CHARGING SYSTEM ON-VEHICLE INSPECTION

PROCEDURE

  1. CHECK BATTERY CONDITION

    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 the battery for damage and deformation. If severe damage, deformation or a leak is found, replace the battery.

    2. Check the volume of electrolyte 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 below 9.6 V, recharge or replace the battery.

        Tip:

        Before checking the battery voltage, turn off all the electrical systems (headlights, blower motor, rear defogger, etc.).

      2. 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 voltage is below 9.6 V, recharge or replace the battery.

          Tip:

          Before checking the battery voltage, turn off all of 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
        Tip:

        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. INSPECT FUSES

    1. Measure the resistance of the fuses.

      Standard resistance

      Below 1 Ω

      If the results are not as specified, replace the fusesas necessary.

  4. INSPECT V-RIBBED BELT

    Click here

  5. INSPECT GENERATOR WIRING

    1. Check that the wiring is in good condition.

  6. CHECK FOR ABNORMAL NOISES FROM GENERATOR

    1. Check that the generator does not emit any abnormal noise while the engine is running.

  7. INSPECT CHARGE WARNING LIGHT CIRCUIT

    1. for Segment Type:

      1. Turn the ignition 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.

    2. for TFT Type:

      1. Check that nothing is displayed on the multi-information display.

  8. INSPECT CHARGING CIRCUIT WITHOUT LOAD

    1. A111820C04

      *1

      Generator

      *2

      Terminal B

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

      Tip:

      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 reading 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.

        Tip:

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

  9. 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 current, repair the generator.

      Tip:

      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 wipers, rear window defogger, etc.) and check the reading on the ammeter again.