LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2002 >> Sienna LE >> Repair and Diagnosis >> Electrical >> Charging Systems >> Charging System >> On-Vehicle Inspection

On-Vehicle Inspection

  1. CHECK BATTERY ELECTROLYTE LEVEL 
    Fig 1: Checking Battery Electrolyte Level
    G01050018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Check the electrolyte quantity of each cell.

    1. Maintenance-Free Battery:
    2. If under the MAX (LOWER) level, replace the battery (or add distilled water if possible). Check the charging system.
    1. Except Maintenance-Free Battery:
    2. If under the MAX (LOWER) level, add distilled water.
  2. Except Maintenance-Free Battery: 

    CHECK BATTERY SPECIFIC GRAVITY 

    Check the specific gravity of each cell.

    Fig 2: Checking Battery Specific Gravity
    G01050019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Standard specific gravity: 1.25 - 1.29 at 20°C (68°F) 

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

  3. Maintenance-Free Battery: 

    CHECK BATTERY VOLTAGE 

    Fig 3: Checking Battery Voltage
    G01050020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

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

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

      NOTE: Check the indicator as shown in the illustration.
      Fig 4: Identifying Battery Condition Indicators
      G01050021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES 
    1. Check that the battery terminals are not loose or corroded.

      If the terminals are corroded, clean the terminals.

    2. Check the fusible link, H-fuses, M-fuse and fuses for continuity.
  5. INSPECT DRIVE BELTS 
      Fig 5: Inspecting Drive Belts
      G01050022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Visually check the drive belt for excessive wear, frayed cords etc.

      If any defect has been found, replace the drive belt.

      NOTE: Cracks on the rib side of a drive belt are considered acceptable. If the drive belt has chunks missing from the ribs, it should be replaced.
    2. Using a belt tension gauge, measure the belt tension.
      Fig 6: Measuring Belt Tension
      G01050023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Belt tension gauge:
      2. DENSO BTG-20 (95506-00020)
      3. Borrougs No. BT-33-73F
      1. Drive belt tension: 
        1. New belt: 175 +/- 5 lbf 
        2. Used belt: 115 +/- 20 lbf 

      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.
        Fig 7: Ensuring Drive Belt Is Properly Installed
        G01050024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • 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.
  6. VISUALLY CHECK GENERATOR WIRING AND LISTEN FOR ABNORMAL NOISES 
      Fig 8: Visually Inspecting Generator Condition
      G01050025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
  7. CHECK DISCHARGE WARNING LIGHT CIRCUIT 
    1. Warm up the engine and then turn it off.
    2. Turn off all accessories.
    3. Turn the ignition switch "ON". Check that the discharge warning light is lit.
    4. Start the engine. Check that the light goes off.

      If the light does not go off as specified, troubleshoot the discharge light circuit.

  8. INSPECT CHARGING CIRCUIT WITHOUT LOAD 
    NOTE: If a battery/generator tester is available, connect the tester to the charging circuit as per manufacturer's instructions.
      Fig 9: Inspecting Generator Charging Circuit
      G01050026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. If a tester is not available, connect a voltmeter and ammeter to the charging circuit as follows
      • Disconnect the wire from terminal B of the generator, and connect it to the negative (-) tester probe of the ammeter.
      • Connect the positive (+) tester probe of the ammeter to terminal B of the generator.
      • Connect the positive (+) tester probe of the voltmeter to terminal B of the generator.
      • Ground the negative (-) tester probe of the voltmeter.
      :
    2. Check the charging circuit as follows:

      With the engine running from idling to 2,000 rpm, check the reading on the ammeter and voltmeter.

      1. Standard amperage: 10 A or less 
      2. Standard voltage: 13.2 - 14.8 V 

      If the value is not specified, check the generator (See INSPECTION ).

  9. 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 "HI".
    2. Check the reading on the ammeter.
      1. Standard amperage: 30 A or more 

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

      NOTE: If the battery is fully charged, the indication will sometimes be less than standard amperage.
scientia non olet · About LEMON Manuals