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Diesel Engines

    NOTE: Verify battery condition. Charge or replace battery as necessary.
  1. Turn ignition switch to OFF position. Inspect generator belt tension and condition. If generator belt indicates wear, replace generator belt. If generator belt does not indicate wear, go to next step.
  2. Start engine. Turn on all accessories. Manually set engine speed to 2000 RPM for 30 seconds, then return to idle. Using scan tool, record DTCs. If any DTCs are set, perform appropriate test in accordance with DTC retrieved. See SCAN TOOL DTC MESSAGES  table under SELF-DIAGNOSTIC SYSTEM. If no DTCs are set, go to next step.
  3. Turn ignition switch to ON position. Using scan tool, monitor battery voltage and record results. Using voltmeter, measure and record voltage between battery terminals. Compare both voltage measurements. If difference in voltages is less than one volt, test is complete. If difference in voltages is one volt or greater, go to next step.
  4. Using scan tool, actuate generator field circuit. Using 12-volt test light, backprobe between ground and generator field driver terminal at generator. Voltage should cycle from zero volts to battery voltage every 1.4 seconds. Wiggle field terminal harness from generator to Powertrain Control Module (PCM). If any interruption of voltage cycling occurred, repair harness where wiggling caused failure. See WIRING DIAGRAMS . Perform CHARGING SYSTEM VERIFICATION TEST  under VERIFICATION TESTS. If wiggling did not interrupt voltage cycling, go to next step.
  5. Using an external voltmeter, check voltage between generator B+ terminal and battery positive terminal. See Fig 1 or Fig 2 . Ensure voltmeter wires are clear of moving engine parts. Start engine and observe voltmeter. If voltage is less than 0.4 volt, go to next step. If voltage is 0.4 volt or greater, repair high resistance in circuit between generator B+ terminal and battery positive terminal. See WIRING DIAGRAMS . Perform CHARGING SYSTEM VERIFICATION TEST  under VERIFICATION TESTS.
  6. Using scan tool, record DTCs. If any DTCs are set, perform appropriate test in accordance with DTC retrieved. See SCAN TOOL DTC MESSAGES  table under SELF-DIAGNOSTIC SYSTEM. If no DTCs are set, go to next step.
  7. Turn ignition switch to OFF position. Using an external voltmeter, check voltage between generator case and battery negative terminal. Start engine. If voltage is 0.1 volt or greater, repair high resistance in circuit between generator battery negative terminal and battery negative terminal. See WIRING DIAGRAMS . Perform CHARGING SYSTEM VERIFICATION TEST  under VERIFICATION TESTS. If voltage is less than 0.1 volt, go to next step.
  8. Turn ignition switch to ON position. Using scan tool, monitor and record battery voltage. Turn ignition switch to OFF position. Disconnect Powertrain Control Module (PCM) harness connector. Turn ignition switch to ON position. Using voltmeter, measure voltage between ground and terminals No. 48 and 50 (both Red/White wires) at PCM harness connector.

    If voltage is within one volt of scan tool voltage, repair high resistance in Red/White wire(s) between PCM and power distribution center. See WIRING DIAGRAMS . Perform CHARGING SYSTEM VERIFICATION TEST  under VERIFICATION TESTS. If voltage is not within one volt of scan tool voltage, replace PCM. Perform CHARGING SYSTEM VERIFICATION TEST  under VERIFICATION TESTS.

Fig 1: Identifying Generator Terminals (Denso Generator)
G99I02121Courtesy of CHRYSLER CORP.
Fig 2: Identifying Generator Terminals (Bosch Generator)
G99A02122Courtesy of CHRYSLER CORP.
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