On-Vehicle Inspection

Check the electrolyte quantity of each cell. If under the lower level, replace the battery (or add distilled water if possible), and check the charging system.

Fig 1: Checking Battery Electrolyte Level

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the specific gravity of each cell.

Fig 2: Checking Battery Specific Gravity

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard specific gravity: 

1.25-1.29 at 20° C (68° F) 

If the specific gravity is less than specification, charge the battery.

1. After having driven the vehicle and in the case that 20 minutes have not passed after having stopped the engine, turn the ignition switch ON and turn on the electrical system (headlight, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge.
Fig 3: Checking Battery Voltage
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Turn the ignition switch OFF and turn off the electrical systems.
3. Measure the battery voltage between the negative (-) and positive (+) terminals of the battery.

   Standard voltage: 

   12.5 - 12.9 V at 20° C (68° F) 

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

Fig 4: Checking Battery Indicator

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check that the battery terminals are not loose or corroded.
2. Check the fusible link and fuses for continuity.

1. Visually check the drive belt for excessive wear, frayed cords etc.
   Fig 5: Inspecting Drive Belt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   If necessary, replace the drive belt.

   NOTE:

   • Cracks on the rib side of a drive belt are considered acceptable. If the drive belt has chunks missing from the ribs, it should be replaced.
   • The drive belt tension can be released by turning the belt tensioner counterclockwise. The pulley bolt for the belt tensioner has a left-hand thread.
2. Check the belt tensioner operation.
   • Check that the belt tensioner moves downward when the drive belt is pressed down at the points indicated in the illustration with approx. 98 N (10 kgf, 22.0 lbf) of force.
     Fig 6: Inspecting Drive Belt Tension

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • Check the alignment of the belt tensioner pulley to make sure the drive belt has not slipped off the pulley.

     If necessary, replace the belt tensioner.

   • Check that the arrow mark on the belt tensioner falls within area A of the scale.
   Fig 7: Checking Mark "A" Falls Within Area
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   If it is outside area A, replace the drive belt.

   NOTE:

   • When a new belt is installed, it should lie within area B. If not, the drive belt is not correct.
   • After installing a belt, check that it fits properly in the ribbed grooves.
     Fig 8: Displaying Correct Placement

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • Check by hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley.

1. Check that the wiring is in good condition.
2. Check that there is no abnormal noise from the generator while the engine is running.

1. Warm up the engine and then turn it off.
2. Switch off all accessories.
3. Turn the ignition switch ON, and check that the charge warning light is lit.
4. Start the engine, and check that the light goes off.

If the light does not go off as specified, troubleshoot the charge light circuit.

Fig 9: Inspecting Charging Circuit Without Load

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. If a tester is not available, connect a voltmeter and ammeter to the charging circuit as follows:
   • Disconnect the wire from terminal B of the generator, and connect it to the negative (-) tester probe of the ammeter.
   • Connect the positive (+) tester probe of the ammeter to terminal B of the generator.
   • Connect the positive (+) tester probe of the voltmeter to terminal B of the generator.
   • Ground the negative (-) tester probe of the voltmeter.
2. Check the charging circuit as follows:

   With the engine running from idling to 2,000 rpm, check the reading on the ammeter and voltmeter.

   Standard amperage: 10 A or less 

   Standard voltage: 13.2 - 14.8 V 

   If the value is not specified, check the generator.

1. With the engine running at 2,000 rpm, turn on the high beam headlights and place the heater blower switch at HI.
2. Check the reading on the ammeter.

   Standard amperage: 

   30 A or more 

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