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On-Vehicle Inspection

WARNING: This page is about a different car, the 2002 Toyota Tundra. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
  • Check that the battery cables are connected to the correct terminals.
  • Disconnect the battery cables when the battery is given a quick charge.
  • Do not perform tests with a high voltage insulation resistance tester.
  • Never disconnect the battery while the engine is running.
  1. Check Battery Electrolyte Level 

    Check the electrolyte quantity of each cell. Maintenance-Free Battery:

    If 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: Displaying Battery Electrolyte Level Indicators
    G01092033Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Except Maintenance-Free Battery: Check Battery Specific Gravity 

    Check the specific gravity of each cell.

    1. Standard specific gravity: 1.25 - 1.29 at 20°C (68°F) 

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

  3. Maintenance-Free Battery: Check Battery Voltage 
    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.
    2. Turn the ignition switch OFF and turn off the electrical systems.
      Fig 2: Displaying Except Maintenance-Free Battery
      G01092034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Measure the battery voltage between the negative (-) and positive (+) terminals of the battery.
      1. Standard voltage: 12.5 - 12.9 V at 20°C (68°F) 

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

    Fig 3: Displaying Maintenance-Free Battery
    G01092035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Check the indicator as shown in the illustration.
  4. Check Battery Terminals, Fusible Link And Fuses 
    1. Check that the battery terminals are not loose or corroded.
    2. Check the fusible link and fuses for continuity.
    Fig 4: Checking Battery Indicator
    G01092036Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Inspect Drive Belt 
    1. Visually check the belt for excessive wear, frayed cords etc.
      NOTE: Cracks on the ribbed side of the belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced.
      Fig 5: Checking Drive Belt For Damage
      G01092037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a belt tension gauge, check the drive belt tension.

    Belt tension gauge: DENSO BTG 20 (95506-00020) or Borroughs No. BT-33-73F

    Drive belt tension: 

    Fig 6: Displaying Drive Tension Specifications
    G01092038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    If necessary, adjust the drive belt tension.

    Fig 7: Checking Drive Belt Tensioner Using Belt Tensioner Gauge
    G01092039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 8: Checking For Correct Installation
    G01092040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • "New belt" refers to a belt which has been used less than 5 minutes on a running engine.
    • "Used belt" refers to a belt which has been used on a running engine for 5 minutes or more.
    • After installing the drive belt, check that it fits properly in the ribbed grooves. Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the crank pulley.
    • After installing a new belt, run the engine for approx. 5 minutes and then recheck the tension.
  6. Visually Check Generator Wiring And Listen For Abnormal Noises 
    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.
  7. Check Charging Circuit Without Load 
    NOTE: If a battery/generator tester is available, connect the tester to the charging circuit as per 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 the wire to the negative (-) terminal of the ammeter.
      • Connect the test lead from the positive (+) terminal of the ammeter to terminal B of the generator.
      • Connect the positive (+) lead of the voltmeter to terminal B of the generator.
      • Ground the negative (-) lead 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.
      1. Standard amperage: 10 A or less 
      2. Standard voltage: 13.2 - 14.8 V 

      If the voltage reading is greater than the standard voltage, replace the voltage regulator.

      Fig 9: Checking Charger Circuit Without Load
      G01092041Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. Inspect Charging Circuit With Load 
    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.
      1. Standard amperage: 30 A or more 

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

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