CHARGING SYSTEM ON-VEHICLE INSPECTION

PROCEDURE


  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 12.6 to 12.8 V Auxiliary battery is OK
      12.2 to 12.4 V Recharge auxiliary battery
      11.8 to 12.0 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 shown in the table below.

      Auxiliary Battery Type Charging Current
      S46B24L Below 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 12.6 to 12.8 V Auxiliary battery is OK
      12.2 to 12.4 V Recharge auxiliary battery
      11.8 to 12.0 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.

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

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

    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


    1. Remove the service plug grip.

      Click here

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

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

    3. Check that the nut for the AMD terminal is tightened to the specified torque.


      1. B004FR8C02
        *a Inverter with Converter Assembly Side
        *b Inverter Bus-bar Plate Sub-assembly Side
        *c No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly Side

        for LHD:

        Torque:
        Inverter with converter assembly side
        18 N*m  { 184 kgf*cm, 13 ft.*lbf }
        Inverter bus-bar plate sub-assembly side
        10.5 N*m  { 107 kgf*cm, 8 ft.*lbf }
        No. 1 engine room relay block and No. 1 junction block assembly side
        10.5 N*m  { 107 kgf*cm, 8 ft.*lbf }

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

      2. B004GQGC02
        *a Inverter with Converter Assembly Side
        *b No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly Side

        for RHD:

        Torque:
        Inverter with converter assembly side
        18.0 N*m  { 184 kgf*cm, 13 ft.*lbf }
        No. 1 engine room relay block and No. 1 junction block assembly side
        10.5 N*m  { 107 kgf*cm, 8 ft.*lbf }

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

    4. Install the service plug grip.

      Click here

  6. CHECK DC/DC CONVERTER FUNCTION


    1. B004EBVC13
      *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 is until the electric current flowing to the auxiliary battery becomes 10 A or less.

    3. Turn on the high beam headlights, and turn the blower motor switch to the HI position and the rear window defogger on.

    4. B004ER6C01
      *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 high beam headlights are on, the blower motor switch is 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

      If the result is not as specified, replace the inverter with converter assembly.