Page 1341 of 3000
CH–62GR-FE CHARGING – CHARGING SYSTEM
CH
ON-VEHICLE INSPECTION
1. CHECK BATTERY ELECTROLYTE LEVEL
(a) Check the electrolyte level.
(1) If the electrolyte level is low, replace the battery
(or add distilled water) and check the charging
system.
2. CHECK BATTERY SPECIFIC GRAVITY
(a) Check the color of the hydrometer.
Result
3. CHECK BATTERY VOLTAGE
(a) If it has not been 20 minutes since the vehicle was
driven or since the engine was stopped, turn the
ignition switch to the ON position and turn on the
electrical systems (headlights, blower motor, rear
defogger, etc.) for 60 seconds. This will remove the
surface charge from the battery.
(b) Turn the ignition switch off and the electrical
systems off.
(c) Measure the battery voltage between the negative (-
) and positive (+) terminals of the battery.
Standard voltage:
12.5 to 12.9 V at 20
C (68F)
HINT:
If the voltage is below the specification, charge the
battery.
4. CHECK BATTERY TERMINAL
(a) Check that the battery terminals are not loose or
corroded.
If the terminals are corroded, clean them.
5. CHECK FUSES
(a) Measure the resistance of the ALT fuse, ALT-S fuse,
GAUGE fuse and GAUGE 1 fuse.
Standard resistance:
Below 1
If the result is not as specified, replace the fuses as
necessary.
6. CHECK V-RIBBED BELT
(a) Check the belt for wear, cracks or other signs of
damage.
If any of the following defects is found, replace the
V-ribbed belt.
• The belt is worn out, cracked, or the cords are
exposed.
• The cracks reach the cords in more than one
place.
• The belt has chunks missing from the ribs.
A115815E02
Hydrometer Color Condition
Green Good
Dark Charging necessary
Clear or Light Yellow Replacement necessary
A081052E01
B000543
Page 1342 of 3000
2GR-FE CHARGING – CHARGING SYSTEMCH–7
CH
(b) Check that the belt fits properly in the ribbed
grooves.
HINT:
Check with your hand to confirm that the belt has
not slipped out of the groove on the bottom of the
pulley.
If it has slipped out, replace the V-ribbed belt. Install
a new V-ribbed belt correctly.
7. INSPECT GENERATOR WIRING
(a) Visually check the generator wiring.
(1) Check that the wiring is in good condition.
8. CHECK FOR ABNORMAL NOISES
(a) Listen for abnormal noises from the generator.
(1) Check that no abnormal noises are heard from
the generator while the engine is running.
9. CHECK CHARGE WARNING LIGHT CIRCUIT
(a) Turn the ignition switch to the ON position. Check
that the charge warning light comes on.
(b) Start the engine and check that the light goes off.
If the light does not operate as specified,
troubleshoot the charge warning light circuit.
10. INSPECT CHARGING CIRCUIT WITHOUT LOAD
(a) Connect a voltmeter and ammeter to the charging
circuit as follows.
(1) Disconnect the wire from terminal B of the
generator, then connect it to the negative (-)
lead of an ammeter.
(2) Connect the positive (+) lead of the ammeter to
terminal B of the generator.
(3) Connect the positive (+) lead of a voltmeter to
positive (+) terminal of the battery.
(4) Ground the negative (-) lead of the voltmeter.
(b) Check the charging circuit.
(1) Keep the engine speed at 2000 rpm and check
the reading on the ammeter and voltmeter.
Standard amperage:
10 A or less
Standard voltage:
13.2 to 14.8 V
If the result is not as specified, replace the
generator.
HINT:
If the battery is not fully charged, the ammeter
reading will sometimes be more than the
standard amperage.
11. INSPECT CHARGING CIRCUIT WITH LOAD
(a) Keep the engine speed at 2000 rpm, turn on the
high beam headlights, and turn the heater blower
switch to the "HI" position.
(b) Check the reading on the ammeter.
Standard amperage:
30 A or more
B000540E03
A165083E01
Page 1344 of 3000
2GR-FE CHARGING – CHARGING SYSTEMCH–9
CH
INSPECTION PROCEDURE
(a) Check the lock function with the pulley installed in the
vehicle.
(1) Visually check that the rotor in the generator
operates with the engine started.
(b) Check the lock function with the pulley removed from the
vehicle.
(1) Remove the generator pulley cap. Using SST, hold
the generator rotor.
(2) Turn the clutch pulley clockwise and check that the
outer ring locks.
OK:
The outer ring locks.
SST 09820-63020
NG
OK
(a) Start the engine and visually check for looseness of the
clutch pulley.
OK:
The clutch pulley is not loose.
NG
OK
Charge Warning Light Comes ON while Driving
1CHECK LOCK FUNCTION OF CLUTCH PULLEY
A128078E01
REPLACE CLUTCH PULLEY
2CHECK LOCK OF CLUTCH PULLEY
TIGHTEN CLUTCH PULLEY TO THE
SPECIFIED TORQUE
REPLACE GENERATOR ASSEMBLY
Page 1345 of 3000
CH–102GR-FE CHARGING – CHARGING SYSTEM
CH
INSPECTION PROCEDURE
(a) Check the tension of the belt by pushing it down with a
finger.
OK:
The tension of the belt is enough.
NG
OK
(a) Check the V-ribbed belt for wear.
OK:
The V-ribbed belt is not worn.
NG
OK
(a) Check the clutch pulley groove for wear or other defects.
OK:
The clutch pulley groove is not damaged.
NG
OK
(a) Perform a road test and check if noise occurs when
decelerating.
OK:
Noise does not occur.
NG
OK
Noise Occurs from Generator while Engine is Running
1CHECK LOOSENESS OF V-RIBBED BELT
REPLACE V-RIBBED BELT TENSIONER
ASSEMBLY
2CHECK V-RIBBED BELT FOR WEAR
REPLACE V-RIBBED BELT
3CHECK CLUTCH PULLEY FOR WEAR
REPLACE CLUTCH PULLEY
4CHECK FOR NOISE WHILE CLUTCH PULLEY IS OPERATING
REPLACE CLUTCH PULLEY
REPLACE GENERATOR ASSEMBLY
Page 1346 of 3000
CH–62GR-FE CHARGING – CHARGING SYSTEM
CH
ON-VEHICLE INSPECTION
1. CHECK BATTERY ELECTROLYTE LEVEL
(a) Check the electrolyte level.
(1) If the electrolyte level is low, replace the battery
(or add distilled water) and check the charging
system.
2. CHECK BATTERY SPECIFIC GRAVITY
(a) Check the color of the hydrometer.
Result
3. CHECK BATTERY VOLTAGE
(a) If it has not been 20 minutes since the vehicle was
driven or since the engine was stopped, turn the
ignition switch to the ON position and turn on the
electrical systems (headlights, blower motor, rear
defogger, etc.) for 60 seconds. This will remove the
surface charge from the battery.
(b) Turn the ignition switch off and the electrical
systems off.
(c) Measure the battery voltage between the negative (-
) and positive (+) terminals of the battery.
Standard voltage:
12.5 to 12.9 V at 20
C (68F)
HINT:
If the voltage is below the specification, charge the
battery.
4. CHECK BATTERY TERMINAL
(a) Check that the battery terminals are not loose or
corroded.
If the terminals are corroded, clean them.
5. CHECK FUSES
(a) Measure the resistance of the ALT fuse, ALT-S fuse,
GAUGE fuse and GAUGE 1 fuse.
Standard resistance:
Below 1
If the result is not as specified, replace the fuses as
necessary.
6. CHECK V-RIBBED BELT
(a) Check the belt for wear, cracks or other signs of
damage.
If any of the following defects is found, replace the
V-ribbed belt.
• The belt is worn out, cracked, or the cords are
exposed.
• The cracks reach the cords in more than one
place.
• The belt has chunks missing from the ribs.
A115815E02
Hydrometer Color Condition
Green Good
Dark Charging necessary
Clear or Light Yellow Replacement necessary
A081052E01
B000543
Page 1347 of 3000
2GR-FE CHARGING – CHARGING SYSTEMCH–7
CH
(b) Check that the belt fits properly in the ribbed
grooves.
HINT:
Check with your hand to confirm that the belt has
not slipped out of the groove on the bottom of the
pulley.
If it has slipped out, replace the V-ribbed belt. Install
a new V-ribbed belt correctly.
7. INSPECT GENERATOR WIRING
(a) Visually check the generator wiring.
(1) Check that the wiring is in good condition.
8. CHECK FOR ABNORMAL NOISES
(a) Listen for abnormal noises from the generator.
(1) Check that no abnormal noises are heard from
the generator while the engine is running.
9. CHECK CHARGE WARNING LIGHT CIRCUIT
(a) Turn the ignition switch to the ON position. Check
that the charge warning light comes on.
(b) Start the engine and check that the light goes off.
If the light does not operate as specified,
troubleshoot the charge warning light circuit.
10. INSPECT CHARGING CIRCUIT WITHOUT LOAD
(a) Connect a voltmeter and ammeter to the charging
circuit as follows.
(1) Disconnect the wire from terminal B of the
generator, then connect it to the negative (-)
lead of an ammeter.
(2) Connect the positive (+) lead of the ammeter to
terminal B of the generator.
(3) Connect the positive (+) lead of a voltmeter to
positive (+) terminal of the battery.
(4) Ground the negative (-) lead of the voltmeter.
(b) Check the charging circuit.
(1) Keep the engine speed at 2000 rpm and check
the reading on the ammeter and voltmeter.
Standard amperage:
10 A or less
Standard voltage:
13.2 to 14.8 V
If the result is not as specified, replace the
generator.
HINT:
If the battery is not fully charged, the ammeter
reading will sometimes be more than the
standard amperage.
11. INSPECT CHARGING CIRCUIT WITH LOAD
(a) Keep the engine speed at 2000 rpm, turn on the
high beam headlights, and turn the heater blower
switch to the "HI" position.
(b) Check the reading on the ammeter.
Standard amperage:
30 A or more
B000540E03
A165083E01
Page 1349 of 3000
2GR-FE CHARGING – CHARGING SYSTEMCH–9
CH
INSPECTION PROCEDURE
(a) Check the lock function with the pulley installed in the
vehicle.
(1) Visually check that the rotor in the generator
operates with the engine started.
(b) Check the lock function with the pulley removed from the
vehicle.
(1) Remove the generator pulley cap. Using SST, hold
the generator rotor.
(2) Turn the clutch pulley clockwise and check that the
outer ring locks.
OK:
The outer ring locks.
SST 09820-63020
NG
OK
(a) Start the engine and visually check for looseness of the
clutch pulley.
OK:
The clutch pulley is not loose.
NG
OK
Charge Warning Light Comes ON while Driving
1CHECK LOCK FUNCTION OF CLUTCH PULLEY
A128078E01
REPLACE CLUTCH PULLEY
2CHECK LOCK OF CLUTCH PULLEY
TIGHTEN CLUTCH PULLEY TO THE
SPECIFIED TORQUE
REPLACE GENERATOR ASSEMBLY
Page 1350 of 3000
CH–102GR-FE CHARGING – CHARGING SYSTEM
CH
INSPECTION PROCEDURE
(a) Check the tension of the belt by pushing it down with a
finger.
OK:
The tension of the belt is enough.
NG
OK
(a) Check the V-ribbed belt for wear.
OK:
The V-ribbed belt is not worn.
NG
OK
(a) Check the clutch pulley groove for wear or other defects.
OK:
The clutch pulley groove is not damaged.
NG
OK
(a) Perform a road test and check if noise occurs when
decelerating.
OK:
Noise does not occur.
NG
OK
Noise Occurs from Generator while Engine is Running
1CHECK LOOSENESS OF V-RIBBED BELT
REPLACE V-RIBBED BELT TENSIONER
ASSEMBLY
2CHECK V-RIBBED BELT FOR WEAR
REPLACE V-RIBBED BELT
3CHECK CLUTCH PULLEY FOR WEAR
REPLACE CLUTCH PULLEY
4CHECK FOR NOISE WHILE CLUTCH PULLEY IS OPERATING
REPLACE CLUTCH PULLEY
REPLACE GENERATOR ASSEMBLY
