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 or deformation. If severe damage, deformation or leakage is found, replace the battery.

    2. Check the electrolyte level in each cell.


      • If the electrolyte level 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 or more at 20°C (68°F)

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

    3. Check the voltage.


      1. Turn the ignition switch off and turn ON the headlights for 20 to 30 seconds. This will remove the surface charge from the battery.

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

        Standard Voltage
        Tester Connection Condition Specified Condition
        Positive (+) terminal - Negative (-) terminal 20°C (68°F) 12.3 V or higher

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

  2. REPLACE BATTERY (WITH ENGINE STOP AND START SYSTEM)


    1. Replace the battery.

      Note

      Use a genuine battery specifically specifications to a genuine battery. If an unsupported battery is used, Stop and Start system functions may be restricted to protect the battery.

      Also, battery performance may decrease and the engine may not be able to restart.

      Battery Type
      LN4 type or equivalent to a genuine battery

  3. INSPECT BATTERY TERMINAL, BATTERY STATE SENSOR ASSEMBLY AND FUSIBLE LINK AND FUSE


    1. Check whether the battery terminals and engine wire harness are loose or corroded.

    2. Check whether the battery state sensor assembly is deformed or cracked.

      Torque:
      Positive (+) Battery Terminal
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
      Negative (-) Battery Terminal (Battery State Sensor Assembly)
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
      Wire Harness
      7.6 N*m  { 77 kgf*cm, 67 in.*lbf }

    3. Measure the resistance of the fuses.

      Standard Resistance
      Below 1 Ω

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

  4. INSPECT FAN AND GENERATOR V BELT

    Click here

  5. INSPECT GENERATOR WIRING


    1. Visually check the generator wiring.


      1. Check that the wiring is in good condition.

  6. CHECK FOR ABNORMAL NOISE


    1. Check for abnormal noises from the generator assembly.


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

        If noise occurs, refer to Problem Symptoms Table.

        Click here

  7. INSPECT CHARGING CIRCUIT WITHOUT LOAD


    1. B0024FIC02
      *1 Battery
      *2 Generator Assembly
      *a Terminal B

      Connect a voltmeter and an ammeter to the charging circuit as follows.

      Tech Tips

      If a battery/generator assembly tester is available, connect the tester to the charging circuit in accordance with the manufacturer's instructions.


      1. Disconnect the wire from terminal B of the generator assembly and connect it to the negative (-) lead of the ammeter.

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

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

      4. Ground the voltmeter negative (-) lead.

    2. Check the charging circuit.


      1. Maintain the engine speed at 2000 rpm and check the readings on the ammeter and voltmeter.

        Standard Current
        10 A or higher
        Standard Voltage
        13.5 to 14.35 V

        If the result is not as specified, repair or replace the generator assembly.

  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 result is not as specified, repair or replace the generator assembly.

      Tech Tips

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

  9. INSPECT CHARGING SYSTEM


    1. Check the harness and connector.


      1. Disconnect the C60 ECM connector.

      2. Disconnect the C9 generator assembly connector.

      3. Disconnect the A63 battery state sensor assembly connector.

      4. Measure the resistance according to the value(s) in the table below.

        Standard Resistance
        Tester Connection Condition Specified Condition
        C60-7 (LIN) - C9-2 (LIN) Always Below 1 Ω
        C60-7 (LIN) or C9-2 (LIN) - Body ground

        Ignition switch off

        (while LIN communication is stopped)

        		 10 kΩ or higher
        C60-7 (LIN) - A63-2 (LIN1) Always Below 1 Ω
        C60-7 (LIN) or A63-2 (LIN1) - Body ground

        Ignition switch off

        (while LIN communication is stopped)

        		 10 kΩ or higher

        If the result is not as specified, repair or replace the harness or connector.