On-Vehicle Inspection

WARNING: This page is about a different car, the 2002 Toyota ECHO. However, it is still accessible from the selected car via links, so may be relevant.

Check Battery Electrolyte Level
Check the electrolyte quantity of each cell.

Fig 1: Checking Electrolyte Quantity Of Cell
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Maintenance-Free Battery:

If under the lower level, replace the battery (or add distilled water if possible) and check the charging system.

Except Maintenance-Free Battery:

If under the lower level, add distilled water.
Except Maintenance-Free Battery:
Check Battery Specific Gravity

Check the specific gravity of each cell.

Standard specific gravity:

1.25 - 1.29 at 20 °C (68 °F)

Fig 2: Checking Specified Gravity
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the specific gravity is less than specification, charge the battery.
Check Battery Voltage
1. After having driven the vehicle and in the case that 20 minutes have not passed after having stopped the engine, turn the ignition switch ON and turn on the electrical system (headlight, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge.
2. Turn the ignition switch OFF and turn off the electrical systems.
3. Measure the battery voltage between the negative (-) and positive (+) terminals of the battery.
  1. Standard voltage: 12.5 - 12.9 V at 20°C (68 °F)
Fig 3: Checking Battery Voltage
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

NOTE: Check the indicator as shown in illustration.
Check Battery Terminals, Fusible Link And Fuses
1. Check that the battery terminals are not loose or corroded.
2. Check the fusible link, H-fuses and fuses for continuity.
  
  Fig 4: Checking Battery Fusible Link & Fuses
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Inspect Drive Belt
1. Visually check the belt for excessive wear, frayed cords etc.
  If any defect has been found, replace the drive belt.
  
  Fig 5: Displaying Drive Belt Inspection
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced.
2. Using a belt tension gauge, measure the belt tension.
  Belt tension gauge:
  
  DENSO BTG-20 (95506-00020)
  
  Borroughs No. BT-33-73F
  1. Drive belt tension:
  2. New belt: 540 - 640 N (55 - 65 kgf)
  3. Used belt: 250 - 390 N (25 - 40 kgf)
  Fig 6: Measuring Belt Tension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the belt tension is not as specified, adjust it.
  NOTE:
  - "New belt" refers to a belt which has been used less than 5 minutes on a running engine.
  - "Used belt" refers to a belt which has been used on a running engine for 5 minutes or more.
  - After installing a belt, check that it fits properly in the ribbed grooves.
  - Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley.
  - After installing a new belt, run the engine for about 5 minutes and recheck the belt tension.
3. Adjust drive belt tension.
  1. Loosen the 2 mount bolts.
  2. Insert a bar between the entine RH mount bracket and the generator, and pull it forward to make the adjustment.
  3. Torque the 2 bolts.
    1. Torque:
    2. 14 mm head 18 N.m (185 kgf.Cm, 14 ft.lbf)
    3. 17 mm head 54 N.m (550 kgf.Cm, 40 ft.lbf)
  Fig 8: Adjusting Drive Belt Tension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Visually Check Generator Wiring And Listen For Abnormal Noises
1. Check that the wiring is in good condition.
2. Check that there is no abnormal noise from the generator while the engine is running.
Inspect Discharge Warning Light Circuit
1. Turn the ignition switch "ON". Check that the discharge warning light comes on.
2. Start the engine. Check that the light goes off.
If the light does not operate as specified, troubleshoot the discharge warning light circuit.
Inspect Charging Circuit Without Load
NOTE: If a battery/generator tester is available, connect the tester to the charging circuit as premanufacturer's instructions.
1. If a tester is not available, connect a voltmeter to the charging circuit as follows:
  - Disconnect to the wire from terminal B of the generator and connect it to the negative (-) lead of the ammeter.
  - Connect the positive (+) lead of the ammeter to terminal B of the generator.
  - Connect the positive (+) lead of the voltmeter to terminal B of the generator.
  - Ground the negative (-) lead of the voltmeter.
2. Check the charging circuit as follows:
With the engine running from idle to 2,000 rpm, check the reading on the ammeter and voltmeter.
1. Standard amperage: 10A or less
2. Standard voltage: 13.5 - 15.1 V
If the voltmeter reading is more than standard voltage, replace the voltage regulator.

If the voltmeter reading is less than the standard voltage, check the voltage regulator and generator as follows:
Inspect Charging Circuit With Load
1. With the engine running at 2,000 rpm, turn on the high beam headlights and place the heater blower switch at "H".
2. Check the reading on the ammeter.
  1. Standard amperage: 30 A or more

If the ammeter reading is less than standard amperage, repair the generator.

NOTE:

If the battery is fully charged, the indication will sometimes be less than standard amperage.

Fig 10: Inspecting Charging Circuit Without Load