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Test A: Charging System Test

  1. If diagnostic system check was not performed, perform ENGINE ELECTRICAL DIAGNOSTIC SYSTEM CHECK  under SELF-DIAGNOSTIC SYSTEM. If diagnostic system check was performed, go to next step.
  2. Turn off all electrical loads. Connect scan tool to DLC. DLC is located under driver's side of instrument panel. Start engine. Using scan tool, observe Battery Voltage parameter in Electronic Control Module (ECM) data list. If voltage is 11-15.5 volts, problem is intermittent. Check wiring and connections. If voltage is not 11-15.5 volts, go to next step.
  3. Turn ignition switch to OFF position. Connect charging system tester to battery. Operate engine at 2500 RPM. Adjust carbon pile as necessary in order to obtain maximum current output. If current output is not 74-94 amps, go to next step. If current output is 74-94 amps, go to step  9 .
  4. Maintain engine speed at 2500 RPM and continue to operate generator at load test value. Measure voltage drop between generator output terminal and battery positive terminal. If voltage drop is 0.5 volt or less, go to next step. If voltage drop is greater than 0.5 volt, go to step  6 .
  5. Maintain engine speed at 2500 RPM and continue to operate generator at load test value. Measure voltage drop between battery negative terminal and generator metal housing. If voltage drop is 0.5 volt or less, go to step  8 . If voltage drop is greater than 0.5 volt, go to step  7 .
  6. Check Red wire between generator output terminal and battery positive terminal for high resistance or poor connections. See WIRING DIAGRAMS  . If problem exists, repair as necessary. After repair, go to step  9 . If problem does not exist, go to next step.
  7. Repair high resistance or poor connection in ground circuit between battery negative terminal and generator housing. See WIRING DIAGRAMS  . After repair, go to step  9 .
  8. Replace generator. See GENERATOR  under REMOVAL & INSTALLATION.
  9. Operate system to verify repair. If system is not operating correctly, repeat test beginning at step  2 .
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