On-Vehicle Inspection

Check the electrolyte quantity of each cell.

Maintenance-free Battery:

If the electrolyte level is under the LOWER LEVEL, replace the battery (or add distilled water if possible). and check the charging system.

Except Maintenance-free Battery:

If under the LOWER LEVEL, add distilled water.

Fig 1: Identifying Battery

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

CHECK BATTERY SPECIFIC GRAVITY 

Check the specific gravity of each cell.

Standard specific gravity: 

1.25 to 1.29 at 20°C (68°F) 

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

Fig 2: Checking Specific Gravity Of Each Cell

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

CHECK BATTERY VOLTAGE 

1. Drive the vehicle and then turn off the engine.
2. Remove the surface charge.
   1. Within 20 minutes, turn the ignition switch ON.
   2. Turn on electrical systems (headlamp dimmer switch, heater blower switch, rear defogger, etc.) for 60 seconds.
3. Turn the ignition switch OFF and turn off the electrical systems.
4. 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) 

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

Fig 3: Measuring Battery Voltage

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Check the indicator as shown in the illustration.

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

Fig 4: View Of Indicators

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Manual belt tension adjustment is not necessary. The belt tensioner automatically adjusts belt tension.

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 the following defects are found:

   • If the belt has worn out until the wire can be seen.
   • If the cracks reach the wire in more than one place.
   • If the belt has chunks missing from the ribs.
   Fig 5: Identifying Belt Wear, Cracks And Other Signs

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 a force of approximately. 98 N (10 kgf, 22.0 lbf).
   • 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 is within area A in the illustration.

   If the arrow mark is not within area A, replace the drive belt.

   HINT:

   • When a new belt is installed, the arrow mark should be within area B. If not, the drive belt is installed incorrectly.
     Fig 6: Checking Belt Tensioner Operation

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
     Fig 7: Checking Arrow Mark On Belt Tensioner Is Within Area A

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • After installing a belt, check that it fits properly in the ribbed grooves.
     Fig 8: Identifying Ribbed Grooves Positions For Installing Belt

     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 illuminated.
4. Start the engine, and check that the light turns off.

If the light does not turn off, troubleshoot the charge light circuit.

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:
   • 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.
   Fig 9: Inspecting Charging Circuit Without Load

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 to 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 turn the heater blower switch to 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.

HINT:

If the battery is fully charged, the indication will sometimes be less than the standard amperage.