ON-VEHICLE INSPECTION

PROCEDURE

1. CHECK BATTERY CONDITION

NOTICE:

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.

(a) Check the battery for damage and deformation. If severe damage, deformation or leak is found, replace the battery.

(b) Check the voltage.

(1) Turn the ignition switch off and turn on the headlights for 20 to 30 seconds. This will remove the surface charge from the battery.

(2) Measure the battery voltage according to the value(s) in the table below.

Standard Voltage:

HINT:

If the voltage is not as specified, charge the battery.

2. CHECK BATTERY TERMINAL

(a) Check that the battery terminals are not loose or corroded.

If the terminals are corroded, clean them.

Torque:

Positive (+) Battery Terminal :

5.4 N·m {55 kgf·cm, 48 in·lbf}

Negative (-) Battery Terminal :

5.4 N·m {55 kgf·cm, 48 in·lbf}

3. CHECK FUSES

(a) Measure the resistance of the fuses.

Standard resistance:

Below 1 Ω

4. CHECK V-RIBBED BELT

5. INSPECT GENERATOR WIRING

(a) Check that the wiring is in good condition.

6. LISTEN FOR ABNORMAL NOISE FROM GENERATOR

(a) Check that the generator does not emit any abnormal noise while the engine is running.

7. INSPECT CHARGE WARNING LIGHT CIRCUIT

(a) Turn the ignition switch to ON. Check that the charge warning light comes on.

(b) Start the engine and check that the light goes off.

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

8. INSPECT CHARGING CIRCUIT WITHOUT LOAD

(a) Connect a voltmeter and an ammeter to the charging circuit as follows. HINT: If a battery / generator tester is available, connect the tester to the charging circuit in accordance with the manufacturer's instructions. (1) Disconnect the wire from terminal B of the generator and connect it to the negative (-) lead of the ammeter. (2) Connect the ammeter positive (+) lead to terminal B of the generator. (3) Connect the voltmeter positive (+) lead to positive (+) terminal of the battery. (4) Ground the voltmeter negative (-) lead.

(b) Check the charging circuit.

(1) Keep the engine speed at 2000 rpm and check the reading on the ammeter and voltmeter.

Standard current:

Below 10 A

Standard voltage:

13.2 to 14.8 V

Text in Illustration

If the result is not as specified, replace the generator.

HINT:

If the battery is not fully charged, the ammeter reading will sometimes be more than the standard current.

9. INSPECT CHARGING CIRCUIT WITH LOAD

(a) With the engine running at 2000 rpm, turn the high beam headlights on and turn the heater blower switch to the "HI" position.

(b) Check the reading on the ammeter.

Standard current:

30 A or more

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

HINT:

If the battery is fully charged, the indication will sometimes be less than the standard current. If this is the case, add more electrical load (operate the wipers, rear window defogger, etc.) and check the reading on the ammeter again.