Charging System: Testing and Inspection

2UZ-FE CHARGING: CHARGING SYSTEM: ON-VEHICLE INSPECTION

ON-VEHICLE INSPECTION

1. CHECK BATTERY ELECTROLYTE LEVEL
(a) Check the electrolyte quantity of each cell.
(1) If under the lower level, replace the battery (or add distilled water if possible) and check the charging system.
2. CHECK BATTERY VOLTAGE





(a) Turn the ignition switch off and turn on the headlight for 20 to 30 seconds. This will remove the surface charge from the battery.
(b) Measure the battery voltage between the negative (-) and positive (+) terminals of the battery.
Standard voltage:
12.5 to 12.9 V at 20°C (68°F)

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





(c) Check the indicator as shown in the illustration.

HINT:
- Blue: OK
- White: Charging Necessary
- Red: Insufficient Water

3. CHECK BATTERY TERMINAL
(a) Check that the battery terminals are not loose or corroded.
4. CHECK FUSIBLE LINK AND FUSES
(a) Check the fusible link, H-fuses and fuses for continuity.
5. INSPECT FAN AND GENERATOR V BELT





(a) Check the belt for wear, cracks or other signs of damage.
If any of the following defects is found, replace the fan and generator V belt.
- The belt is cracked.
- The belt is worn out to the extent that the cords are exposed.
- The belt has chunks missing from the ribs.





(b) 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 groove on the bottom to the pulley. If it has slipped out, replace the fan and generator V belt. Install a new fan and generator V belt correctly.

6. VISUALLY CHECK GENERATOR WIRING
(a) Check that the wiring is in good condition.
7. LISTEN FOR ABNORMAL NOISES FROM GENERATOR
(a) Check that there is no abnormal noise from the generator while the engine is running.
8. INSPECT CHARGE WARNING LIGHT CIRCUIT
(a) Turn the ignition switch to ON. Check that the charge warning light comes on.
(b) Start the engine. Check that the light goes off.

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

9. INSPECT CHARGING CIRCUIT WITHOUT LOAD
(a) If a battery/generator tester is available, connect the tester to the charging circuit as per manufacturer's instructions.





(b) If a tester is not available, connect a voltmeter 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 positive (+) lead of the ammeter to terminal B of the generator.
(3) Connect the positive (+) lead of the voltmeter to terminal B of the generator.
(4) Ground the negative (-) lead of the voltmeter.
(c) Check the charging circuit.
(1) With the engine running from idle to 2,000 rpm, check the reading on the ammeter and voltmeter.
Standard amperage:
10 A or less
Standard voltage:
13.2 to 14.0 V

HINT:
- If the voltmeter reading is more than standard voltage, replace the voltage regulator.
- If the voltmeter reading is less than the standard voltage, check the voltage regulator and generator.

10. INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn on the high beam headlights and place the heater blower switch at "H".
(b) Check the reading on the ammeter.
Standard amperage:
30 A or more

HINT:
- If the ammeter reading is less than standard amperage, repair the generator.
- If the battery is fully charged, the indication will sometimes be less than standard amperage.