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

    2. Check the electrolyte level in each cell.

      1. For maintenance-free batteries:

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

        • If the electrolyte level 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.

          Tip:

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

      2. For non-maintenance-free batteries:

        • 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 to 1.29 at 20°C (68°F)

        • If the electrolyte level is above the lower line, check the battery voltage while cranking the engine. If the battery voltage is less than 9.6 V, recharge or replace the battery.

          Tip:

          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)

        12.6 to 12.8 V

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

  2. CHECK BATTERY TERMINAL

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

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

      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

  3. CHECK FUSES

    1. Measure the resistance of each fuse for the charging system.

      Tip:

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

      Standard Resistance

      Below 1 Ω

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

  4. INSPECT V-RIBBED BELT

  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. A125200C21

      *1

      Generator Assembly

      *2

      Battery

      *a

      Terminal B

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

      Tip:

      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 the positive (+) terminal of the battery.

      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

        14 A or higher

        Standard Voltage

        12 to 15.3 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

      40 A or higher

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

      Tip:

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