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:
  
  Fig 1: Checking Belt For Wear, Cracks & Other Signs Of Damage
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - 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.
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.
  
  Fig 2: Checking Belt Fits Properly In Ribbed Grooves
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
INSPECT CHARGE WARNING LAMP CIRCUIT
1. Turn the ignition switch on (IG). Check that the charge warning lamp comes on.
2. Start the engine and check that the lamp goes off.
  If the lamp does not operate as specified, troubleshoot the charge warning lamp 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.
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.
INSPECT 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
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.

MATRIX FOR EACH PROBLEM SYMPTOM

HINT:

Perform troubleshooting to determine if the problem occurs in the generator assy or the generator w/clutch pulley.

CONFIRM PROBLEM SYMPTOM

Confirm the problem symptom and perform inspection by following the corresponding chart.

Standard:

PROBLEM SYMPTOM

Problem in charging system (battery is dead and charging lamp comes on)	A
Belt noise and excessive slip	B
Noise from generator	C

B : GO TO STEP 3
C : GO TO STEP 7
A : PROCEED TO NEXT STEP

CHECK LOCK OF GENERATOR w/CLUTCH PULLEY
1. Check the function with the pulley installed in the vehicle.
  1. Visually check that the rotor in the generator operates with the engine started.
2. Check the function with the pulley removed from the vehicle.
  1. Remove the generator pulley cap. Using SST, fix the alternator rotor.
    SST 09820-63020
    
    HINT:
    
    Be sure to replace the generator pulley cap with a new one because it cannot be reused.
  2. Turn the generator w/clutch pulley clockwise and check that it does not operate.
1. NG REPLACE GENERATOR w/CLUTCH PULLEY
2. OK REPAIR OR REPLACE GENERATOR ASSY
CHECK V BELT FOR WEAR
1. Check the V belt for wear.
1. NG REPLACE FAN & GENERATOR V BELT
2. OK PROCEED TO NEXT STEP
CHECK GENERATOR w/CLUTCH PULLEY FOR WEAR
1. Check the generator w/clutch pulley groove for wear or other defects.
1. NG REPLACE GENERATOR w/CLUTCH PULLEY
2. OK PROCEED TO NEXT STEP
CHECK OPERATION OF ONE-WAY CLUTCH
1. Check that the generator w/clutch pulley (outer ring) turns counterclockwise.
1. NG REPLACE GENERATOR w/CLUTCH PULLEY
2. OK PROCEED TO NEXT STEP
CHECK LOOSENESS OF GENERATOR w/CLUTCH PULLEY
1. Start the engine and check looseness of the generator w/clutch pulley.
1. NG TIGHTEN GENERATOR w/CLUTCH PULLEY TO THE SPECIFIED TORQUE (110 N.m (1,125 kgf.cm, 81 ft.lbf))
2. OK CHECK OTHER PULLEYS
CHECK LOCK OF GENERATOR w/CLUTCH PULLEY
1. Remove the generator pulley cap. Using SST, fix the generator rotor.
  SST 09820-63020
  
  HINT:
  
  Be sure to replace the generator pulley cap with a new one because it cannot be reused.
  1. Turn the generator w/clutch pulley counterclockwise and check that it locks.
1. NG REPLACE GENERATOR w/CLUTCH PULLEY
2. OK PROCEED TO NEXT STEP
CHECK FOR NOISE WHILE GENERATOR w/CLUTCH PULLEY IS OPERATING
1. Perform the driving test and check if noise occurs when decelerating.
1. NG REPLACE GENERATOR w/CLUTCH PULLEY
2. OK REPAIR OR REPLACE GENERATOR ASSY