On-Vehicle Inspection

CAUTION: 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.

CHECK BATTERY CONDITION
1. Check the battery for damage and deformation. If severe damage, deformation or leakage is found, replace the battery.
2. Check the electrolyte quantity of each cell.
  For batteries that are maintenance-free:
  - If the electrolyte quantity is below the recommended amount, replace the battery.
  For batteries that are not maintenance-free:
  - If the electrolyte quantity is below the recommended amount, add distilled water.
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 that the resistance of the fusible link, H-fuse and fuses is below 1 Ω.
  If the fusible link or fuses are not as specified, replace the past.
INSPECT DRIVE BELT
1. Check the belt for wear, cracks and other signs of damage.
  If any defect is found, replace the drive belt.
  
  HINT:
  
  Replace the drive belt if any of the following defects are found:
  - The belt has worn out until the wire can be seen.
  - The cracks reach the wire in more than one place.
  - The belt has chunks missing from the ribs.
    
    Fig 1: Identifying Drive Belt Cracks And Damage
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check that the belt fits properly in the ribbed grooves.
  HINT:
  
  Confirm that the belt has not slipped out of the groove on the bottom of the pulley by hand.
VISUALLY CHECK GENERATOR WIRING
1. Check that the wiring is in good condition.
CHECK FOR ABNORMAL NOISES FROM GENERATOR
1. Check that there is no abnormal noise from the generator while the engine is running.
  
  Fig 2: Identifying Correct And Incorrect Belt Ribbed Grooves
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CHARGE WARNING LIGHT CIRCUIT
1. Turn the ignition switch on (IG). Check that the charge warning light comes on.
2. Start the engine and check that the light goes off. If the light does not operate as specified, troubleshoot the charge warning light circuit.
INSPECT CHARGING CIRCUIT WITHOUT LOAD
HINT:

If a battery / generator tester is available, connect the tester to the charging circuit according to the manufacturer's instructions.
1. If a tester is not available, connect a voltmeter and ammeter 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 ammeter's positive (+) lead to terminal B of the generator.
  3. Connect the voltmeter's positive (+) lead to terminal B of the generator.
  4. Ground the voltmeter's negative (-) lead.
    
    Fig 3: Connecting Voltmeter And Ammeter To Charging Circuit
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the charging circuit.
  1. Keep the engine speed at 2000 rpm. Check the reading on the ammeter and voltmeter.
    Standard amperage:
    
    10 A or less
    
    Standard voltage:
    
    13.2 to 14.8 V
    
    If the result is not as specified, replace the generator.
INSPECT CHARGING CIRCUIT WITH LOAD
1. With the engine running at 2000 rpm, turn on the high beam headlights and turn the heater blower switch to the HI position.
2. 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 ammeter reading will sometimes be less than the standard amperage.