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Checking Charging System Performance With No DTC'S: Testing

  1. Verify that the battery is able to pass a load test before continuing. Turn ignition on, engine not running. With the DRBIII®, read the battery voltage and record the results. Measure the battery voltage between the battery positive and negative terminals and record the results. Compare the 2 voltage readings. If the voltage difference is less than one volt, go to next step. If the resistance is more than one volt, go to step  8.
  2. Turn the ignition on, engine not running. Measure the voltage between the generator B+ terminal and the battery positive post. Ensure all wires are clear of the engine's moving parts. Start the engine. If the voltage is above .4 volt, repair the excessive resistance in the battery positive circuit between the generator and battery. If the resistance is not above .4 volt, go to next step.
  3. Turn ignition on, engine not running. Record all DTC's and freeze frame data, then erase codes. Carefully inspect all connectors for corrosion or spread terminals before continuing. With the DRBIII®, actuate the generator field driver. Measure the voltage of the (K125) generator field source circuit by backprobing the back of generator field harness connector. If the voltage is above 10 volts, go to next step. If the voltage is not above 10 volts, repair the (K125) generator field source circuit for an open of short to ground. Perform POWERTRAIN VERIFICATION TEST VER-3 (GAS)  under VERIFICATION TESTS.
  4. 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 negative post. If the voltage is above .10 volt, repair the excessive resistance in the generator ground circuit between the generator case and battery ground side. Perform POWERTRAIN VERIFICATION TEST VER-3 (GAS)  under VERIFICATION TESTS. If the voltage is not above .10 volt, go to next step.
  5. Turn the ignition off. Disconnect the generator field harness connector at back of the generator. Measure resistance across the generator field terminals at the generator. If the resistance is above 15 ohms, replace or repair the generator as necessary. Perform POWERTRAIN VERIFICATION TEST VER-3 (GAS)  under VERIFICATION TESTS. If the resistance is not above 15 ohms, go to next step.
  6. Disconnect the PCM harness connectors. Measure the resistance of the (K20) generator field driver circuit between the PCM harness connector and the generator harness connector. If the resistance is below 5 ohms, go to next step. If the resistance is not below 5 ohms, repair the open in the (K20) gen field control circuit. Perform POWERTRAIN VERIFICATION TEST VER-3  under VERIFICATION TESTS. (GAS)
    7. NOTE: Before continuing, check the PCM harness connector terminals for corrosion, damage, or pushed out terminals. Repair as necessary.
  7. If there are no possible causes remaining, replace and program the PCM. See PROGRAMMING . Perform POWERTRAIN VERIFICATION TEST VER-3 (GAS)  under VERIFICATION TESTS.
  8. Turn ignition off. Battery condition must be verified prior to this test. Inspect the generator belt tension and condition. If the belt is okay, go to next step. If the belt is not okay, repair as necessary. Perform POWERTRAIN VERIFICATION TEST VER-3 (GAS)  under VERIFICATION TESTS.
  9. Start the engine. Turn on all accessories. Raise engine speed to 2000 RPM for 30 seconds then return to idle. With the DRBIII®, read DTC's. If there are any "CHARGING SYSTEM" trouble codes, see SCAN TOOL DTC MESSAGES  table. Perform POWERTRAIN VERIFICATION TEST VER-3 (GAS)  under VERIFICATION TESTS. If there are not any codes, go to next step.
  10. Turn ignition on, engine not running. With the DRBIII®, actuate the generator field driver. Using a 12-volt test light, backprobe the generator field driver terminal at the back of the generator. The test light should blink ON and OFF every 1.4 seconds. While monitoring the 12-volt test light, wiggle the field terminals to the PCM and ASD relay. If there was any interruption in the normal cycle of the test light, repair the wire or connector where the wiggling interrupted the voltage cycle. Perform POWERTRAIN VERIFICATION TEST VER-3 (GAS)  under VERIFICATION TESTS. If there was no interruption, test is complete.
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