Generator Output Wire Resistance Test
WARNING: This page is about a different car, the 1995 Plymouth Voyager, 1995 Plymouth Grand Voyager, 1995 Dodge Grand Caravan, 1995 Dodge Caravan, and 1995 Chrysler Town & Country. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
Resistance test will show amount of voltage drop across generator output wire between generator B+ terminal and positive battery post.
- Ensure battery is fully charged. Turn ignition off. Disconnect negative battery cable. Disconnect generator output wire from generator B+ terminal. See Fig 1
- Using a DC ammeter (0-150 amps), connect positive lead to generator B+ terminal. Connect negative lead to generator output wire. See Fig 2 Using a voltmeter (0-18 volts minimum), connect positive lead to generator output wire. Connect negative lead to positive battery cable.CAUTION: Generator has 2 field terminals: generator field driver (Dark Green or Dark Green/White wire) and ASD relay output (Dark Green/Orange or Dark Blue wire). DO NOT connect generator ASD relay output terminal to ground.
- Remove air hose between PCM and air cleaner. Connect jumper wire between ground and generator field driver terminal (Dark Green or Dark Green/White wire) on back of generator.
- Connect engine tachometer, and reconnect negative battery cable. Connect carbon pile rheostat between battery terminals. Ensure carbon pile is in OFF position before connecting leads.
- Start engine, and immediately reduce engine speed to idle. Adjust engine speed and carbon pile to maintain 20-amp current flow in circuit. Note voltmeter reading. Voltage drop should be .5 volt or less.
- If voltage drop exceeds .5 volt, inspect, clean and tighten all connections between generator B+ terminal and positive battery post. Perform voltage drop test at each connection to locate connection with excessive resistance. If resistance is okay, reduce engine speed, and turn off carbon pile and ignition.
- Disconnect negative battery cable. Remove test ammeter, voltmeter, carbon pile and tachometer. Remove jumper wire between generator field driver terminal and ground. Connect generator output wire to generator B+ terminal. Reconnect negative battery cable. Connect hose between PCM and air cleaner, if removed.