Charging System: Testing and Inspection
ON-VEHICLE INSPECTION1. CHECK BATTERY CONDITION
NOTE: If the battery is weak or if the engine is difficult to start, perform the following procedures.
a. Check the battery for damage and deformation. If severe damage, deformation or leakage is found, replace the battery.
b. Check the electrolyte quantity of each cell.
1. For maintenance-free batteries:
- If the electrolyte quantity is below the lower line, replace the battery.
- If the electrolyte quantity 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.
HINT: Before checking the battery voltage, turn off all the electrical systems (headlights, blower motor, rear defogger, etc.).
2. For non-maintenance-free batteries:
- If the electrolyte quantity is below the lower line, add distilled water to each cell. Then, recharge the battery and check the electrolyte's specific gravity.
Standard specific gravity: 1.25 to 1.29 at 20 degrees C (68 degrees F)
- If the electrolyte quantity 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.
HINT: Before checking the battery voltage, turn off all the electrical systems (headlights, blower motor, rear defogger, etc.).
c. Reference:
Check the indicator as shown in the illustration.
HINT:
- Blue: OK
- White: Charging necessary
- Red: Insufficient water
2. CHECK BATTERY TERMINALS, H-FUSES AND FUSES
a. Check that the battery terminals are not loose or corroded.
b. Check the resistance of the H-fuses and fuses.
Standard resistance: Below 1 Ohm
If the H-fuse or fuse is not as specified, replace as necessary.
3. INSPECT DRIVE BELT
a. Visually check the belt for excessive wear, frayed cords, etc.
HINT:
- If any defect has been found, replace the drive belt.
- Cracks on the rib side of a belt are considered acceptable.
If the belt has chunks missing from the ribs, it should be replaced.
b. Check that the belt fits properly in the ribbed grooves.
HINT: Check with your hand to confirm that the belt has not slipped out of the grooves on the bottom of the pulley.
4. VISUALLY CHECK GENERATOR WIRING
a. Check that the wiring is in good condition.
5. LISTEN FOR ABNORMAL NOISES FROM GENERATOR
a. Check that there is no abnormal noise from the generator while the engine is running.
6. CHECK CHARGE WARNING LIGHT CIRCUIT
a. Turn the ignition switch ON.Check that the charge warning light comes on.
b. Start the engine. Check that the light goes off.
HINT: If the light does not operate as specified, troubleshoot the charge warning light circuit.
7. CHECK CHARGING CIRCUIT WITHOUT LOAD
a. If a battery / generator tester is available, connect the tester to the charging circuit according to the manufacturer's instructions.
b. If a tester is not available, connect a voltmeter to the charging circuit as follows:
1. Disconnect the wire from terminal B of the generator and connect it to the negative (-) lead of the ammeter.
2. Connect the positive (+) lead of the ammeter to terminal B of the generator.
3. Connect the positive (+) lead of the voltmeter to the positive (+) terminal of the battery.
4. Ground the negative (-) lead of the voltmeter.
c. Check the charging circuit.
1. With the engine running from idle to 2,000 rpm, check the reading on the ammeter and voltmeter.
Standard amperage: 10 A or less
Standard voltage:13.2 to 14.8 V
HINT:
- If the voltmeter reading is more than the standard voltage, replace the voltage regulator.
- If the voltmeter reading is less than the standard voltage, check the voltage regulator and generator using the "Check charging circuit with load" procedures below.
8. CHECK CHARGING CIRCUIT WITH LOAD
a. With the engine running at 2,000 rpm, turn on the high beam headlights and set the heater blower switch to "HI".
b. Check the reading on the ammeter.
Standard amperage: 30 A or more
HINT:
- If the ammeter reading is less than the standard amperage, repair the generator.
- If the battery is fully charged, the indication will sometimes be less than the standard amperage.