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Test A: Charging System Test

  1. Did you review the DESCRIPTION & OPERATIONS? If so, go to next step. If not, go to SYMPTOMS - ENGINE ELECTRICAL  under TROUBLE SHOOTING.
  2. Turn OFF all electrical loads. Start the engine. Install a scan tool. With a scan tool view the BATTERY VOLTAGE PARAMETER in the POWERTRAIN DATA LIST. Does the scan tool indicate the voltage is within the specified value of 11.0-15.5V? If so, go to next step. If not, see INTERMITTENTS  in SYMPTOMS - ENGINE ELECTRICAL.
  3. Turn OFF the ignition. Connect a charging system tester to the battery (follow the manufacturer's instructions). Operate the engine at 2500 RPM. Adjust the carbon pile as necessary in order to obtain the maximum current output. Is the generator output within 10 A of the specified value of 89A? If so, go to step  9 . If not, go to next step.
  4. Maintain the engine speed at 2500 RPM and continue to operate the generator at the load test value. Measure the voltage drop between the generator output terminal and the battery positive terminal. Is the voltage above the specified value of 0.5V? If so, go to step  6 . If not, go to next step.
  5. Maintain the engine speed at 2500 RPM and continue to operate the generator at the load test value. Measure the voltage drop between the battery negative terminal and the generator metal housing. Is the voltage above the specified value of 0.5V? If so, go to step  7 . If not, go to step  8 .
  6. Test the battery positive circuit between the generator output terminal and the battery positive terminal for a high resistance. Did you find and correct the condition? If so, go to step  9 . If not, go to next step.
  7. Repair the high resistance in the ground circuit between the generator housing and the battery negative terminal. After repair is complete, go to step  9 .
  8. Replace the generator. See GENERATOR  under REMOVAL & INSTALLATION. After repair is complete, go to next step.
  9. Operate the system in order to verify the repair. Did you correct the condition? If so, then system is okay. If not, go to step  3 .