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Test A: Charging System Test

  1. If engine electrical diagnostic system check was performed, go to next step. If engine electrical diagnostic system check was not performed, go to ENGINE ELECTRICAL DIAGNOSTIC SYSTEM CHECK  under ON-VEHICLE TESTING.
  2. Turn off all electrical loads. Connect scan tool to Data Link Connector (DLC). Start engine. Using scan tool, observe IGNITION 1 parameter from PCM data list. If IGNITION 1 parameter indicates voltage is 11-15.5 volts, go to next step. If IGNITION 1 parameter indicates voltage is not 11-15.5 volts, problem may be intermittent. Check wiring and connections, and see PRELIMINARY INSPECTION  under TROUBLE SHOOTING.
    3. NOTE: Green POWER light of tester should remain illuminated while tester is being used.
  3. Turn ignition switch to OFF position. Using charging system Electronic Generator Tester (J-41450-B), connect Red lead to generator output terminal and Black lead to metal generator housing. If Green POWER light does not illuminate, go to next step. If Green POWER light illuminates, go to step  6 .
  4. Using a DVOM, measure voltage between output terminal of generator and generator metal housing. If battery voltage does not exist, go to next step. If battery voltage exists, go to step  14 .
  5. Using a DVOM, measure voltage between output terminal of generator and battery negative terminal. If battery voltage exists, go to step  12 . If battery voltage does not exist, go to step  11 .
    6. CAUTION: Make sure load is completely turned off before connecting or disconnecting carbon pile load tester to battery.
  6. Connect carbon pile tester to battery. Connect inductive ammeter to output circuit of generator. Disconnect generator harness connector. Locate matching harness connector on charging system electronic generator tester and connect it to generator. If Red DIAGNOSTIC light illuminates, go to next step. If Red DIAGNOSTIC light does not illuminate, go to step  13 .
  7. Start engine and allow to idle for 30 seconds. Increase engine speed to 2500 RPM. If Red DIAGNOSTIC light does not illuminate, go to next step. If Red DIAGNOSTIC light illuminates, go to step  15 .
  8. Maintain engine speed at 2500 RPM. Turn On load of carbon pile tester and increase load until load is equal to test value of generator. See GENERATOR SPECIFICATIONS  . If Red DIAGNOSTIC light does not illuminate, go to next step. If Red DIAGNOSTIC light illuminates, go to step  15 .
  9. Maintain engine speed at 2500 RPM and continue to operate generator at load test value. See GENERATOR SPECIFICATIONS  . Using a DVOM, measure voltage drop between generator output terminal and positive battery terminal. If voltage drop is less than 0.5 volt, go to next step. If voltage drop is 0.5 volt or more, go to step  11 .
  10. Maintain engine speed at 2500 RPM and continue to operate generator at load test value. See GENERATOR SPECIFICATIONS  . Using a DVOM, measure voltage drop between generator metal housing and negative battery terminal. If voltage drop is less than 0.5 volt, go to step  16 . If voltage drop is 0.5 volt or more, go to step  12 .
  11. Repair high resistance or open in generator battery positive voltage circuit. See WIRING DIAGRAMS  . After repairs are made, go to step  16 .
  12. Repair high resistance or open in ground circuit of generator. See WIRING DIAGRAMS  . After repairs are made, go to step  16 .
  13. Disconnect charging system electronic generator tester harness connector from generator, but leave alligator clips connected so Green POWER light remains illuminated. Connect a jumper wire with an in-line 100-ohm resistor between the charging system electronic generator tester harness connector terminal "B" and a good ground. If Red DIAGNOSTIC light does not illuminate, go to next step. If Red DIAGNOSTIC light illuminates, go to step  15 .
  14. There is a problem with the charging system electronic generator tester. Refer to manufacturers instructions, how to test the charging system electronic generator tester for proper operation. If the tester has been repaired or replaced, go to step  3 .
  15. Replace generator. See GENERATOR  under REMOVAL & INSTALLATION. After repairs are made, go to next step.
  16. Retest system to verify repair. If problems were found and corrected, system is okay. If problem was not found, go to step  2 .
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