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Test A: Charging System Test

  1. If diagnostic system check was not performed, perform ENGINE ELECTRICAL DIAGNOSTIC SYSTEM CHECK  under ON-VEHICLE TESTING. If diagnostic system check was performed, go to next step.
  2. The battery must be above a 70 percent state of charge. If battery inspection test was performed, go to next step. If battery inspection test was not performed, see BATTERY TESTING & INSPECTION  under ON-VEHICLE TESTING.
  3. Install a scan tool. Start the engine. With a scan tool, command the GEN-L Terminal OFF and ON. Observe the IGNITION 1 SIGNAL parameter. The voltage should change with each command. If voltage changes with each command, go to next step. If voltage does not change with each command, go to step  8 .
  4. Turn ON the following accessories:
    • Headlights - high beams.
    • A/C on MAX.
    • Blower fan - ON high.
    • Heated seats - if equipped.
    With a scan tool, observe the ignition 1 signal parameter in the engine data list. Increase engine speed to 2500 RPM. Voltage should 12.0-15.5 volts. If voltage is as specified, go to next step. If voltage is not as specified, go to step  6 .
  5. Turn OFF all accessories. Turn OFF the ignition. Connect a carbon pile tester to the vehicle. Connect an inductive ammeter probe to the output circuit of the generator. Start the engine. With a scan tool, command the GEN-L Terminal ON. Increase engine speed to 2500 RPM. Adjust the carbon pile as necessary in order to obtain maximum current output of greater than or equal to 94-amps. If amperage is as specified, system is okay. If amperage is not as specified, go to step  7 .
  6. If the voltage measured is greater than 15.5 volts, go to step  12 . If the voltage measured is not greater than 15.5 volts, go to next step.
  7. Leave the vehicle accessories ON or maintain load test value. Maintain engine speed at 2500 RPM. Measure the voltage between the generator output terminal and the generator metal housing. If B+ voltage is measured, go to step  14 . If B+ voltage is not measured, go to step  9 .
  8. Turn ignition switch to OFF position. Disconnect generator harness connector. Turn ON the ignition, with the engine OFF. Measure voltage between ground and generator harness connector terminal "B" (Red wire). Using scan tool, command GEN-L Terminal ON and OFF. Voltage should be zero volts with generator commanded OFF, and greater than 4.7 volts with generator commanded ON. If voltage is as specified, go to step  14 . If voltage is not as specified, go to step  11 .
  9. Maintain engine speed at 2500 RPM and continue to operate generator at load test value. Using a DVOM, measure voltage drop between battery negative terminal and the metal housing of the generator. If voltage drop is 0.5 volt or less, go to next step. If voltage drop is greater than 0.5 volt, go to step  15 .
  10. Maintain engine speed at 2500 RPM and continue to operate generator at load test value. Using a DVOM, measure the voltage drop from the output terminal of the generator to the positive terminal on the battery. If voltage drop is 0.5 volt or less, go to step  14 . If voltage drop is greater than 0.5 volt, go to step  16 .
  11. Test Red wire for a short or open between generator harness connector terminal "B" and PCM harness connector C2 terminal No. 61. See WIRING DIAGRAMS  . If problem does not exist, go to step  13 . If problem exists, repair as necessary. After repair, go to step After repair, go to step  19 .
  12. Test Orange wire (if equipped, this wire would be located at generator harness connector terminal "D") for a high resistance or open. If problem does not exist, go to step  14 . If problem exists, repair as necessary. After repair, go to step  19 .
  13. Inspect PCM harness connector for poor connections. If problem does not exist, go to step  17 . If problem exists, repair as necessary. After repair, go to step  19 .
  14. Inspect generator harness connector for poor connections. If problem exists, repair as necessary. After repair, go to step  19 . If problem does not exist, go to step  18 .
  15. Repair high resistance or open in ground circuit of generator. See WIRING DIAGRAMS  . After repair, go to step  19 .
  16. Test B+ circuit for a high resistance or open. If problem exists, repair as necessary. After repair, go to step  19 .
  17. Replace PCM. See REMOVAL & INSTALLATION article in ENGINE PERFORMANCE. Program PCM. After repair, go to step  19 .
  18. Replace generator. See GENERATOR  under REMOVAL & INSTALLATION. After repair, go to next step.
  19. Operate system to verify repair. If system is not operating correctly, repeat test beginning at step  2 .
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