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DTC P2503: Charging System Low: Testing

    NOTE: Inspect the vehicle for aftermarket accessories that may exceed the Generator System output.
  1. Turn the ignition off. The battery must be fully charged. The Generator belt tension and condition must be checked before continuing. Start the engine. Allow the idle to stabilize. With the DRBIII(R), read the Target Charging Voltage. If the Target Charging Voltage above 15.1 volts, see INTERMITTENT CONDITIONS  . Perform POWERTRAIN VERIFICATION TEST VER-3  . If the Target Charging Voltage is not above 15.1 volts, go to next step.
    2. WARNING: When the engine is operating, DO NOT stand in a direct line with the fan. DO NOT put your hands near the pulleys, belts or fan. DO NOT wear loose clothing.
  2. Turn ignition on, engine not running. Ensure all wires are clear of the engine's moving parts. Start the engine. Measure the voltage between the (A11) Generator B+ Terminal and the Battery+ Post. If the voltage is above 0.4 volt, repair the (A11) B+ circuit for high resistance between the Generator and Battery. Perform POWERTRAIN VERIFICATION TEST VER-3  . If the voltage is not above 0.4 volts, go to next step.
    3. CAUTION: When the engine is operating, DO NOT stand in a direct line with the fan. DO NOT put your hands near the pulleys, belts or fan. DO NOT wear loose clothing.
  3. Start the engine. Warm the engine to operating temperature. Ensure all wires are clear of the engine's moving parts. Measure the voltage between the Generator case and Battery ground post. If the voltage is above 0.1 volt, repair Generator Ground for high resistance, Generator Case to Battery ground side. Perform POWERTRAIN VERIFICATION TEST VER-3  . If the voltage is not above 0.1 volt, go to next step.
  4. Turn the ignition off. Disconnect the Generator Field harness connector. Using a 12-volt test light, jumper it across the Generator Field harness connector. Turn the ignition on, engine not running. With the DRBIII(R), actuate the Gen Field Control circuit. If the test light illuminates brightly and flash on and off, replace the Generator. Perform POWERTRAIN VERIFICATION TEST VER-3  . If the test light does not illuminate of flash on and off, go to next step.
  5. Turn the ignition off. Disconnect the Generator Field harness connector. Using a 12-volt test connected to battery voltage, probe the (Z1) Gen Field Ground circuit in the Generator Field harness connector. If the test light illuminates brightly, go to next step. If the test light does not illuminate, repair the open in the (Z1) Gen Field Ground circuit. Perform POWERTRAIN VERIFICATION TEST VER-3  .
  6. Turn the ignition off. Disconnect the Generator Field harness connector. Disconnect the PCM harness connector. Measure the voltage on the (K20) Gen Field Control circuit at the Generator Field harness connector. If the voltage is above 1.0 volt, repair the short to voltage in the (K20) Gen Field Control circuit. Perform POWERTRAIN VERIFICATION TEST VER-3  . If the voltage is not above 1.0 volt, go to next step.
  7. Turn the ignition on. Disconnect the Generator Field harness connector. Disconnect the PCM harness connector. Measure the resistance between ground and the (K20) Gen Field Control circuit in the Generator Field harness connector. If the resistance is below 100 ohms, repair the (K20) Gen Field Control circuit for a short to ground. Perform POWERTRAIN VERIFICATION TEST VER-3  . If the resistance is not below 100 ohms, go to next step.
    8. CAUTION: DO NOT probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install Miller Special Tool (8815) to perform diagnosis.
  8. Turn the ignition off. Disconnect the Generator Field harness connector. Disconnect the PCM harness connector. Measure the resistance of the (K20) Gen Field Control circuit from the Generator Field harness connector to the appropriate terminal of the Miller Special Tool (8815). If the resistance is below 5.0 ohms, go to next step. If the resistance is not below 5.0 ohms, repair the open in the (K20) Generator Field Control circuit. Perform POWERTRAIN VERIFICATION TEST VER-3  .
  9. If there are no possible causes remaining, replace and program the Powertrain Control Module. See PROGRAMMING  . Perform POWERTRAIN VERIFICATION TEST VER-3  .
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