On-Vehicle Inspection

1. Check the battery electrolyte level.
   1. Check the electrolyte quantity of each cell.

   If the electrolyte quantity is below the recommended amount, replace the battery.

2. Check the battery voltage.
   1. If it has been less than 20 minutes since you stopped driving the vehicle or since the engine was stopped, turn the ignition switch and electrical systems (headlight, blower motor, rear defogger etc.) to the ON position for 60 seconds. This will remove the surface charge on the battery.
   2. Turn the ignition switch and electrical systems OFF.
   3. Using a voltmeter, measure the battery voltage between the negative (-) and positive (+) terminals of the battery.

   Standard voltage: 12.5 to 12.9 V at 20°C (68°F) 

   Fig 1: Checking Battery Voltage

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   If the voltage is less than the specification, charge the battery.

3. Check the indicator as shown in the illustration.

HINT:

• Blue: OK
• White: Charging Necessary
• Red: Insufficient Water

Fig 2: Identifying Battery Indicators

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check the battery electrolyte level.
   1. Check the electrolyte quantity of each cell.

   If the electrolyte quantity is below the recommended amount, add distilled water.

2. Check the battery specific gravity.
   1. Check the specific gravity of each cell.

   Standard specific gravity: 1.25 to 1.29 at 20°C (68°F) 

   If the specific gravity is less than specification, charge the battery.

   Fig 3: Checking Battery Specific Gravity

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check the battery voltage.
   1. If it has been less than 20 minutes since you stopped driving the vehicle or since the engine was stopped, turn the ignition switch and electrical systems (headlight, blower motor, rear defogger etc.) to the ON position for 60 seconds. This will remove the surface charge on the battery.
   2. Turn the ignition switch and electrical systems OFF.
   3. Using a voltmeter, measure the battery voltage between the negative (-) and positive (+) terminals of the battery.

   Standard voltage: 12.5 to 12.9 V at 20°C (68°F) 

   Fig 4: Checking Battery Voltage

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   If the voltage is less than the specification, charge the battery.

4. Check the indicator as shown in the illustration.

HINT:

• Blue: OK
• White: Charging Necessary
• Red: Insufficient Water

Fig 5: Identifying Battery Charge Stater Indicators

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Visually check the battery terminals.
   1. Check that the battery terminals are not loosened or corroded.
2. Visually check the fusible link and fuses.

1. Check that there is continuity of the fusible links, high current fuses and regular fuses.

1. Visually check the belt for excessive wear, frayed cords, etc.
   • If any defects are found, replace the v-ribbed belt.
   • Cracks on the rib side of the belt are considered acceptable.
   Fig 6: Inspecting V-Ribbed Belt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   If the belt has chunks missing from the ribs, it should be replaced.

2. Check that the belt fits properly in the ribbed grooves. Confirm that the belt has not slipped out of the groove on the bottom of the pulley by hand.

Fig 7: Inspecting Belt Fitting Onto Ribbed Grooves

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Visually check the generator wiring.

1. Check that the wiring is in good condition.

1. Listen to abnormal noises from generator.

1. Check that no abnormal noise is heard from the generator while the engine is running.

1. Turn the ignition switch ON. Check that the charge warning light comes on.
2. Start the engine, then check that the light goes off.

If the light does not operate as specified, troubleshoot the charge warning light circuit

1. 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, then 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 terminal B of the generator.
   4. Ground the negative (-) lead of the voltmeter.
2. Check the charging circuit.
   1. Keep the engine speed at 2,000 rpm, then check the reading on the ammeter and voltmeter.

   Standard amperage: 10 A or less 

   Standard voltage: 13.2 to 14.8 V 

   Fig 8: Inspecting Charging Circuit Without Load

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. With the engine running at 2,000 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 amperage: 30 A or more 

• 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.