- a) Check the tension of the drive belt and its condition. If the belt is worn or deformed, replace it.
- b) Make sure the generator mounting and adjusting bolts are tightened.
- c) Inspect the alternator wiring harness and the alternator and charge regulator connectors. The connectors should be in good condition and tight.
- d) Check the fuse link(s). If the link is burnt out, determine the cause, repair and install a new link (if the fuse link is burnt out, the engine will not start and/or the instruments will not work). Sometimes a faulty link may look like a working one. In this case, remove it and check for conductivity.
- d) Start the engine and listen to the generator noise (creaking and squealing indicate a bearing fault).
- e) Check the specific gravity of the battery electrolyte. If it is low, charge the battery (do not service an uncharged battery).
- g) Make sure the battery is fully charged (one bad battery cell can cause the others to overcharge and boil away).
- h) Disconnect the battery cables (negative first, then positive). Inspect the battery terminals and cable clamps for corrosion. Clean them thoroughly if necessary (see Chapter 1). Reconnect the positive battery cable.
- i) With the ignition off, install a test lamp between the negative battery terminal and the disconnected negative cable clamp.
1) If the light does not light, disconnect it and proceed to the next step.
2) If the light is on, there is a short circuit in the vehicle's electrical circuit. The short circuit must be eliminated before checking the charging system.
3) Disconnect the generator wiring harness.
(a) If the light goes out, the generator is faulty.
(b) If the light continues to glow, remove each fuse one by one until the light goes out (this will determine which component of the circuit is shorted).
2. Using a voltmeter, check the battery voltage with the engine off. The voltage should be approximately 12 V.
3. Start the engine and check the battery voltage again. The voltage should be between 14 and 15 V.
4. Turn on the headlights. The voltage should drop and then rise to its previous value if the charging system is working properly.
5. If the voltmeter reading is greater than the specification for the charging system, replace the voltage regulator (section 16). If the voltmeter readings are less than those indicated in specifications, the generator diodes, stator or rectifier may be faulty, or the voltage regulator may have failed.