CAUTION
- Prior to starting work, pay special attention to the following: Always wear work clothes, a safety cap, protective shoes. Additionally, wear a helmet, protective goggles, etc. if necessary. Protect the vehicle using a seat cover, fender cover, etc. Prepare the service tools, clean cloth, containers to catch grease and oil, etc.
- Vehicle components are extremely hot immediately after driving. Be wary of receiving burns from heated parts.
- When performing a repair, identify the cause of trouble and avoid unnecessary removal, disassembly and replacement.
- Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery.
- Always use the jack-up point when the shop jacks or rigid racks are used to support the vehicle.
- Remove contamination including dirt and corrosion before removal, installation, disassembly or assembly.
- Keep the removed parts in order and protect them from dust and dirt.
- All removed parts, if to be reused, should be reinstalled in the original positions with attention to the correct directions, etc.
- Bolts, nuts and washers should be replaced with new parts as required.
- Be sure to tighten the fasteners including bolts and nuts to the specified torque.
GENERAL TOOL
| TOOL NAME | REMARKS |
|---|---|
| Circuit tester | Used for measuring resistance, voltage and current. |
Scheme 112
Scheme 113
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Scheme 116
- Disconnect the ground cable from battery.
- Loosen the clamp (A) which connects the air intake boot assembly.
- Loosen the bolt (B) which secures the air intake boot assembly to the collector cover bracket.
- Remove the air intake boot assembly, and move it to the left side wheel apron.
- Disconnect the connector (B) and terminal (A) from starter.
- Remove the starter from transmission.
DIODE
| CAUTION | There is the possibility of damaging the diodes if a mega-tester (used to measure high voltages) or a similar measuring instrument is used. Never use a mega tester or equivalent for this test. |
Scheme 117
- Check for continuity between the diode lead and terminal E or B. If continuity is not as shown in the table, replace the rectifier. At analog type tester Tester lead Continuity -lead +lead E P1, P2, P3, P4, P5, P6 Yes B None P1, P2, P3, P4, P5, P6 E None B Yes At digital type tester Tester lead Continuity -lead +lead E P1, P2, P3, P4, P5, P6 None B Yes P1, P2, P3, P4, P5, P6 E Yes B None
Scheme 118
Scheme 119
- Inspect the slip rings for contamination or any roughness on the sliding surface. Repair the slip ring surface using a lathe or sand paper.
- Measure the slip ring outer diameter. Replace the rotor if the slip ring is worn. Slip ring outer diameter: Standard 22.7 mm (0.894 in) Limit 22.1 mm (0.870 in)
- Using a circuit tester, check the resistance between slip rings. If resistance exceeds the standard, replace the rotor. Standard: Approx. 1.8 - 2.2 ohms
- Check the continuity between slip ring and rotor core or shaft. If there is continuity, replace the rotor because the rotor coil is grounded.
- Check the ball bearings. If there is any noise, or the rotor does not rotate smoothly, replace the bearings.
Scheme 120
Scheme 121
Scheme 122
- Continuity test Inspect the continuity between the stator coil terminals. If continuity is not as shown in the table, replace the stator coil.
- Insulation test Inspect the continuity between the stator coil stator core and lead wire terminals. If there is continuity, replace the stator coil because the stator coil is grounded.
Scheme 123
Scheme 124
- Measure the length of each brush. Replace the brush if wear exceeds service limits. There is a service limit mark (A) on each brush. Brush length: Standard (1) 22.5 mm (0.886 in) Limit (2) 5.0 mm (0.197 in)
- Using a spring pressure indicator, push the brush into the brush holder until its tip protrudes 2 mm (0.08 in). Then measure the pressure of brush spring. If the pressure is 2.648 N (270 g, 9.52 oz) or less, replace the brush spring with a new part. 4.609 - 5.786 N (470 - 590 g, 16.58 - 20.810 oz) pressure is required on the new spring.
BALL BEARING
Check the ball bearings. Replace the ball bearings if there is resistance in the rotation, or if there is any abnormal noise.
EXTERNAL PARTS
Check the battery case, top cover, vent plugs, and terminal posts for dirt or cracks. If necessary, clean with water and wipe with a dry cloth. Apply a thin coat of grease on the terminal posts to prevent corrosion.
ELECTROLYTE LEVEL
Check the electrolyte level in each cell. If the level is below MIN level, bring the level to MAX level by pouring distilled water into the battery cell. Do not fill beyond MAX level.
Scheme 125
- Measure specific gravity of electrolyte using a hydrometer and a thermometer. Specific gravity varies with temperature of electrolyte so that it must be corrected at 20°C (68°F) using the following calculation: S 20 = St + 0.0007 x (t - 20) S 20 : Specific gravity corrected at electrolyte temperature of 20°C (68°F) St: Measured specific gravity t: Measured temperature (°C) Judge whether or not the battery requires charging according to corrected specific gravity. Standard specific gravity: 1.220 - 1.290 [at 20°C (68°F)]
- Measuring the specific gravity of the electrolyte in the battery will disclose the state of charge of the battery. The relation between specific gravity and state of charge is as shown in the figure.
MEASUREMENT
| WARNING | Do not bring an open flame close to the battery when working. |
| CAUTION | Prior to charging, corroded terminals should be cleaned with a brush and common caustic soda solution. Be careful since battery electrolyte overflows while charging the battery. Observe instructions when handling the battery charger. Before charging the battery on the vehicle, disconnect the battery ground terminal to prevent damage of generator diodes or other electrical units. |
JUDGMENT OF BATTERY IN CHARGED CONDITION
- Specific gravity of electrolyte should be held within the specific range of 1.250 - 1.290 for one hour or more.
- Voltage per battery cell should be held at a specific value in a range of 2.5 - 2.8 V for one hour or more.
CHECK CONDITION OF CHARGE WITH HYDROMETER
| Hydrometer indicator | State of charge | Corrective action |
|---|---|---|
| Green dot | 65% or more | Load test |
| Dark dot | 65% or less | Charge battery |
| Clear dot | Low electrolyte | Replace the battery. (1) (If cranking is difficult) |
| (1) Check electrical system before replacement. | ||
| (1) | Check electrical system before replacement. |
NORMAL CHARGING
Charge the battery at the current value specified by manufacturer or at approximately 1/10 of battery's ampere-hour rating.
QUICK CHARGING
| CAUTION | Observe the items in "3. NORMAL CHARGING". Never use 10 A or more when charging the battery because it will shorten the battery life. |
Quick charging is a method that the battery is charged in a short period of time with a relatively large current by using a quick charger.
Since a large current flow raises electrolyte temperature, the battery is subject to damage if the large current is used for prolonged time. For this reason, quick charging must be carried out within a current range that will not raise the electrolyte temperature to 40°C (104°F) or more.
Also the quick charging is a temporary mean to bring battery voltage up to some level, and battery should be charged slowly with low current as a rule.