CHARGING SYSTEM ON-VEHICLE INSPECTION

CAUTION / NOTICE / HINT

Note

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.

PROCEDURE


  1. CHECK BATTERY CONDITION


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

    2. Check the electrolyte quantity of each cell.


      1. For maintenance-free batteries:


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

        • If the electrolyte quantity is above the lower line, check the battery voltage when cranking the engine. If the voltage is below 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 quantity is below the lower line, add distilled water to each cell. Then, recharge the battery and check the electrolyte specific gravity.

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

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

    3. Turn the engine switch off and turn on the headlights for 20 to 30 seconds. This removes the surface charge from the battery.

    4. Measure the battery voltage between the negative (-) and positive (+) terminals of the battery.

      Standard Voltage
      12.5 to 12.9 V at 20°C (68°F)

      If the voltage is less than the specification, recharge the battery.

  2. INSPECT BATTERY TERMINAL AND FUSE


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

      Torque:
      Positive (+) battery terminal
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
      Negative (-) battery terminal
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

      If the terminals are corrected, clean the terminals.

    2. Measure the resistance of all related fuses.

      Standard Resistance
      Below 1 Ω

      Tech Tips

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

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

  3. INSPECT V-RIBBED BELT

    Click here

  4. INSPECT GENERATOR WIRING


    1. Visually check the generator wiring.


      1. Check that the wiring is in good condition.

  5. CHECK FOR ABNORMAL NOISES


    1. Listen for abnormal noises from the generator.


      1. Check that no abnormal noises are heard from the generator while the engine is running.

  6. INSPECT CHARGE WARNING LIGHT CIRCUIT


    1. Turn the engine 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. INSPECT CHARGING CIRCUIT WITHOUT LOAD


    1. A01WW5YE04
      Text in Illustration
      *1 Battery
      *2 Generator Assembly
      *a Terminal B

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


      1. Disconnect the wire from terminal B of the generator, then connect it to the negative (-) lead of an ammeter.

      2. Connect the positive (+) lead of the ammeter to terminal B of the generator.

      3. Connect the positive (+) lead of a voltmeter to terminal B of the generator assembly.

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

    2. Check the charging circuit.


      1. Keep the engine speed at 2000 rpm and check the reading on the ammeter and voltmeter.

        Standard current
        10 A or higher
        Standard voltage
        13.2 to 14.0 V

        If the voltmeter reading is higher than the standard voltage, replace the voltage regulator.

        Tech Tips

        If the battery is not fully charged, the ammeter reading will sometimes be higher than the standard amperage.

  8. INSPECT CHARGING CIRCUIT WITH LOAD


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

    2. Check the reading on the ammeter.

      Standard current
      30 A or higher

      If the ammeter reading is below the standard amperage, repair the generator.

      Tech Tips

      If the battery is fully charged, the indication will sometimes be below the standard amperage. If this is the case, add more electrical load (operate the wipers, rear window defogger, etc.) and check the reading on the ammeter again.