NOTE:
To ensure a complete and thorough diagnosis, the battery, starter and generator test segments must be done as a set from start to finish. 1.PRELIMINARY Inspection
Perform the preliminary Inspection. Refer to See: Charging System Preliminary Inspection.
>> GO TO 2 2.DISABLE THE POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM
Disable the power generation voltage variable control with either of the following procedures.
After selecting "ENGINE" on the "SELECT SYSTEM" screen of CONSULT-III, set the "ALTERNATOR DUTY" value to 0 % by selecting "ALTERNATOR DUTY" with "Active Test". Continue "Active Test" until the end of Inspection. (When the DUTY value is 0 or 100 %, the normal power generation is performed according to the characteristic of the IC regulator of the generator.)
Turn the ignition switch OFF, disconnect the battery current sensor connector and leave it disconnected during the course of the test.
NOTE:
Running the engine with the battery current sensor disconnected will cause DTC's (P1550-P1554) to set.
After finishing the Inspection, connect the battery current sensor connector and erase the self-diagnostic results history of the engine using CONSULT-III.
>> GO TO 3 3.DIAGNOSIS WITH STARTING/CHARGING SYSTEM TESTER
Perform the charging system test using Starting/Charging System Tester (J-44373). For details and operating instructions, refer to Technical Service Bulletin.
Test result
CHARGING SYSTEM NORMAL>>Charging system is normal and will also show "DIODE RIPPLE" test result.
NO CHARGING VOLTAGE>>GO TO 4
LOW CHARGING VOLTAGE>>GO TO 12
HIGH CHARGING VOLTAGE>>GO TO 14
DIODE RIPPLE NORMAL>>Diode ripple is OK and will also show "CHARGING VOLTAGE" test result.
EXCESS RIPPLE DETECTED>>Replace the generator. Perform "DIODE RIPPLE" test again using Starting/Charging System Tester (J-44373) to confirm repair.
DIODE RIPPLE NOT DETECTED>>GO TO 4 4.Inspection WITH CHARGE WARNING LAMP (IGNITION SWITCH IS ON)
Turn the ignition switch ON.
Does the charge warning lamp illuminate?
YES >> GO TO 6
NO >> GO TO 5 5.TERMINAL"2" (OPEN) CIRCUIT Inspection
Check terminal "2" circuit for open circuits. Refer to See: Component Tests and General Diagnostics\L Terminal Circuit.
Is the terminal "2" circuit normal?
YES >> Replace generator. Refer to See: Alternator\Service and Repair\Removal and Replacement.
NO >> Repair as needed. 6.Inspection WITH CHARGE WARNING LAMP (IDLING)
Start the engine and run it at idle.
Does the charge warning lamp turn OFF?
YES >> GO TO 9
NO >> GO TO 7 7.TERMINAL "2"(SHORT) CIRCUIT Inspection
Check terminal "2" circuit for short to ground. Refer to See: Component Tests and General Diagnostics\L Terminal Circuit.
Is the terminal "2" circuit normal?
YES >> GO TO 8
NO >> Repair as needed. 8.TERMINAL"3" CIRCUIT Inspection
Check terminal "3" circuit. Refer to See: Component Tests and General Diagnostics\S Terminal Circuit.
Is the terminal "3" circuit normal?
YES >> GO TO 10
NO >> Repair as needed. 9.Inspection WITH CHARGE WARNING LAMP (ENGINE AT 3,000 RPM)
Increase and maintain the engine speed at 3,000 rpm.
Does the charge warning lamp remain off?
YES >> GO TO 11
NO >> GO TO 10 10.Inspection OF GENERATOR PULLEY
Check generator pulley. Refer to See: Alternator\Service and Repair\Inspection.
Is generator pulley normal?
YES >> Replace generator. Refer to See: Alternator\Service and Repair\Removal and Replacement.
NO >> Repair as needed. 11.TERMINAL "1" CIRCUIT Inspection
Check terminal "1""circuit. Refer to See: Component Tests and General Diagnostics\B Terminal Circuit.
Is terminal "1" circuit normal?
YES >> Replace generator. Refer to See: Alternator\Service and Repair\Removal and Replacement.
NO >> Repair as needed. 12.TERMINAL "1" CIRCUIT Inspection
Check terminal "1" circuit. Refer to See: Component Tests and General Diagnostics\B Terminal Circuit.
Is terminal "1" circuit normal?
YES >> GO TO 13
NO >> Repair as needed. 13.Inspection OF GENERATOR PULLEY
Check generator pulley. Refer to See: Alternator\Service and Repair\Inspection.
Is generator pulley normal?
YES >> Replace generator. Refer to See: Alternator\Service and Repair\Removal and Replacement.
NO >> Repair as needed. 14.TERMINAL "3" CIRCUIT Inspection
Check terminal "3" circuit. Refer to See: Component Tests and General Diagnostics\S Terminal Circuit.
Is the terminal "3" circuit normal?
YES >> Replace generator. Refer to See: Alternator\Service and Repair\Removal and Replacement.
NO >> Repair as needed.
