On-Vehicle Inspection

WARNING: This page is about a different car, the 2002 Toyota Sequoia. However, it is still accessible from the selected car via links, so may be relevant.

Check battery electrolyte level of each cell . See Fig 1.
If under the lower level, replace the battery (or add distilled water if possible) and check the charging system.

Fig 1: Checking Electrolyte Level
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Except maintenance-free battery, check battery specific gravity of each cell. . See Fig 2.
Standard specific gravity : 1.25-1.29 at 20°C (68°F)

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

Fig 2: Measuring Specific Gravity Of Electrolyte
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
For 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.
3. Measure the battery voltage between the negative (-) and positive (+) terminals of the battery. See Fig 3.
Fig 3: Measuring Battery Voltage
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard voltage : 12.5-12.9 V at 20°C (68°F).

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

Check the indicator as shown in the illustration. See Fig 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: Identifying Battery Indicator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: A belt tensioner is used, so checking the belt tension is not necessary.

Cracks on the rib side of a drive belt are considered acceptable. If the drive belt has chunks missing from the ribs, it should be replaced. See Fig 5.
The drive belt tension can be released by turning the belt tensioner counterclockwise. The pulley bolt for the belt tensioner has a left-hand thread.

Fig 8: Checking Tensioner Operation

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Inspect drive belt :
1. Visually check the drive belt for excessive wear, frayed cords etc.
  If necessary, replace the drive belt.
  
  Fig 5: Identifying Belt Wear Types
  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 approx. 98 N (10 kgf, 22.0 lbf) of force.
  - Check the alignment of the belt tensioner pulley to make sure the drive belt has not slipped off the pulley. See Fig 8.
  - Check that the arrow mark on the belt tensioner falls within area A of the scale.
    If it is outside area A, replace the drive belt.
  - If necessary, replace the belt tensioner.
Remove engine under cover No. 1.
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.
Check charge warning light circuit :
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 lit.
4. Start the engine, and check that the light goes off.
If the light does not go off as specified, troubleshoot the charge light circuit.

NOTE: If a battery/generator tester is available, connect the tester to the charging circuit as per manufacturer's instructions.

Inspect charging circuit without load :
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. See Fig 9.
    
    Fig 9: Performing Charging System No-load Test Without Tester
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - 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.
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 - 14.8 V .
  
  If the voltmeter reading is more than standard voltage, replace the voltage regulator.

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

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.
  Standard amperage: 30 A or more .
  
  If the ammeter reading is less than the standard amperage, repair the generator.
Reinstall engine under cover No. 1.