Battery: Testing and Inspection
2ZR-FE CHARGING: CHARGING SYSTEM: 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.
1. CHECK BATTERY CONDITION
(a) Check the battery for damage and deformation. If severe damage, deformation or leakage is found, replace the battery.
(b) Check the volume of electrolyte in each cell.
(1) For batteries that are maintenance-free:
* If the electrolyte volume is below the lower line, replace the battery.
* If the electrolyte volume 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.
HINT
Before checking the battery voltage, turn off all electrical systems (headlights, blower motor, etc.).
(2) For batteries that are not maintenance-free:
* If the electrolyte volume is below the lower line, add distilled water to each cell. Then, recharge the battery and check the electrolyte specific gravity.
Standard specific gravity:
1.25 to 1.29 at 20 °C ( 68°F)
If the electrolyte volume 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.
HINT
Before checking the battery voltage, turn off all electrical systems (headlights, blower motor, rear defogger, etc.).
2. CHECK BATTERY VOLTAGE
(a) If it has been less than 20 minutes since you stopped driving the vehicle, turn the ignition switch and electrical systems (headlight, blower motor, rear defogger, etc.) for 60 seconds to remove the surface charge on the battery.
(b) Turn off the ignition switch and electrical systems.
(c) Measure the battery voltage between the negative (-) and positive (+) terminals of the battery.
Standard voltage:
11 to 14 V at 20°C (68°F)
If the voltage is less than the specified range, charge the battery.
3. CHECK BATTERY TERMINAL AND FUSE
(a) Check that the battery terminals are not loose or corroded.
If the terminals are corroded, clean the terminals.
(b) Measure the resistance of the H-fuse and remaining fuses.
Standard resistance:
Below 1 Ohms
If the results are not as specified, replace the fuses as necessary.
4. CHECK V-RIBBED BELT
(a) Check the belt for wear, cracks and other signs of damage.
If any defects are found, replace the V-ribbed belt.
HINT
Replace the drive belt if any of the following defects are found:
* The belt is worn out and the wire is exposed.
* The cracks reach the the wire in more than one place.
* The belt has pieces missing from the ribs.
(b) Check that the belt fits properly into the ribbed grooves.
HINT
Confirm by hand that the belt has not slipped out of the grooves on the bottom of the pulley.
5. VISUALLY CHECK GENERATOR WIRING
(a) Check that the wiring is in good condition.
6. LISTEN FOR ABNORMAL NOISES FROM GENERATOR
(a) Check that the generator does not emit any abnormal noise while the engine is running.
7. CHECK CHARGE WARNING LIGHT CIRCUIT
(a) Turn the ignition switch on (IG). Check that the charge warning light turns on.
(b) Start the engine and check that the light turns off. If the light does not operate as specified, troubleshoot the charge warning light circuit.
8. CHECK 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 according to 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 positive (+) ammeter lead to terminal B of the generator.
(3) Connect the positive (+) voltmeter lead to positive (+) terminal of the battery.
(4) Ground the negative (-) voltmeter 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:
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 current.
9. CHECK CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2000 rpm, turn on the high beam headlights 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, replace the generator.
HINT
If the battery is fully charged, the ammeter reading will sometimes be less than the standard current. In this case, operate the wiper motor and the window defogger to increase the load and then check the charging circuit again.