Toyota CH-R Service Manual: On-vehicle Inspection

ON-VEHICLE INSPECTION

CAUTION / NOTICE / HINT

NOTICE:

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.

PROCEDURE

1. CHECK BATTERY CONDITION

(a) Check the battery for damage or deformation. If severe damage, deformation or leakage is found, replace the battery.

(b) Check the electrolyte level in each cell.

(1) For maintenance-free batteries:

(2) For non-maintenance-free batteries:

(c) Check the voltage.

(1) Turn the ignition switch off and turn on the headlights for 20 to 30 seconds. This will remove the surface charge from the battery.

(2) Measure the battery voltage according to the value(s) in the table below.

Standard Voltage:

If the result is not as specified, recharge or replace the battery.

2. CHECK BATTERY TERMINAL

(a) Check that the battery terminals are not loose or corroded.

If a terminal is loose or corroded, tighten or clean the terminal.

Torque:

Positive (+) Battery Terminal :

5.4 N·m {55 kgf·cm, 48 in·lbf}

Negative (-) Battery Terminal :

5.4 N·m {55 kgf·cm, 48 in·lbf}

3. CHECK FUSES

(a) Measure the resistance of each fuse for the charging system.

HINT:

The fuses shown in System Diagram are related to the charging system.

Standard Resistance:

Below 1 Ω

4. INSPECT FAN AND GENERATOR V BELT

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5. INSPECT GENERATOR WITH REGULATOR ASSEMBLY WIRING

(a) Visually check the generator assembly wiring.

(1) Check that the wiring is in good condition.

6. CHECK FOR ABNORMAL NOISE

(a) Listen for abnormal noises from the generator assembly.

(1) Check that no abnormal noises are heard from the generator assembly while the engine is running.

If noise occurs, check the generator assembly.

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7. INSPECT CHARGE WARNING LIGHT

(a) Turn the ignition switch to ON.

(b) Check that the charge warning light comes on.

(c) Start the engine and check that the charge warning light goes off.

If the charge warning light does not operate as specified, troubleshoot the charge warning light.

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8. INSPECT CHARGING CIRCUIT WITHOUT LOAD

(a) Connect a voltmeter and an ammeter to the charging circuit as follows. HINT: If a battery/generator assembly tester is available, connect the tester to the charging circuit in accordance with the manufacturer's instructions. (1) Disconnect the wire from terminal B of the generator assembly, and then connect it to the negative (-) lead of the ammeter. (2) Connect the ammeter positive (+) lead to terminal B of the generator assembly. (3) Connect the voltmeter positive (+) lead to the terminal B of the generator assembly. (4) Ground the voltmeter negative (-) lead.

*1 Battery *2 Generator Assembly *a Terminal B

(b) Check the charging circuit.

(1) Maintain the engine speed at 2000 rpm and check the readings on the ammeter and voltmeter.

Standard Current:

10 A or more

Standard Voltage:

13.2 to 14.8 V

If the result is not as specified, repair or replace the generator assembly.

HINT:

If the result is not fully charged, the ammeter reading will sometimes be more than the standard current.

9. INSPECT CHARGING CIRCUIT WITH LOAD

(a) With the engine running at 2000 rpm, turn the high beam headlights on and turn the heater blower switch to the "HI" position.

(b) Check the reading on the ammeter.

Standard Current:

30 A or more

If the result is not as specified, repair or replace the generator assembly.

HINT:

If the battery is fully charged, the reading will sometimes be less than the standard. If this is the case, add more electrical load (operate the wipers, rear window defogger, etc.) and check the reading on the ammeter again.