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Charging System Test

  1. Turn off all electrical loads. Start engine. Connect scan tool. Using scan tool, observe IGNITION 1 parameter in Powertrain Control Module (PCM) data list. If scan tool indicates voltage is 11.0-15.5 volts, go to next step. If scan tool does not indicate voltage is 11.0-15.5, check for intermittent or poor connections.
  2. Turn ignition off. Connect charging system tester to battery. Operate engine at 2500 RPM. Adjust carbon pile as necessary to obtain maximum current output (KCB2 is 70 amps; NCB1 is 88 amps). If current output is not within 10 amps of specified value, go to next step. If current output is within 10 amps of specified value, go to step  8 .
  3. Maintain engine speed at 2500 RPM and continue to operate generator at load test value. Using a DVOM, measure voltage drop between generator output terminal and battery positive terminal. If voltage drop is less than 0.5 volt, go to next step. If voltage drop is more than 0.5 volt, go to step  5 .
  4. Maintain engine speed at 2500 RPM and continue to operate generator at load test value. Using a DVOM, measure voltage drop between generator housing and battery negative terminal. If voltage drop is less than 0.5 volt, go to step  7 . If voltage drop is more than 0.5 volt, go to step  6 .
  5. Check Red wire between generator output terminal and battery positive terminal for high resistance or poor connections. See WIRING DIAGRAMS  . If problem was found, repair as necessary and go to step  8 . If problem was not found, go to next step.
  6. Repair high resistance or poor connection in ground circuit between generator housing and negative battery cable. See WIRING DIAGRAMS  . Go to step  8 .
  7. Replace generator. See GENERATOR  under REMOVAL & INSTALLATION.
  8. Operate system in order to verify repair.
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