165

2. BATTERY REMOVAL AND INSTALLATION

HINT:

(1) The battery is not allowed to contact lubricating grease.

(2) The battery terminal is only allowed to be softly pulled out, in order to void damaging the battery.

REMOVAL

(1) Remove the negative (-) ground cable

(2) Remove the battery positive (+) cable

(3) Loosen the fixing clamp on the battery.

INSTALLATION

Install according to the inverted order of removal.

Tighten the torque

Tighten the battery cable clip to 6N.m (61kgf.cm, 4ft.lbf)

Tighten the fixing clamp to 12N.m (123kgf.cm, 8.6ft.lbf)

166

II. CHARGING SYSTEM INSPECTION

1. CHECK BATTERY WORKING VOLTAGE

(a) 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) for 60

seconds to remove the surface charge.

(b) Turn the ignition switch OFF and

turn off the electrical systems. Then

m e a s u r e   t h e   b a t t e r y   v o l t a g e

between the negative and positive

terminals of the battery.

Standard voltage: 12.5-12.9V at

20°C

HINT:

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

2. CHECK BATTERY TERMINALS, FUSE BOX AND FUSE

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

(b) Check if fuse box and fuse for continuity.

167

3. INSPECT DRIVE BELT

(a) Check the belt for excessive wear, frayed cords etc.

HINT:

If any defect has been found, replace the drive belt.

Cracks on the rib side of a belt are considered acceptable. If

the belt has chunks missing from the ribs, it should be

replaced.

(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 pulley.

4. CHECK ALTERNATOR WIRING

Check that the wiring is in good condition.

5. LISTEN FOR ABNORMAL NOISES FROM ALTERNATOR

 Check that there is no abnormal noise from the alternator while the engine is running.

6. INSPECT CHARGE WARNING LIGHT CIRCUIT

(1) Turn the ignition ON. Check that the charge warning light comes on.

(2) Start the engine. Check that the light goes off.

HINT:

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

168

7. INSPECT CHARGING CIRCUIT WITHOUT LOAD

(a) I f   a   b a t t e r y / s t a r t e r   t e s t e r   i s

available, connect the tester to the

charging circuit as per instructions.

(b) If a tester is not available, connect

an ammeter and voltmeter to the

charging circuit as follows.

1

Disconnect to the wire from

terminal B of the alternator and

connect it to the negative (-) pole

of the ammeter.

2

Connect the positive (+) pole of the

ammeter to terminal B of the

alternator.

3

Connect the positive (+) pole of the voltmeter to terminal B of the alternator.

4

Ground the negative (-) pole of the voltmeter.

(c) Check the charging circuit

With the engine running from idle to 2,000 rpm, check the reading on the ammeter.

Standard amperage: 10A or less

Standard voltage: 13.2V---14.8V

8. INSPECT CHARGING CIRCUIT WITH LOAD

(a) With the engine running at 2,000 rpm, turn on the high beam headlights and place the blower switch at "4".

Check the reading on the ammeter.

Standard amperage: 20A or more

(b) HINT:

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

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

Ammeter

Disconnect Wire 
from Terminal B

Battery

Voltmeter

Alternator