  4. CHECK AUXILIARY BATTERY TERMINAL, FUSIBLE LINK AND FUSE


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

      If a terminal is loose or corroded, tighten or clean the terminal.

      Torque:
      Positive (+) Auxiliary Battery Terminal
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
      Negative (-) Auxiliary Battery Terminal
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    2. Measure the resistance of each fusible link and fuse for the auxiliary battery charging system.

      Standard Resistance
      Below 1 Ω

      If the result is not as specified, replace the fusible link or fuse as necessary.

  5. CHECK AMD TERMINAL

    CAUTION:

    Be sure to wear insulated gloves.


    1. Remove the service plug grip.

    2. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    3. Check that the AMD terminal is connected securely, and there is no contact problem.

      If there are any arc marks, replace the affected parts.

    4. Check that the nuts for the AMD terminal is tightened to the specified torque.

      If there are no arc marks and the AMD terminal connection is faulty, connect the AMD terminal securely.

    5. Install the service plug grip.

  6. CHECK DC/DC CONVERTER FUNCTION


    1. A01I29UE20
      Text in Illustration
      *a Probe Direction
      *b Current Flowing into Auxiliary Battery

      Connect the AC/DC 400 A probe to the positive (+) auxiliary battery cable.

    2. Turn the power switch on (READY) and leave the vehicle as it is until the electric current flowing into the auxiliary battery becomes 10 A or less.

    3. Turn the power switch on (READY), the headlight position switch and blower motor switch to the HI position, and the rear window defogger on.

    4. A01I4ARE01
      Text in Illustration
      *a Probe Direction
      *b Current Flowing from Auxiliary Battery

      Measure the current and voltage according to the value(s) in the table below.

      Result
      Item Tester Connection Condition Specified Condition
      Current flowing from auxiliary battery Positive (+) auxiliary battery cable

      Power switch on (READY)

      (The headlight position switch and blower motor switch are in the HI position, and the rear window defogger is turned on.)

      0 A or less

      (No current from auxiliary battery)
      Auxiliary battery voltage Positive (+) auxiliary battery terminal - Negative (-) auxiliary battery terminal 13 to 15 V

      Tech Tips


      • If the values are not as specified, replace the DC/DC converter assembly.

      • Some vehicle models have an inverter with converter assembly with a built-in DC/DC converter. In this case, replace the inverter with converter assembly.