CHARGING SYSTEM ON-VEHICLE INSPECTION

CAUTION / NOTICE / HINT

The necessary procedures(adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the generator assembly removal/installation are shown below.

*: When performing learning using the GTS.
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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.

      
      

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

      • 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)

   3. Check the voltage.

      
      

      1. Turn the engine 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 more

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

2. 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)

      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

      Wire Harness

      10.2 N*m  { 104 kgf*cm, 8 ft.*lbf }

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

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

      Torque:

      Positive (+) Battery Terminal

      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

      Negative (-) Battery Terminal

      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

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

      Tech Tips

      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.

3. INSPECT V-RIBBED BELT

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4. INSPECT GENERATOR WIRING

   
   

   1. Visually check the generator wiring.

      
      

      1. Check that the wiring is in good condition.

5. 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

6. INSPECT CHARGING CIRCUIT WITHOUT LOAD

   
   
   1. 

      *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
         10.275 to 16.25 V

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

7. 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 current. In this case, add more electrical load (operate the wipers, rear window defogger, etc.) and check the reading on the ammeter again.

8. INSPECT CHARGING SYSTEM

   
   

   1. Check the harness and connector.

      
      

      1. Disconnect the D65 ECM connector.

      2. Disconnect the D6 generator assembly connector.

      3. Disconnect the P5 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 D65-135 (LIN) - D6-2 (LIN) Always Below 1 Ω D65-135 (LIN) or D6-2 (LIN) - Body ground Engine switch off (while LIN communication is stopped) 10 kΩ or higher D65-135 (LIN) - P5-2 (LIN) Always Below 1 Ω D65-135 (LIN) or P5-2 (LIN) - Body ground Engine 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.