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Test NTC-25: Checking Charging System

NOTE: Possible causes are: DTCs present, generator field terminals intermittently defective, generator ground circuit high resistance, B+ circuit high resistance, PCM defective or generator belt defective.
NOTE: Verify battery is in satisfactory condition before performing procedure.
  1. Turn ignition off. Inspect generator belt tension and condition. If generator belt is okay, go to next step. If generator belt is not okay, replace as necessary.
  2. Start engine. Using scan tool, set engine speed to 1600 RPM for 30 seconds. Using scan tool, return engine to idle and read DTCs. If charging system DTCs are not present, go to next step. If any charging system DTCs are present, go to DTC MESSAGES & CODES  table.
  3. Turn ignition off. Turn ignition on with engine off. Using scan tool, actuate generator field driver. Using a DVOM, backprobe generator field driver circuit (Dark Green wire) at generator field driver 2-pin connector on back of generator. Voltage should cycle from zero to battery voltage every 1.4 seconds. While observing DVOM, wiggle wiring harness from back of generator to PCM and to ASD relay. PCM is located to left of Power Distribution Center (PDC) in engine compartment. If voltage cycling was not interrupted, go to next step. If voltage cycling was interrupted, repair wiring harness where wiggling caused problem to appear. Perform TEST VER-3A: CHARGING VERIFICATION  .
  4. Start engine. Using scan tool, read DTCs. If charging system DTCs are not present, go to next step. If charging system DTCs are present, go to DTC MESSAGES & CODES  table.
  5. Turn ignition off. Ensure all wires are clear of moving engine parts. Start engine. Using a DVOM, check voltage between generator case and battery negative terminal. If voltage is .1 volt or less, go to next step. If voltage is more than .1 volt, repair generator ground high resistance between generator and negative battery terminal. Perform TEST VER-3A: CHARGING VERIFICATION  .
  6. Turn ignition off. Connect a DVOM between generator B+ terminal and battery positive terminal. Ensure all wires are clear of moving engine parts. Start engine. If voltage is .4 volts or less, go to next step. If voltage is more than .4 volts, repair B+ circuit for high resistance between generator and battery. Perform TEST VER-3A: CHARGING VERIFICATION  .
  7. Turn ignition off. Turn ignition on with engine off. Using scan tool, read battery voltage and record. Using a DVOM, check battery voltage at battery and record. Compare 2 voltage readings. If difference is one volt or more, go to next step. If difference is less than one volt, test is complete.
  8. Using scan tool, read battery voltage and record. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector C2 (located nearest to rear of vehicle). PCM is located to left of Power Distribution Center (PDC) in engine compartment. Inspect electrical connector and clean/repair as necessary. Using a DVOM, check voltage of fused B+ circuit (Red/Tan wire) at PCM connector terminal No. 46 and record. Compare 2 voltage readings. If voltage at PCM is not within one volt of scan tool reading, go to next step. If voltage at PCM is within one volt of scan tool reading, repair B+ circuit high resistance between PCM and battery. Perform TEST VER-3A: CHARGING VERIFICATION  .
  9. Turn ignition off. If no other potential causes are remaining, PCM is assumed to be defective. Replace PCM. Perform TEST VER-3A: CHARGING VERIFICATION  .
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