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Gasoline 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. NOTE: 12-volt test light should blink on and off every 1.4 seconds.
  3. Turn ignition switch to ON position. Using scan tool, actuate generator field circuit. Using a 12-volt test light, backprobe generator field driver circuit terminal at rear of generator. Wiggle field terminal harness from generator to Powertrain Control Module (PCM) and Auto Shut Down (ASD) relay. 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.
  4. 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.
    5. NOTE: Before starting engine, ensure all test equipment wires are clear of moving engine parts.
  5. Measure voltage between positive battery terminal and generator B+ terminal. Start engine. If voltage is less than 0.4 volt, go to next step. If voltage is 0.4 volt or greater, repair high resistance in B+ circuit between generator and battery. See WIRING DIAGRAMS . Perform CHARGING SYSTEM VERIFICATION TEST  under VERIFICATION TESTS.
  6. With engine running, measure voltage between generator case and negative battery terminal. If voltage is less than 0.1 volt, go to next step. If voltage is 0.1 or greater, repair high resistance in generator ground circuit between generator case and negative battery terminal. See WIRING DIAGRAMS . Perform CHARGING SYSTEM VERIFICATION TEST  under VERIFICATION TESTS.
  7. Using scan tool, monitor and record battery voltage. Measure battery voltage between positive and negative field circuits. 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.
  8. Using scan tool, monitor and record battery voltage. Turn ignition switch to OFF position. Disconnect PCM harness connector. Turn ignition switch to ON position. Measure voltage between ground and fused B+ terminal at PCM harness connector. Compare both voltage measurements.

    If voltage is within one volt of scan tool recorded reading, replace PCM. Perform CHARGING SYSTEM VERIFICATION TEST  under VERIFICATION TESTS. If voltage is not within one volt of scan tool recorded reading. Repair high resistance in B+ circuit between PCM and battery. See WIRING DIAGRAMS . Perform CHARGING SYSTEM VERIFICATION TEST  under VERIFICATION TESTS.

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