On-Vehicle Inspection

CHECK BATTERY CONDITION
NOTE: If the battery is weak or if the engine is difficult to start, perform the following procedures.
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.
  1. For maintenance-free batteries:
    - If the electrolyte quantity is below the lower line, replace the battery.
    - If the electrolyte quantity is above the lower line, check the battery voltage when cranking the engine. If the voltage is less than 9.6 V, recharge or replace the battery.
      
      Fig 1: Checking Battery Condition
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      
      HINT:
      
      Before checking the battery voltage, turn off all the electrical systems (headlights, blower motor, rear defogger, etc.).
  2. For non-maintenance-free batteries:
    If the electrolyte quantity is below the lower line, add distilled water to each cell. Then, recharge the battery and check the electrolyte's specific gravity.
    
    Standard specific gravity:
    
    1.25 to 1.29 at 20°C (68°F)
    
    If the electrolyte quantity is below the lower line, check the battery voltage when cranking the engine. If the voltage is less than 9.6 V, recharge or replace the battery.
    
    HINT:
    
    Before checking the battery voltage, turn off all the electrical systems (headlights, blower motor, rear defogger, etc.).
    
    Fig 2: Checking Electrolyte Quantity Of Each Cell
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK BATTERY TERMINAL AND FUSE
1. Check that the battery terminals are not loose or corroded.
  If the terminals are corroded, clean the terminals.
2. Measure the resistance of the H-fuse and fuses.
  Standard resistance:
  
  Below 1 Ω
  
  If the results are not as specified, replace fuses as necessary.
CHECK FAN AND GENERATOR V BELT
1. Check the belt for wear, cracks and other signs of damage.
  HINT:
  
  Replace the V-ribbed belt if the following defects are found:
  - The belt is worn out and wire is exposed.
  - The cracks reach the wire in more than one place.
  - The belt has chunks missing from the ribs.
    
    Fig 3: Identifying Damaged V-Ribbed Belt
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check that the belt fits properly in the ribbed grooves.
  HINT:
  
  Check with your hand to confirm that the belt has not slipped out of the grooves on the bottom of the pulley.
  
  Fig 4: Identifying Belt Correct And Incorrect Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
VISUALLY CHECK GENERATOR WIRING
1. Check that the wiring is in good condition.
LISTEN FOR ABNORMAL NOISE FROM GENERATOR
1. Check that the generator does not emit any abnormal noise while the engine is running.
CHECK CHARGE WARNING LIGHT CIRCUIT
1. Turn the ignition switch ON. Check that the charge warning light turns ON.
2. Start the engine. Check that the light turns OFF. If the light does not operate as specified, troubleshoot the charge warning light circuit.
CHECK CHARGING CIRCUIT WITHOUT LOAD
1. Connect a voltmeter and ammeter to the charging circuit as follows.
  HINT:
  
  If a battery / generator tester is available, connect the tester to the charging circuit according to the manufacturer's instructions.
  1. Disconnect the wire from terminal B of the generator and connect it to the ammeter's negative (-) lead.
  2. Connect the ammeter's positive (+) lead to terminal B of the generator.
  3. Connect the voltmeter's positive (+) lead to the positive (+) terminal of the battery.
  4. Ground the voltmeter's negative(-) lead.
    
    Fig 5: Connecting Voltmeter And Ammeter To Charging Circuit
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the charging circuit.
  1. Keep the engine speed at 2,000 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.
    
    HINT:
    
    If the battery is not fully charged, the ammeter reading will sometimes be more than the standard amperage.
CHECK CHARGING CIRCUIT WITH LOAD
1. With the engine running at 2,000 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
  
  If the ammeter reading is less than the standard amperage, replace the generator.
  
  HINT:
  
  If the battery is fully charged, the ammeter reading will sometimes be less than the standard amperage.