CHARGING SYSTEM ON-VEHICLE INSPECTION

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.


  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 volume of electrolyte quantity in each cell.


      1. For batteries that are maintenance-free:


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

        • If the electrolyte volume 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. A0116ZD

        For batteries that are not maintenance-free:


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

        • If the electrolyte volume 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 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) 12.5 to 12.9 V

        Tech Tips

        If the voltage is not as specified, charge the battery.

  2. CHECK BATTERY TERMINAL


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

      If the terminals are corroded, clean them.

  3. CHECK FUSES


    1. Measure the resistance of the fuses.

      Standard resistance
      Below 1 Ω

      If the result are not as specified, replace fuses as necessary.

  4. CHECK V-RIBBED BELT


    1. A0116ZWE02

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

      If any of the following defects is found, replace the V-ribbed belt.

      Tech Tips


      • The belt is cracked.

      • The belt is worn out to the extent that the cords are exposed.

      • The belt has chunks missing from the ribs.

    2. A0119WKE03

      Check that the belt fits properly in the ribbed grooves.

      Tech Tips

      Check with your hand to confirm that the belt has not slipped out of the grooves on the bottom of the pulley. If it has slipped out, replace the V-ribbed belt. Install a new V-ribbed belt correctly.

  5. VISUALLY CHECK GENERATOR WIRING


    1. Check that the wiring is in good condition.

      If damaged, repair or replace the generator wire.

  6. 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, replace the pulley or generator.

  7. 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 turns off.

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

  8. CHECK CHARGING CIRCUIT WITHOUT LOAD


    1. A0117BBE03
      Text in Illustration
      *1 Ammeter
      *2 Terminal B
      *3 Battery
      *4 Voltmeter
      *5 Generator

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

      Tech Tips

      If a battery/generator 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 and connect it to the negative (-) lead of the ammeter.

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

      3. Connect the voltmeter positive (+) lead to positive (+) terminal of the battery.

      4. Ground the voltmeter negative (-) lead.

    2. Check the charging circuit.


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

        Standard current
        10 A or less
        Standard voltage
        13.2 to 14.8 V

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

        Tech Tips

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

  9. CHECK 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 more

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

      Tech Tips

      If the battery is fully charged, the indication will sometimes be less than the standard current. If this is the case, add more electrical load (operate the wiper motor and the rear window defogger, etc.) and then check the charging circuit again.