Troubleshooting Guide

The charging system troubleshooting guide is shown in the following steps.

1. STEP 1. 

   Q: Is the battery in good condition? (Refer to  BATTERY TEST  ). 

   1. YES:  Go to Step 2.
   2. NO:  Charge or replace the battery.
2. STEP 2. 

   Q: Is the generator drive belt in good condition? (Refer to  DRIVE BELTS (FOR GENERATOR, POWER STEERING PUMP AND AIR CONDITIONING) (CHECK)  ). 

   1. YES:  Go to Step 3.
   2. NO:  Adjust the belt tension or replace the belt.
3. STEP 3. 

   Q: Does the generator malfunction light come on when the ignition switch is turned on? 

   1. YES:  Go to Step 4.
   2. NO:  Check the ignition switch. (Refer to INSPECTION ).

      Check the generator malfunction light and its related circuits.

      Check the generator. (Refer to CHARGING SYSTEM - GENERATOR ASSEMBLY - INSPECTION  ).

4. STEP 4. 

   Q: Does the generator malfunction light go out after starting the engine? 

   1. YES:  Go to Step 5.
   2. NO:  Check the generator (Refer to CHARGING SYSTEM - GENERATOR ASSEMBLY - INSPECTION  ).
5. STEP 5. 

   Q: Is an oscilloscope available? 

   1. YES:  Go to Step 6.
   2. NO:  Go to Step  7.
6. STEP 6. 

   Q: Does the oscilloscope show a normal wave pattern? (Refer to  CHARGING SYSTEM - ON-VEHICLE SERVICE - WAVE PATTERN CHECK USING AN OSCILLOSCOPE   ). 

   1. YES:  Go to Step 7.
   2. NO:  Check the generator. (Refer to CHARGING SYSTEM - GENERATOR ASSEMBLY - INSPECTION  ).
7. STEP 7. 
   • Engine: 2, 500 r/min
   • Headlight: ON (high beam)
   • Voltage between generator terminal B and the positive battery terminal

     OK: 0.5 V or less

   • Voltage between the negative battery terminal and generator body

     OK: 0.5 V or less

     Q: Are the generator output line and ground line in good condition? 

     1. YES:  Go to Step 8.
     2. NO:  Check the generator output line and ground line.
8. STEP 8. 

   Q: Is the output current normal? (Refer to  CHARGING SYSTEM - ON-VEHICLE SERVICE - OUTPUT CURRENT TEST   ). 

   1. YES:  Go to Step 9.
   2. NO:  Check the generator (Refer to CHARGING SYSTEM - GENERATOR ASSEMBLY - INSPECTION  ).
9. STEP 9. 

   Q: Is the regulated voltage normal? (Refer to  CHARGING SYSTEM - ON-VEHICLE SERVICE - REGULATED VOLTAGE TEST   ). 

   1. YES:  Go to Step 10.
   2. NO:  Check the generator (Refer to CHARGING SYSTEM - GENERATOR ASSEMBLY - INSPECTION  ).
10. STEP 10. 

    Q: Is the voltage drop in the generator output line normal? 

    1. YES:  Generator is normal. Check other systems.
    2. NO:  Check the output line.