Home ReviewsRefund Car not listed?
Home/Chrysler/300M/Chrysler 300M I (1998-2004)/Repair manual/Charging System/Charging System - Generators & Regulators: Diagnosis
Contents Wiring diagrams Section: Charging System All sections

Charging System - Generators & Regulators: Diagnosis Chrysler 300M I

Charging System 1 illustration ~5707 words

TROUBLE SHOOTING

Verify customer's concern by operating system. Inspect for blown fuses, damaged fusible links, wiring or harness connectors. Check for loose or frayed drive belt, loose generator ground wire, or corroded battery terminals. Ensure battery is fully charged, and battery cables are in good condition with connections clean and secure. Inspect generator and Powertrain Control Module (PCM) harness connections. Check engine ground strap. If fault is found, repair as necessary. If no fault is found, perform self-diagnostics. See SELF-DIAGNOSTIC SYSTEM .

ON-VEHICLE TESTING

CAUTIONWhen vehicle battery is disconnected, vehicle computer systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION article.

CURRENT OUTPUT TEST

Note. A volt/amp tester equipped with both a battery load control (carbon pile) and an inductive-type pick-up clamp is required to perform following test.

  1. Ensure battery is in good condition and is fully charged. Clean battery terminals (if necessary). Connect volt/amp tester leads to battery. Ensure carbon pile is in OFF position before connecting leads. Connect inductive pick-up clamp.
  2. Connect tachometer to engine. Start engine and raise engine speed to 2500 RPM. Slowly adjust rheostat control (load) on volt/amp tester until highest amperage reading is obtained. DO NOT allow voltage to drop less than 12 volts.
  3. Note reading on ammeter. Generator amperage reading should be greater than minimum amperage rating specification. See «GENERATOR APPLICATIONS»(ref-95600-S38553029332001040300000) table under DESCRIPTION. If amperage is not within minimum specification, go to next step.
  4. Rotate load control knob to OFF position. Continue to hold engine speed at 2500 RPM. Output amperage should change to less than 20 amps, indicating EVR circuity is okay and charging system is functioning properly. It may take several minutes for amperage to change. If amperage does not significantly decrease, check battery. Using scan tool, check for any possible DTCs. See «SELF-DIAGNOSTIC SYSTEM»(ref-95600-S37769698942001040300000) .

VOLTAGE OUTPUT TEST

Note. Voltage output test determines if generator is capable of delivering its rated current output.

  1. Before performing this test, ensure battery is fully charged. Connect voltmeter leads across battery terminals. Record voltage with ignition switch in OFF position and all electrical loads off. Fully engage parking brake. For automatic transmission, place gear selector in Park. For manual transmission, place gear selector in Neutral.
  2. Start engine and bring to operating temperature. Record voltage with engine speed at 1500 RPM with no electrical loads. Voltage should not be greater than 2.5 volts to voltage recorded in step 1 . If voltage is not as specified, perform self-diagnostics. See «SELF-DIAGNOSTIC SYSTEM»(ref-95600-S37769698942001040300000) .
  3. Record voltage with engine speed at 2000 RPM, blower motor on high speed and headlights on high beam. Voltage should be more than 0.5 volt greater than battery voltage previously recorded in step 1 . If voltage is less than 0.5 volt above previously recorded battery voltage, check for any possible DTCs. See «SELF-DIAGNOSTIC SYSTEM»(ref-95600-S37769698942001040300000) . If voltage tests are satisfactory, reduce engine speed, and turn off blower motor, headlights and ignition switch to OFF position.

VOLTAGE DROP TEST

Note. Voltage drop tests determines amount of resistance in circuits between generator and battery.

  1. Ensure battery is in good condition and is fully charged. Clean battery terminals (if necessary). Using external voltmeter, connect positive lead to generator B+ terminal. Connect voltmeter negative lead to positive battery terminal. Connect tachometer to engine. Fully engage parking brake, and place gear selector in Neutral position. Start engine and run for 2 minutes to allow for warm-up.
  2. Turn A/C system on, blower motor to high speed and headlights on high beam. Increase engine speed to 2400 RPM. Voltmeter reading should not be greater than 0.6 volt.
  3. If voltage drop is greater than 0.6 volt, inspect, clean and tighten all connections between generator B+ terminal and positive battery terminal. Voltage drop test may be performed at each connection to locate connection with excessive resistance. If resistance tests are satisfactory, reduce engine speed, turn off all electrical loads and ignition switch to OFF position.

SELF-DIAGNOSTIC SYSTEM

CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

Note. Sebring Coupe and Stratus Coupe models have no self-diagnostic capabilities. See ON-VEHICLE TESTING .

If a problem is sensed in a monitored circuit, a DTC will be stored in PCM memory. Voltage indicator light and Malfunction Indicator Light (MIL) will illuminate, provided specific criteria are met. A specific DTC results from a particular system failure. DTC only indicates problem in circuit. It does not identify specific component failure in circuit.

If problem is repaired or ceases to exist, PCM automatically clears DTC after 40 warm-up cycles. DTCs can also be cleared using scan tool. See CLEARING DIAGNOSTIC TROUBLE CODES .

RETRIEVING DIAGNOSTIC TROUBLE CODES

Note. Diagnostic tests are written specifically for Chrysler's Diagnostic Readout Box (DRB-III) scan tool. A generic scan tool may also be used for system diagnostics, but may have limited diagnostic capability.

Ensure battery is fully charged. Connect scan tool to Data Link Connector (DLC). DLC is located below instrument panel, near steering column. If scan tool does not communicate with all modules, repair communication concerns See appropriate BODY CONTROL MODULES article in ACCESSORIES & EQUIPMENT. Using scan tool, retrieve and record DTCs. If any DTCs are retrieved, perform appropriate test procedure in accordance with DTCs retrieved. See SCAN TOOL DTC MESSAGES table. Once repairs are made, clear DTCs from PCM memory. See CLEARING DIAGNOSTIC TROUBLE CODES . On PT Cruiser, if no DTCs are retrieved, repair by symptom. See SYSTEM TESTS .

DTC (1)Scan Tool Display
P0622GENERATOR FIELD NOT SWITCHING PROPERLY
(2) P1478BATTERY TEMPERATURE SENSOR VOLTS OUT OF LIMIT
(3) P1492BATTERY TEMPERATURE SENSOR VOLTAGE TOO HIGH
(3) P1493BATTERY TEMPERATURE SENSOR VOLTAGE TOO LOW
P1594CHARGING SYSTEM VOLTAGE TOO HIGH
P1682CHARGING SYSTEM VOLTAGE TOO LOW
(1) DTCs listed in this table are only testing procedures covered in this article. For a complete listing of PCM DTCs, see appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE. (2) Applies to Concorde, Intrepid, LHS and 300M only. (3) Does not apply to Neon and PT Cruiser.
(1)DTCs listed in this table are only testing procedures covered in this article. For a complete listing of PCM DTCs, see appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.
(2)Applies to Concorde, Intrepid, LHS and 300M only.
(3)Does not apply to Neon and PT Cruiser.

SCAN TOOL DTC MESSAGES

CLEARING DIAGNOSTIC TROUBLE CODES

Powertrain Control Module (PCM) automatically clears DTC after 40 warm-up cycles. DTCs can also be cleared using scan tool.

SCAN TOOL PROBLEMS & ERROR MESSAGES

Note. For more information on scan tool and PCM diagnostics, see appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.

DIAGNOSTIC TESTS

Note. When using diagnostic tests, DO NOT skip any steps or incorrect diagnosis may result. Ensure battery is fully charged.

Diagnostic Aids

DTC is set when Powertrain Control Module (PCM) attempts to regulate generator field with no result during monitoring. Possible causes are open in Automatic Shut Down (ASD) relay output circuit, generator field resistance 5 ohms or greater, open in generator field driver circuit, generator short to ground in field driver circuit, or defective generator or defective PCM.

Diagnostic Procedure

  1. Turn ignition switch to ON position. Using scan tool, actuate generator field driver circuit. Using a 12-volt test light, backprobe generator field driver terminal connector. (Scheme 6) If 12-volt test light illuminates and flashes, go to next step. If 12-volt test light does not illuminate and flash, go to step 4.
  2. With generator field driver circuit actuated, wiggle harness from generator to Powertrain Control Module (PCM). Using scan tool, record DTCs. If P0622 resets, repair circuit as necessary where wiggling caused problem to appear. See «WIRING DIAGRAMS»(ref-95600-S25724316682001040300000). Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. If P0622 does not reset, go to next step.
  3. Turn ignition switch to OFF position. Inspect wiring harness and connector. See «WIRING DIAGRAMS»(ref-95600-S25724316682001040300000). If fault is found, repair as necessary. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. If no fault is found, test is complete.
  4. Using scan tool, record all DTCs and freeze frame data. Erase DTCs. Carefully inspect all connectors for corrosion. Disconnect generator field driver harness connector. Using scan tool, actuate generator field driver circuit. Using a 12-volt test light, probe between ground and Auto Shut Down (ASD) relay circuit terminal at generator field harness connector. See «WIRING DIAGRAMS»(ref-95600-S25724316682001040300000). If 12-volt test light illuminates, go to next step. If 12-volt test light does not illuminate, repair open in ASD relay circuit. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS.
  5. Turn ignition switch to OFF position. Disconnect PCM harness connector. Measure resistance between ground and generator field driver circuit terminal at PCM harness connector. If resistance is less than 5 ohms, repair short to ground in generator field driver circuit between generator and PCM. See «WIRING DIAGRAMS»(ref-95600-S25724316682001040300000). Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. If resistance is 5 ohms or greater, go to next step.
  6. Measure resistance of generator field driver circuit between PCM harness connector and generator field driver harness connector. See «WIRING DIAGRAMS»(ref-95600-S25724316682001040300000). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or greater, repair open in generator field driver circuit between generator and PCM. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS.
  7. Measure resistance between generator field terminals (component side) at generator. If resistance is less than 5 ohms, replace shorted generator. See «GENERATOR»(ref-95600-S00840380022001040300000) under REMOVAL & INSTALLATION. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. If resistance is 5 ohms or greater, replace PCM. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS.

Scheme 6

Scheme 6
Scheme 6

Note. Battery temperature sensor is also known as ambient air temperature sensor.

When Powertrain Control Module (PCM) monitors ambient air temperature sensor with voltage 4.9 volts or greater or less than one volt for more than 3 seconds, DTC will set. Possible causes are battery temperature sensor voltage less than one volt, high resistance in sensor ground circuit, high resistance in battery temperature sensor, or defective PCM.

  1. Turn ignition switch to ON position. Using scan tool, record DTCs. If DTC P1492 or P1493 was set with P1478, repair DTCs before proceeding. Perform «DTC P1492: BATTERY TEMPERATURE SENSOR VOLTAGE TOO HIGH»(ref-95600-S03582872482001040300000) or «DTC P1493: BATTERY TEMPERATURE SENSOR VOLTAGE TOO LOW»(ref-95600-S30543383612001040300000) . If scan tool displays good trip and equal to zero, go to next step. If scan tool does not display good trip and equal to zero, go to step 6 .
  2. Turn ignition switch to OFF position. Disconnect ambient air temperature sensor harness connector. Turn ignition switch to ON position. Using scan tool, monitor ambient air temperature sensor voltage. If voltage is less than 4.6 volts, go to step 4 . If voltage is 4.6 volts or greater, go to next step.
  3. Turn ignition switch to OFF position. Connect a jumper wire between terminals at ambient air temperature sensor harness connector. Turn ignition switch to ON position. Using scan tool, monitor ambient air temperature sensor voltage. If voltage is less than one volt, replace ambient air temperature sensor. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. If voltage is one volt or greater, go to next step.
  4. Perform voltage drop test of Black/Light Blue wire by backprobing between terminal No. 43 at PCM harness connector and terminal No. 2 at ambient air temperature sensor. Start engine and allow to idle. If voltage is less than 0.1 volt, go to next step. If voltage is 0.1 volt or greater, repair high resistance in Black/Light Blue wire between ambient temperature sensor and PCM. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS.
  5. Turn ignition switch to OFF position. Perform voltage drop test of Violet/Light Green wire by backprobing between terminal No. 52 at PCM harness connector and terminal No. 3 at ambient air temperature sensor. Start engine and allow to idle. If voltage is less than 0.1 volt, replace PCM. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. If voltage is 0.1 volt or greater, repair high resistance in Violet/Light Green wire between ambient temperature sensor and PCM. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS.
  6. Start engine and bring to operating temperature. Using scan tool, monitor parameters related to DTC, and wiggle ambient air temperature sensor harness. Look for parameter values to change and/or DTCs. Review freeze frame data. If possible, try to duplicate conditions which DTC was set. Refer to any Technical Service Bulletins (TSB) that may apply. Inspect for any chafed, pinched or pierced wire. Visually inspect harness connectors for broken, bent, pushed out or corroded terminals. If any above conditions are found, repair as necessary. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. If all above conditions are not found, test is complete.
  1. Turn ignition switch to ON position. Using scan tool, monitor ambient temperature sensor voltage. If voltage is less than 4.8 volts, go to step 6 . If voltage is 4.8 volts or greater, go to next step.
  2. Turn ignition switch to OFF position. Disconnect ambient temperature sensor harness connector. Turn ignition switch to ON position. Measure voltage between ground and Violet/Light Green wire terminal at ambient temperature sensor harness connector. See «WIRING DIAGRAMS»(ref-95600-S25724316682001040300000) . If voltage is less than 5.2 volts, go to next step. If voltage is 5.2 volts or greater, repair short to voltage in Violet/Light Green wire between ambient temperature sensor and Powertrain Control Module (PCM). Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS.
  3. Turn ignition switch to OFF position. Connect a jumper wire between terminals at ambient temperature sensor harness connector. Turn ignition switch to ON position. Using scan tool, monitor ambient temperature sensor voltage. If voltage is less than one volt, replace ambient temperature sensor. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. If voltage is one volt or greater, go to next step.
  4. Turn ignition switch to OFF position. Disconnect PCM harness connector. Measure resistance of Violet/Light Green wire between terminals at ambient temperature sensor harness connector and PCM harness connector. See «WIRING DIAGRAMS»(ref-95600-S25724316682001040300000) . If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or greater, repair open in Violet/Light Green wire between ambient temperature sensor and PCM. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS.
  5. Measure resistance of Black/Light Blue wire between ambient temperature sensor harness connector and PCM harness connector. See «WIRING DIAGRAMS»(ref-95600-S25724316682001040300000) . If resistance is less than 5 ohms, replace PCM. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. If resistance is 5 ohms or greater, repair open in Black/Light Blue wire between ambient temperature sensor and PCM. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS.
  6. Start engine and bring to operating temperature. Using scan tool, monitor parameters related to DTC, and wiggle ambient temperature sensor harness. Look for parameter values to change and/or DTCs. Review freeze frame data. If possible, try to duplicate conditions which DTC was set. Refer to any Technical Service Bulletins (TSB) that may apply. Inspect for any chafed, pinched or pierced wire. Visually inspect harness connectors for broken, bent, pushed out or corroded terminals. If any above conditions are found, repair as necessary. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. If all above conditions are not found, test is complete.
  1. Turn ignition switch to ON position. Using scan tool, monitor ambient temperature sensor voltage. If voltage is less than 0.3 volt, go to next step. If voltage is 0.3 volt or greater, go to step 5 .
  2. Turn ignition switch to OFF position. Disconnect ambient temperature sensor harness connector. Turn ignition switch to ON position. Using scan tool, monitor ambient temperature sensor voltage. If voltage is less than one volt, go to next step. If voltage is one volt or greater, replace ambient temperature sensor. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS.
  3. Turn ignition switch to OFF position. Disconnect Powertrain Control Module (PCM) harness connector. Measure resistance between ground and Violet/Light Green wire terminal at ambient temperature sensor harness connector. See «WIRING DIAGRAMS»(ref-95600-S25724316682001040300000) . If resistance is less than 100 ohms, repair short to ground in Violet/Light Green wire between ambient temperature sensor and PCM. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. If resistance is 100 ohms or greater, go to next step.
  4. Measure resistance between terminals at ambient temperature sensor harness connector. If resistance is less than 100 ohms, repair Violet/Light Green wire for short to Black/Light Blue wire between ambient temperature sensor and PCM. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. If resistance is 100 ohms or greater, replace PCM. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS.
  5. Start engine and bring to operating temperature. Using scan tool, monitor parameters related to DTC, and wiggle ambient temperature sensor harness. Look for parameter values to change and/or DTCs. Review freeze frame data. If possible, try to duplicate conditions which DTC was set. Refer to any Technical Service Bulletins (TSB) that may apply. Inspect for any chafed, pinched or pierced wire. Visually inspect harness connectors for broken, bent, pushed out or corroded terminals. If any above conditions are found, repair as necessary. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. If all above conditions are not found, test is complete.

Diagnostic Aids (Except PT Cruiser)

Voltage is monitored when engine speed is greater than 380 RPM. DTC is set when monitored battery voltage is one volt greater than requested charging system. Powertrain Control Module (PCM) turns off field driver and monitors battery voltage. If voltage remains same, DTC P1594 is set. Possible causes are short to ground in generator field driver circuit, or shorted generator, or defective PCM.

Diagnostic Procedure (Except PT Cruiser)

  1. Ensure battery is fully charged, and generator belt tension and condition are okay. Turn ignition switch to ON position. Using scan tool, actuate generator field driver circuit. Using a 12-volt test light, backprobe between ground and generator field driver circuit terminal at generator harness connector. See «WIRING DIAGRAMS»(ref-95600-S25724316682001040300000) . If 12-volt test light illuminates and flashes, go to next step. If 12-volt test light does not illuminate and flash, go to step 5 .
  2. Using scan tool, stop generator field driver actuation and monitor target charging voltage. If target charging voltage is less than 13 volts, go to step 6 . If target charging voltage is 13 volts or greater, go to next step.
  3. Start engine, and manually set engine speed to 1600 RPM. Using scan tool, monitor and compare battery voltage and target charging voltage. Observe voltage for up to 5 minutes (if necessary) for a one volt difference between battery voltage and target charging voltage. If difference in voltage is less than one volt, go to step 4 . If difference in voltage is one volt or greater, replace Powertrain Control Module (PCM). Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS.
  4. On Neon, Sebring and Stratus models, go to next step. On Concorde, Intrepid, LHS and 300M models, start engine and bring to operating temperature. Using scan tool, monitor battery temperature. Using a thermometer, measure underhood temperature near battery. If scan tool display is within 10°F of actual underhood temperature, go to next step. If scan tool display is not within 10°F of actual underhood temperature, perform «DTC P1478: BATTERY TEMPERATURE SENSOR VOLTS OUT OF LIMIT»(ref-95600-S04297775442001040900000) .
  5. Start engine and bring to operating temperature. Using scan tool, monitor parameters related to DTC, and wiggle ambient temperature sensor harness. Look for parameter values to change and/or DTCs. Review freeze frame data. If possible, try to duplicate conditions which DTC was set. Refer to any Technical Service Bulletins (TSB) that may apply. Inspect for any chafed, pinched or pierced wire. Visually inspect harness connectors for broken, bent, pushed out or corroded terminals. If any above conditions are found, repair as necessary. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. If all above conditions are not found, test is complete.
  6. Turn ignition switch to OFF position. On Concorde, Intrepid, LHS and 300M models, disconnect Powertrain Control Module (PCM) harness connector. On all models, disconnect generator field harness connector. On Concorde, Intrepid, LHS and 300M models, measure resistance between ground and Dark Green wire terminal at PCM harness connector. If resistance is less than 5 ohms, repair short to ground in Dark Green wire between generator and PCM. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. If resistance is 5 ohms or greater, go to next step. On Neon, Sebring and Stratus models, measure resistance between ground and generator field driver circuit terminal at generator field harness connector. If resistance is less than 5 ohms, replace shorted generator. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. See «GENERATOR»(ref-95600-S00840380022001040300000) under REMOVAL & INSTALLATION. If resistance is 5 ohms or greater, replace PCM. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS.
  7. Measure resistance between ground and Dark Green wire terminal at generator field harness connector. If resistance is less than 5 ohms, replace shorted generator. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. See «GENERATOR»(ref-95600-S00840380022001040300000) under REMOVAL & INSTALLATION. If resistance is 5 ohms or greater, replace PCM. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS.

Diagnostic Aids (PT Cruiser)

Voltage is monitored when engine speed is greater than 380 RPM. DTC is set when monitored battery voltage is one volt greater than requested charging system. Powertrain Control Module (PCM) turns off field driver and monitors battery voltage. If voltage remains same, DTC P1594 is set. Possible causes are short to ground in generator field driver circuit, shorted generator or PCM.

Diagnostic Procedure (PT Cruiser)

  1. Turn ignition switch to ON position. Using scan tool, actuate generator field driver circuit. Using a 12-volt test light, backprobe between ground and Dark Green wire terminal at generator. If 12-volt test light blinks, go to next step. If 12-volt test light does not blink, go to step 5 .
  2. Using scan tool, stop generator field driver actuation, and monitor target charging voltage. If target charging voltage is less than 13 volts, go to step 4 . If target charging voltage is 13 volts or greater, go to next step.
  3. Start engine, and manually set engine speed to 1600 RPM. Using scan tool, monitor and compare battery voltage and target charging voltage. Observe voltage for up to 5 minutes (if necessary) for a one volt difference between battery voltage and target charging voltage. If difference in voltage is less than one volt, test is complete. If difference in voltage is one volt or greater, replace Powertrain Control Module (PCM). Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS.
  4. Turn ignition switch to OFF position. Ensure battery is fully charged, and generator belt tension and condition are okay. Start engine and bring to operating temperature. Using scan tool in input/output mode, monitor ambient temperature sensor. Using a thermometer, measure underhood temperature near battery. If ambient temperature is within 10°F of actual underhood temperature, test is complete. If ambient temperature is not within 10°F of actual underhood temperature, replace PCM. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS.
  5. Turn ignition switch to OFF position. Disconnect PCM and generator field harness connectors. Measure resistance between ground and generator field driver circuit terminal at PCM harness connector. If resistance is less than 5 ohms, repair short to ground in field driver circuit between generator and PCM. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. If resistance is 5 ohms or greater, go to next step.
  6. Measure resistance between ground and generator field driver circuit terminal at generator. If resistance is less than 5 ohms, replace shorted generator. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. See «GENERATOR»(ref-95600-S00840380022001040300000) under REMOVAL & INSTALLATION. If resistance is 5 ohms or greater, replace PCM. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS.

DTC is set when monitored battery voltage is one volt less than requested charging system output for 14 seconds. Powertrain Control Module (PCM) turns off field driver and monitors battery voltage. If voltage remains the same, DTC P1682 is set. Possible causes are open in Auto Shut Down (ASD) relay output circuit, high resistance in battery supply circuit between generator and battery, open in field driver circuit, high resistance in ground circuit, or defective generator.

  1. Ensure battery is fully charged. Start engine and allow to idle. Using scan tool, monitor target charging voltage. If target charging voltage is less than 15.1 volts, go to next step. If voltage goal is 15.1 volts or greater, go to step 7 .
  2. On Neon, Sebring and Stratus models, go to next step. On Concorde, Intrepid, LHS and 300M models, start engine and bring to operating temperature. Using scan tool, monitor battery temperature. Using a thermometer, measure underhood temperature near battery. If battery temperature is within 10°F of actual underhood temperature, go to step 8 . If battery temperature is not within 10°F of actual underhood temperature, perform «DTC P1478: BATTERY TEMPERATURE SENSOR VOLTS OUT OF LIMIT»(ref-95600-S04297775442001040900000) .
  3. Connect an external voltmeter between generator B+ terminal and battery positive terminal. Start engine. If voltage is less than 0.4 volt, go to next step. If voltage is 0.4 volt or greater, repair high resistance in B+ circuit between generator and battery. See «WIRING DIAGRAMS»(ref-95600-S25724316682001040300000) . Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS.
  4. Connect an external voltmeter between generator case and battery negative terminal. Start engine and bring to operating temperature. If voltage is less than 0.1 volt, go to next step. If voltage is 0.1 volt or greater, repair high resistance in generator ground circuit between generator case and battery negative terminal. See «WIRING DIAGRAMS»(ref-95600-S25724316682001040300000) . Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS.
  5. Start engine and manually set engine speed to 1600 RPM. Using scan tool, monitor target charging and charging voltage. Compare both readings. If difference in voltage is less than one volt, go to step 7 . If difference is voltage is one volt or greater, go to next step.
  6. Turn ignition switch to OFF position. Disconnect Powertrain Control Module (PCM) and generator field harness connectors. Measure resistance of generator field driver circuit between PCM harness connector and generator field harness connector. See «WIRING DIAGRAMS»(ref-95600-S25724316682001040300000) . On Concorde, Intrepid, LHS and 300M models, if resistance is less than 5 ohms, go to step 8 . On Neon, Sebring and Stratus models, if resistance is less than 5 ohms, go to next step. On all models, if resistance is 5 ohms or greater, repair open in generator field driver circuit between generator and PCM. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS.
  7. Ensure generator field harness connector is still disconnected. Turn ignition switch to ON position. Using a 12-volt test light, probe between ground and Auto Shut Down (ASD) relay output circuit terminal in power distribution center. See «WIRING DIAGRAMS»(ref-95600-S25724316682001040300000) . If 12-volt test light illuminates, replace generator. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. See «GENERATOR»(ref-95600-S00840380022001040300000) under REMOVAL & INSTALLATION. If 12-volt test light does not illuminate, repair open in ASD relay output circuit. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS.
  8. Start engine and bring to operating temperature. Using scan tool, monitor parameters related to DTC, and wiggle ambient temperature sensor harness. Look for parameter values to change and/or DTCs. Review freeze frame data. If possible, try to duplicate conditions which DTC was set. Refer to any Technical Service Bulletins (TSB) that may apply. Inspect for any chafed, pinched or pierced wire. Visually inspect harness connectors for broken, bent, pushed out or corroded terminals. If any above conditions are found, repair as necessary. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. If all above conditions are not found, test is complete.

DTC is set when monitored battery voltage is one volt less than requested charging system output for 14 seconds. Powertrain Control Module (PCM) turns off field driver and monitors battery voltage. If voltage remains the same, DTC P1682 is set. Possible causes are short to ground in Auto Shut Down (ASD) relay output circuit, open in ASD relay output circuit, high resistance in battery supply circuit between generator and battery, short to ground in generator field driver circuit, high resistance in ground circuit, or defective PCM.

  1. Turn ignition switch to ON position. Using scan tool, actuate generator field circuit. Measure voltage between generator field terminals (component side). If voltage is less than 3 volts, go to next step. If voltage is greater than 3 volts, go to step 3 .
  2. Using scan tool, record all DTCs and freeze frame data. Erase DTCs. Carefully inspect connectors for corrosion. Using scan tool, actuate generator field driver circuit. Measure voltage by backprobing between ground and Dark Green/Orange wire terminal at generator. If voltage is less than 10 volts, repair open in Dark Green/Orange wire between Auto Shut Down (ASD) relay and generator. ASD relay is located in power distribution center. See «WIRING DIAGRAMS»(ref-95600-S25724316682001040300000) . Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. If voltage is 10 volts or greater, go to next step.
  3. Ensure battery is fully charged, and generator belt tension and condition are okay. Start engine. Using scan tool, monitor target charging voltage. If target charging voltage is less than 15.1 volts, go to step 9 . If target charging voltage is 15.1 volts or greater, go to next step.
  4. Start engine. Turn all accessories on, and manually set engine speed to 1600 RPM. Using scan tool, monitor target charging and charging voltage. Compare both readings. If difference in voltage is less than one volt, go to step 6 . If difference in voltage is one volt or greater, go to next step.
  5. Turn ignition switch to OFF position. Disconnect Powertrain Control Module (PCM) and generator field harness connectors. Measure resistance between ground and Dark Green wire terminal at PCM harness connector. If resistance is less than 5 ohms, repair short to ground in Dark Green wire between generator and PCM. See «WIRING DIAGRAMS»(ref-95600-S25724316682001040300000) . Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. If resistance is 5 ohms or greater, go to next step.
  6. Turn ignition switch to OFF position. Remove ASD relay from power distribution center. Measure resistance between ground and Dark Green/Orange wire at power distribution center. If resistance is less than 5 ohms, repair short to ground in Dark Green/Orange wire between power distribution center and PCM. See «WIRING DIAGRAMS»(ref-95600-S25724316682001040300000) . Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. If resistance is 5 ohms or greater, go to next step.
  7. Ensure PCM and generator field harness connectors are still disconnected. Measure resistance of Dark Green wire between terminal No. 8 at PCM harness connector and generator. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or greater, repair open in Dark Green wire between generator and PCM. See «WIRING DIAGRAMS»(ref-95600-S25724316682001040300000) . Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS.
  8. Start engine and bring to operating temperature. Measure voltage between generator case and negative battery terminal. If voltage is less than 0.1 volt, go to next step. If voltage is 0.1 volt or greater, repair high resistance in generator ground circuit between generator case and negative battery terminal. See «WIRING DIAGRAMS»(ref-95600-S25724316682001040300000) . Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS.
  9. Turn ignition switch to ON position. Measure voltage between generator B+ terminal and positive battery terminal. Start engine. If voltage is less than 0.4 volt, test is complete. If voltage is 0.4 volt or greater, repair high resistance in B+ circuit between generator and positive battery terminal. See «WIRING DIAGRAMS»(ref-95600-S25724316682001040300000) . Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS.

TEST CH-1A: CHARGING SYSTEM NO CODE TEST (PT CRUISER ONLY)

  1. Turn ignition switch to OFF position. Verify battery condition. Charge or replace battery as necessary. Inspect generator belt tension and condition. If generator belt is okay, go to next step. If generator belt is not okay, replace generator belt as necessary.
  2. Start engine. Turn all accessories on. Set engine speed to 2000 RPM for 30 seconds, then return to idle. Using scan tool, record DTCs. If any DTCs are retrieved, perform appropriate test in accordance with DTC retrieved. See «SCAN TOOL DTC MESSAGES»(ref-95600-S39908945332001040300000) table under SELF-DIAGNOSTIC SYSTEM. If no DTCs are retrieved, go to next step.
  3. Turn ignition switch to ON position. Using scan tool, actuate generator field circuit. Using a 12-volt test light, backprobe generator field terminals at generator. While monitoring 12-volt test light, wiggle field terminal back from Powertrain Control Module (PCM) and Auto Shut Down (ASD) relay. If any interruption of 12-volt test light cycling occurred, repair wiring harness where wiggling caused failure. See «WIRING DIAGRAMS»(ref-95600-S25724316682001040300000) . Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. If wiggling did not interrupt 12-volt test light cycling, go to next step.
  4. Using scan tool, record DTCs. If any DTCs are retrieved, perform appropriate test in accordance with DTC retrieved. See «SCAN TOOL DTC MESSAGES»(ref-95600-S39908945332001040300000) table under SELF-DIAGNOSTIC SYSTEM. If no DTCs are retrieved, go to next step.
  5. Using an external voltmeter, measure voltage between generator B+ terminal and battery positive terminal. Ensure voltmeter wires are clear of moving engine parts. Start engine and observe voltmeter. If voltage is less than 0.4 volt, go to next step. If voltage is 0.4 volt or greater, repair high resistance in B+ circuit between generator and battery positive terminal. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS.
  6. Using an external voltmeter, check voltage between generator case and battery negative terminal. Start engine. If voltage is 0.1 volt or greater, repair high resistance in generator ground circuit between generator and battery negative terminal. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. If voltage is less than 0.1 volt, go to next step.
  7. Using scan tool, monitor and record battery voltage. Measure and record voltage between battery terminals. Compare both readings. If difference in voltage is one volt or greater, test is complete. If difference is voltage is less than one volt, go to next step.
  8. Using scan tool, monitor and record battery voltage. Turn ignition switch to OFF position. Disconnect PCM harness connector. Turn ignition switch to ON position. Measure voltage between ground and terminal No. 46 (Red/White wire) at PCM harness connector. If voltage is within one volt of scan tool voltage, repair high resistance in Red/White wire between PCM and power distribution center. See «WIRING DIAGRAMS»(ref-95600-S25724316682001040300000) . Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS. If voltage is not within one volt of scan tool voltage, replace PCM. Perform «CHARGING SYSTEM VERIFICATION TEST»(ref-95600-S42312034422001040300000) under VERIFICATION TESTS.

CHARGING SYSTEM VERIFICATION TEST

CAUTIONIf Powertrain Control Module (PCM) is replace, correct Vehicle Identification Number (VIN) and mileage must to be programmed. If information is not programmed, Anti-Lock Brake System (ABS) and Air Bag Control Module (ACM) DTCs will be set.
  1. Inspect vehicle to ensure all engine components are connected. Reassemble and connect components as necessary. Connect scan tool to Data Link Connector (DLC). DLC is located below instrument panel, near steering column. Using scan tool, enter correct Vehicle Identification Number (VIN) and mileage into Powertrain Control Module (PCM). Using scan tool, clear DTCs.
  2. Perform «VOLTAGE OUTPUT TEST»(ref-95600-S02120286632001040300000) under ON-VEHICLE TESTING. Increase engine speed to 2000 RPM for at least 30 seconds, and return to idle. Turn ignition switch to OFF, then to ON positions.
  3. Transfer secret key data from SKIM to PCM using scan tool, by selecting THEFT ALARM, SKIM, MISC. Using Personal Identification Number (PIN) code, place SKIM in secured access mode. PIN code is available from vehicle invoice or Chrysler customer center. Select UPDATE SECRET KEY data. Data will be transferred from SKIM to PCM. Go to next step.
  4. Using scan tool, check for stored DTCs. If repaired DTC has reset, repair is not complete, return to appropriate DTC test under DIAGNOSTIC TESTS. If any other DTC exists, perform appropriate test in accordance to DTC retrieved. See «SCAN TOOL MESSAGES»(ref-95600-S39908945332001040300000) table under SELF-DIAGNOSTIC SYSTEM. If no other DTCs exist, repair is complete.

More articles — Charging System - Generators & Regulators