Alternator & Regulator Dodge Caravan II

DESCRIPTION

Chrysler Motors light trucks use either a Bosch or a Denso alternator. The alternator consists of a rotor, stator, rectifiers, front and rear covers and drive pulley. Voltage regulation is controlled by the Single Board Engine Controller (SBEC) on all models except diesel. On diesel models, voltage regulation is controlled by a transistorized voltage regulator.

ALTERNATOR APPLICATION

OPERATION

The SBEC monitors critical input to control fuel injection, ignition, emission and other engine management functions. The SBEC has also been programmed to monitor several charging system related circuits

1. Battery feed to SBEC
2. Alternator field control
3. Battery charging voltage (high and low)

If a problem is sensed in a monitored circuit, a fault code is stored in the SBEC's memory and the CHECK ENGINE light will be turned on (with a few exceptions). Fault codes can be read using the CHECK ENGINE light or with the Chrysler Diagnostic Readout Box-II (DRB-II).

Note. Fault codes remain in memory for 50 engine starts. Fault is erased from memory if failure does not reoccur .

For certain fault codes, CHECK ENGINE light will illuminate and engine controller will enter limp-in mode. In limp-in mode, engine controller attempts to compensate for particular component failure by substituting information from other sources. This allows vehicle operation until proper repairs are made.

BELT TENSION

BELT TENSION

INITIAL CHECKS

Before proceeding with charging system diagnosis, ensure

1. Battery is fully charged and in good condition
2. Battery cables are in good condition with connections clean and secure
3. Alternator belt is in good condition and properly tightened
4. Alternator and SBEC wiring harness connections are clean and tight
5. Engine ground strap is in place

UNSTEADY OR LOW CHARGING

Check for loose alternator belt, charging resistance too high, defective alternator, loose alternator ground wire or corroded battery terminals.

OVERCHARGING

Check for grounded alternator field wiring or faulty alternator.

NOISY ALTERNATOR

Check for worn alternator bearings or loose alternator mounting.

Note. For additional trouble shooting information, refer to the TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section.

TESTING (ON-VEHICLE)

Note. ALTERNATOR OUTPUT WIRE RESISTANCE TEST will show amount of voltage drop across alternator output wire between alternator BAT terminal and positive battery post. When 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 the GENERAL INFORMATION Section before disconnecting battery.

ALTERNATOR OUTPUT WIRE RESISTANCE TEST

1. Charge battery as necessary. Turn ignition off. Disconnect negative battery cable. Disconnect alternator output wire from alternator BAT terminal.
2. Using a 0-150-ampere scale DC ammeter, connect positive ammeter lead to alternator BAT terminal and negative lead to disconnected alternator output wire. (Scheme 1)and (Scheme 2).
3. Using a voltmeter (0-18 volts minimum), connect positive voltmeter lead to disconnected alternator output wire and negative lead to positive battery cable. CAUTION: Alternator has 2 field terminals. One field terminal has Dark Green wire and other field terminal has Dark Blue wire. DO NOT connect jumper wire to alternator field terminal Dark Blue wire.
4. On Caravan, Town & Country and Voyager, remove air hose between SBEC and air cleaner. On all models, connect one end of jumper wire to ground and other end to alternator field terminal Dark Green wire on rear side of alternator.
5. 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.
6. Start engine. Reduce engine speed to idle. Adjust engine speed and carbon pile to maintain 20 amps flowing in circuit. Observe voltmeter reading. Voltage drop should be.5 volt or less.
7. If voltage drop is more than.5 volt, inspect, clean and tighten all connections between alternator BAT terminal and positive battery post. Voltage drop test may be performed at each connection to locate connection with excessive resistance. If resistance tests satisfactorily, reduce engine speed, turn off carbon pile and ignition switch.
8. Disconnect negative battery cable. Remove test ammeter, voltmeter, carbon pile and tachometer. Remove jumper wire between alternator Dark Green field wire and ground. Connect alternator output wire to alternator BAT terminal. Reconnect negative battery cable and hose between SBEC and air cleaner.

Scheme 1

Scheme 2

CURRENT OUTPUT TEST

Note. CURRENT OUTPUT TEST determines if alternator is capable of delivering its rated current output.

1. Charge battery as necessary. Disconnect negative battery cable. Disconnect alternator output wire at alternator BAT terminal. (Scheme 3) Using a 0-150-ampere scale DC ammeter, connect positive ammeter lead to alternator BAT terminal and negative lead to disconnected alternator output wire. (Scheme 4)and (Scheme 5).
2. Using a voltmeter (0-18 volts range minimum), connect positive voltmeter lead to disconnected alternator BAT terminal and negative lead to good ground.
3. 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. CAUTION: Alternator has 2 field terminals. One field terminal has Dark Green wire and other field terminal has Dark Blue wire. DO NOT connect jumper wire to alternator field terminal Dark Blue wire.
4. On Caravan, Town & Country and Voyager, remove air hose between SBEC and air cleaner. On all models, connect one end of jumper wire to ground and other end to alternator field terminal Dark Green wire on back of alternator.
5. Start engine and reduce engine speed to idle. Adjust carbon pile and engine speed in increments until engine speed is 1250 RPM and voltmeter reads 15 volts. DO NOT allow voltage to read more than 16 volts.
6. Ammeter should read within specification. Refer to the «ALTERNATOR MINIMUM OUTPUT»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator) table. If alternator amperage reads less than specified and alternator output wire resistance is not excessive, replace alternator. After CURRENT OUTPUT TEST is completed, reduce engine speed, turn off carbon pile and ignition switch.
7. Disconnect negative battery cable. Remove test ammeter, voltmeter, tachometer and carbon pile. Remove jumper wire between alternator field terminal Dark Green wire and ground. Reconnect alternator output wire to alternator BAT terminal. Reconnect negative battery cable and hose between SBEC and air cleaner.

Scheme 3

Scheme 4

Scheme 5

VOLTAGE REGULATOR TEST (DIESEL)

1. Charge battery as necessary. Turn ignition off. Using a voltmeter with a minimum of a 0-18 volt scale, connect positive lead to positive battery post. Connect voltmeter negative lead to chassis ground. Connect a tachometer to engine (Scheme 6)
2. Start engine and adjust idle to 1250 RPM. Turn all lights and accessories off. Observe voltmeter readings. Voltage regulator is working properly if voltage readings are within specification. See the «VOLTAGE REGULATOR SPECIFICATIONS»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator) table.
3. If voltage is out of range, or is fluctuating, check the following: Voltage regulator is properly grounded Voltage regulator terminals are not spread causing an open Battery voltage is present at both terminals with ignition on
4. If voltage regulator ground connection and wiring check okay,replace regulator.

VOLTAGE REGULATOR SPECIFICATIONS

Scheme 6

TEST CH-1, BATTERY TEST

Note. Perform visual check before proceeding.

1. If battery has a built-in hydrometer, go to step 2). Turn ignition and all accessories off. Using a voltmeter, check battery voltage across battery posts. If voltage is 12.3 volts or more, go to step 3). If voltage is less than 12.3 volts, charge battery and go to step 3).
2. If battery hydrometer is Green, go to step 3). If battery hydrometer is Yellow or a bright color, replace battery and perform «TEST CH-VER, CHARGING VERIFICATION»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator__test-ch-ver-charging-verification) . If battery hydrometer is dark in color, charge battery and go to step 3).
3. Disconnect battery cables and check terminals and posts. Clean terminals and posts as necessary and retest. Connect a load tester to battery posts. Apply 300-amp load for 15 seconds. Wait 15 seconds to allow battery to stabilize. Apply a load equal to 50 percent of battery cold cranking rating for 15 seconds and record minimum voltage reading.
4. Determine battery operating temperature and check battery minimum voltage specification. See «MINIMUM VOLTAGE SPECIFICATIONS»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator) table. If voltage is not to specification, replace battery and perform «TEST CH-VER, CHARGING VERIFICATION»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator__test-ch-ver-charging-verification) . If voltage reading is to specification, go to step 5). MINIMUM VOLTAGE SPECIFICATIONS Battery Temperature Minimum Volts 70°F (21°C) Or More 9.6 60°F (16°C) 9.5 50°F (12°C) 9.4 40°F (4°C) 9.3 30°F (-1°C) 9.1 20°F (-7°C) 8.9 10°F (-12°C) 8.7 0°F (-18°C) 8.5
5. Reconnect battery cables. Inspect alternator belt tension and condition. Replace belt as necessary. Start engine. Set engine speed to 2000 RPM for 30 seconds. Turn ignition off. Connect DRB-II. Turn ignition on with engine off. Read faults.
6. If DRB-II displays BATTERY TEMP SENSOR OUT OF LIMIT, replace SBEC and perform the «TEST CH-VER, CHARGING VERIFICATION»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator__test-ch-ver-charging-verification) test. If DRB-II displays ALTERNATOR FIELD NOT SWITCHING PROPERLY, proceed to «TEST CH-2, ALTERNATOR FIELD NOT SWITCHING PROPERLY»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator__test-ch-2-alternator-field-not-switching) . If DRB-II does not display either message, go to next step.
7. If DRB-II displays CHARGING SYSTEM VOLTAGE TOO LOW, go to «TEST CH-3, CHARGING SYSTEM VOLTAGE LOW»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator__test-ch-3-charging-system-voltage-low) . If DRB-II displays CHARGING SYSTEM VOLTAGE TOO HIGH, see «TEST CH-4, CHARGING SYSTEM VOLTAGE HIGH»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator__test-ch-4-charging-system-voltage-high) . If DRB-II does not display any faults, there are either no fault messages or faults are intermittent.
8. Actuate alternator field. Put DRB-II in voltmeter mode. Probe Dark Green wire at rear of alternator. Voltage reading should fluctuate between zero and battery voltage every 1.4 seconds. While watching DRB-II, wiggle wires between alternator harness and SBEC.
9. If there is no interruption in normal voltage cycle, test is complete. Perform «TEST CH-VER, CHARGING VERIFICATION»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator__test-ch-ver-charging-verification) . If normal voltage cycle is interrupted, repair harness as necessary. Perform «TEST CH-VER, CHARGING VERIFICATION»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator__test-ch-ver-charging-verification) .

TEST CH-2, ALTERNATOR FIELD NOT SWITCHING PROPERLY

Note. Perform TEST CH-1, BATTERY TEST before proceeding.

1. Put DRB-II in voltmeter mode and probe Dark Blue wire at back of alternator. If voltage is less than 10 volts, repair open circuit from ignition switch. If voltage is 10 volts or more, probe Dark Green wire at back of alternator. If voltage is less than 10 volts, go to step 2). If voltage is 10 volts or more, go to step 3).
2. Turn ignition off. Disconnect and inspect SBEC connector. If connector is damaged, repair as necessary. If connector is okay, turn ignition on and probe Dark Green wire at back of alternator. If voltage reading is 10 volts or more, replace the SBEC. Perform the «TEST CH-VER, CHARGING VERIFICATION»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator__test-ch-ver-charging-verification). If voltage is less than 10 volts, turn ignition off and put DRB-II in ohmmeter mode. Probe Dark Green wire in alternator harness. If resistance is less than 10 ohms, repair Dark Green wire for short to ground. If resistance is 10 ohms or more, replace alternator. Perform «TEST CH-VER, CHARGING VERIFICATION»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator__test-ch-ver-charging-verification).
3. Turn ignition off. Disconnect and inspect SBEC connector. If connector is damaged, repair as necessary. If connector is okay, turn ignition on and put DRB-II in voltmeter mode. Probe cavity No. 20. (Scheme 7) If voltage is 10 volts or more, replace the SBEC. Perform the «TEST CH-VER, CHARGING VERIFICATION»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator__test-ch-ver-charging-verification) test. If voltage is less than 10 volts, repair open circuit in Dark Green wire. Perform the «TEST CH-VER, CHARGING VERIFICATION»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator__test-ch-ver-charging-verification).

Scheme 7

TEST CH-3, CHARGING SYSTEM VOLTAGE LOW

Note. Perform TEST CH-1, BATTERY TEST before proceeding.

1. Read voltage goal. If voltage goal is 15.1 volts or more, replace SBEC. If voltage goal is less than 15.1 volts, use an external voltmeter and connect positive lead to alternator BAT (B+) and negative lead to battery positive terminal. CAUTION: Ensure all wires are clear of moving parts.
2. Start engine. If voltage is 0.4 volt or more, repair Black or Red wire for high resistance between alternator and battery. If voltage is less than 0.4 volt, turn ignition off. Using an external voltmeter, connect positive lead to alternator case and negative lead to negative battery terminal.
3. Start engine. If voltage is 0.1 volt or more, repair high resistance between alternator and negative battery cable. If voltage is less than 0.1 volt, manually set engine speed to 1600 RPM. Compare voltage goal on DRB-II and reading on external meter. If difference is 1.0 volt or more, replace alternator. If difference is less than 1.0 volt, go to «TEST CH-5, CHECKING FOR INTERMITTENT PROBLEMS»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator__test-ch-5-checking-for-intermittent-problems) .

TEST CH-4, CHARGING SYSTEM VOLTAGE HIGH

Note. Perform TEST CH-1, BATTERY TEST before proceeding.

1. Turn ignition on. Put DRB-II in voltmeter mode. Probe Dark Green wire at back of alternator. Go to step 3) if voltage is 10.0 volts or more. If voltage is less than 10.0 volts, turn ignition off. Disconnect SBEC connector; inspect and repair if necessary. If connector is okay, turn ignition on. Probe Dark Green wire at back of alternator. If voltage is 10.0 volts or more, replace SBEC. Perform «TEST CH-VER, CHARGING VERIFICATION»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator__test-ch-ver-charging-verification) . If voltage is less than 10.0 volts, go to step 2).
2. Turn ignition off. Disconnect alternator harness from alternator. Put DRB-II in ohmmeter mode. Probe Dark Green wire in alternator harness. If resistance is less than 10.0 ohms, repair Dark Green wire for short to ground. If resistance is 10.0 ohms or more, replace alternator. Perform «TEST CH-VER, CHARGING VERIFICATION»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator__test-ch-ver-charging-verification) .
3. With ignition on and engine off, read the voltage goal. If voltage goal is less than 13.0 volts, replace the SBEC. Perform the «TEST CH-VER, CHARGING VERIFICATION»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator__test-ch-ver-charging-verification) test. If voltage goal is 13.0 volts or more, start engine and read voltage goal. Compare readings. Watch for up to 5 minutes, if necessary, for a 1.0-volt difference. If voltage difference is 1.0 volt or more, replace the SBEC. Perform the «TEST CH-VER, CHARGING VERIFICATION»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator__test-ch-ver-charging-verification) test. If voltage difference is less than 1.0 volt, go to «TEST CH-5, CHECKING FOR INTERMITTENT PROBLEMS»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator__test-ch-5-checking-for-intermittent-problems) .

TEST CH-5, CHECKING FOR INTERMITTENT PROBLEMS

Note. Perform TEST CH-4, CHARGING SYSTEM VOLTAGE HIGH before proceeding.

1. Actuate alternator field. Put DRB-II in voltmeter mode. Probe Dark Green wire at back of alternator. NOTE: Voltage should cycle from zero to battery voltage every 1.4 seconds.
2. While watching DRB-II, wiggle wires between alternator and SBEC. If there is any interruption in voltage cycle, repair wire at interruption point in cycle. If there is no interruption of voltage cycle, test is complete. Perform «TEST CH-VER, CHARGING VERIFICATION»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator__test-ch-ver-charging-verification) .

TEST CH-VER, CHARGING VERIFICATION

1. Inspect and ensure all engine components are connected.
2. If SBEC has been changed and if vehicle is equipped with a factory theft alarm, start vehicle at least 20 times so alarm will activate when desired. If vehicle is a minivan or truck body, write Emission Maintenance Reminder (EMR) mileage into new SBEC.
3. Connect DRB-II to engine diagnostic and erase faults.
4. Ensure no other charging system problems remain by doing the following: Start engine. Raise engine speed to 2000 RPM for at least 30 seconds. Allow engine to idle. Turn engine off. Turn ignition on. With DRB-II, read fault messages.
5. If repaired fault has reset, repair is incomplete. Check all pertinent TECHNICAL SERVICE BULLETINS and return to «TEST CH-1, BATTERY TEST»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator__test-ch-1-battery-test) if necessary. If there are no other faults, repair is complete.

BENCH TESTING

Note. Alternators are non-serviceable and must be replaced as complete units.

SYSTEM DIAGNOSIS

The self-diagnostic capabilities of this system, if properly used, can simplify testing. SBEC monitors several different engine control system circuits.

If a problem is sensed with a monitored circuit, a fault code is stored in SBEC, CHECK ENGINE light illuminates and SBEC enters limp-in mode. In limp-in mode, SBEC compensates for component failure by substituting information from other sources. This allows vehicle operation until repairs can be made.

Once codes are known, refer to CHARGING SYSTEM FAULT CODES table to determine the questionable circuit. Test circuits and repair or replace components as required. If problem is repaired or ceases to exist, SBEC cancels that fault code after 50 ignition on/off cycles. To clear codes, refer to ERASING FAULT CODES under ENTERING ON-BOARD DIAGNOSTICS.

A specific fault code results from a particular system failure. Components in that system are NOT necessarily the reason for that failure. The fault code does not condemn a specific component, it calls out a CIRCUIT malfunction.

Hard Failures

Hard failures cause CHECK ENGINE light to illuminate and remain on until malfunction is repaired. If light comes on and remains on (light may flash) during vehicle operation, cause of malfunction must be determined using diagnostic (code) charts. If a sensor fails, SBEC will use a substitute value in its calculations, allowing engine operation in limp-in mode. In this condition, vehicle will run, but driveability may be poor.

Intermittent Failures

Intermittent failures may cause CHECK ENGINE light to flicker or stay on until intermittent fault goes away. The corresponding trouble code will be retained in SBEC memory, however. If fault does not reoccur within a certain time frame, corresponding trouble code will be erased from SBEC memory. Intermittent failures can be caused by faulty sensor, bad connector or wiring related problems. See INTERMITTENTS in appropriate TESTS W/O CODES article in the ENGINE PERFORMANCE Section.

DIAGNOSTIC PROCEDURE

Refer to ENTERING ON-BOARD DIAGNOSTICS to retrieve fault codes. If fault codes are NOT present and/or DRB-II (Diagnostic Readout Box-II) is used, proceed to TEST CH-1, BATTERY TEST.

Note. When using trouble shooting charts for diagnosis, DO NOT skip any steps in chart or incorrect diagnosis may result.

Before proceeding with diagnosis, the following precautions must be followed

1. Vehicle must have a fully charged battery and functional charging system. Refer to both «TROUBLE SHOOTING»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator) and «TESTING (ON-VEHICLE)»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator__testing-on-vehicle) .
2. Probe SBEC connector from pin side. DO NOT backprobe SBEC connector.
3. DO NOT cause short circuits when performing electrical tests. This will set additional fault codes, making diagnosis of original problem more difficult.
4. DO NOT use a test light in place of a voltmeter.
5. Always repair lowest fault code number (CHECK ENGINE light) or first fault displayed (DRB-II) first.
6. Always perform verification procedure test after repairs are made.
7. Always disconnect DRB-II after use.
8. Always disconnect DRB-II before charging battery.

ENTERING ON-BOARD DIAGNOSTICS

Reading Trouble Codes

Trouble codes may be read by using CHECK ENGINE light on instrument panel or with DRB-II. See CHECK ENGINE LIGHT DIAGNOSTIC MODE and DIAGNOSIS USING DRB-II headings below. A more complete diagnosis is possible using DRB-II.

Note. SBEC CANNOT diagnose every charging system problem. If a fault still exists after performing self-diagnostic procedures, go to TESTING (ON-VEHICLE) .

Trouble Code Explanation

1. See CHARGING SYSTEM FAULT CODES table for charging-related faults.
2. Code 12 will set if battery feed to SBEC has been disconnected within last 50-100 starts. SBEC monitors this circuit whenever ignition is on.
3. Code 41 will set if alternator field control fails to switch properly. SBEC monitors this circuit whenever ignition is on.
4. If battery temperature sense voltage goes out of range, Code 44 will be set in memory. SBEC monitors this circuit any time ignition is on.
5. If battery sense voltage is more than one volt above desired control voltage for more than 20 seconds, a Code 46 will be set in memory. SBEC monitors this signal whenever engine is running.
6. If battery sense voltage is more than one volt below desired control voltage for more than 20 seconds and no significant change in voltage is detected during active test of alternator, Code 47 will be set. SBEC monitors this signal whenever engine speed is more than 1500 RPM.

CHARGING SYSTEM FAULT CODES

Note. Only charging system-related codes are listed here. For engine-related codes, see appropriate G - TEST W/CODES article in ENGINE PERFORMANCE Section.

CHECK ENGINE Light Diagnostic Mode

1. Start engine (if possible). On models equipped with automatic transmission, place foot on brake and cycle transmission shift lever through all positions, ending in Park. On all models, turn A/C switch on and then off (if equipped).
2. Turn engine off. Without starting engine again, turn ignition on, off, on, off and on. CHECK ENGINE light will come on for 2 seconds as a bulb check, followed by fault codes. Record 2-digit fault codes as displayed by flashing CHECK ENGINE light.
3. For example, Code 23 is displayed as flash, flash, 4 second pause, then flash, flash, flash. After a slightly longer pause, any other codes stored are displayed in numerical order.
4. Once check engine light begins to flash fault codes, it cannot be stopped. Go to step 1) to enter diagnostic mode again. Code 55 indicates end of fault code display. For more information on vehicle self-diagnostics, see appropriate G - TEST W/CODES article in ENGINE PERFORMANCE Section.
5. Refer to «CHARGING SYSTEM FAULT CODES»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator) table to translate trouble code number to a system fault description (DRB-II display). Once trouble area is identified, refer to appropriate charging system test procedures.

Note. CHECK ENGINE light CANNOT be used to perform actuation test mode, sensor test modes or engine running test. Fault codes can only be erased using DRB-II. Fault codes will be erased from SBEC memory after 50 key starts if fault does not reoccur.

Diagnosis Using DRB-II

DRB-II is used as part of a charging system diagnostic procedure. Perform tests CH-1, BATTERY TEST through CH-VER, CHARGING VERIFICATION.

DRB-II Diagnostic Mode

1. Turn ignition off. Attach DRB-II to engine diagnostic connector. Connector is located in engine compartment, near SBEC.
2. Start engine (if possible). On models equipped with automatic transmission, place foot on brake pedal and cycle transmission shift lever through all positions, ending in Park. On all models, turn A/C switch on and then off (if equipped).
3. Turn engine off. Without starting engine again, turn ignition on. Enter CHARGING MENU. To enter CHARGING MENU, see DRB-II TEST FUNCTIONS. At CHARGING MENU, press "2" (READ FAULTS) key. Press ENTER key. After fault codes are accessed, see «TEST CH-1, BATTERY TEST»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator__test-ch-1-battery-test) under TESTING (ON-VEHICLE).

Erasing Fault Codes

1. To erase faults, press ATM key. At DRB-II display, press "2" (ERASE) key. DRB-II will display ERASE FAULTS ARE YOU SURE? (ENTER TO ERASE). Press ENTER key.
2. When DRB-II is finished erasing fault codes, it will display FAULTS ERASED. This display will remain until ATM key is pressed. After ATM key is pressed, display will return to CHARGING MENU screen.

DRB-II TEST FUNCTIONS

Note. DO NOT touch DRB-II keypad during DRB-II power-up sequence, or an error message will result.

1. To perform diagnostic tests using DRB-II, DRB-II must be in CHARGING MENU. At CHARGING MENU, fault codes and DRB-II test functions can be accessed.
2. To reach CHARGING MENU, turn ignition off. Attach DRB-II to engine diagnostic connector. Connector is located in engine compartment, near SBEC. Turn ignition switch to RUN position.
3. All DRB-II character positions will illuminate and copyright information will appear on screen for several seconds. If the DRB-II screen is blank or if any error messages appear, refer to «DRB-II PROBLEMS & ERROR MESSAGES»(/dodge/caravan/ii-1990-1995/remont/charging-system/#alternator-regulator) .
4. After several seconds DRB-II menu will appear. At DRB-II menu, press "4" (SELECT SYSTEM) key. Press ENTER key. At SELECT SYSTEM menu, press "1" (ENGINE) key. Press ENTER key. DRB-II menu will appear, indicating engine year and size, type of transmission and SBEC part number.
5. After several seconds AIR COND menu will appear. Press "1" (WITH A/C) or press "2" (WITHOUT A/C). DRB-II display will change to ENGINE SYSTEMS menu. At ENGINE SYSTEMS menu, press "2" (CHARGING) key. Press ENTER key.
6. Display will change to CHARGING MENU. At CHARGING menu of engine diagnostic program, specific test functions programmed into DRB-II can be performed. The following DRB-II modes can be accessed: SYSTEM TEST, READ FAULTS, STATE DISPLAYS, ACTUATOR TEST and ADJUSTMENTS.

SYSTEM TEST Mode

This function is not available in engine diagnostics program.

READ FAULTS Mode

1. This function allows user to read and erase fault codes. A fault counter will appear along with fault displayed on DRB-II. As an example, DRB-II will display 1 OF 2 FAULTS. SBEC will store up to 8 fault messages. Faults are numbered in reverse order of setting. The most recent fault to occur will appear first. Vehicles without A/C will always have A/C CLUTCH RELAY CKT (circuit) stored in memory. This fault will always appear first if vehicle is not equipped with A/C. If no fault messages are stored, DRB-II will display NO FAULTS DETECTED and start counter will show 0 STARTS SINCE ERS.
2. A start counter will appear below DRB-II fault counter display. Start counter tracks the number of times vehicle is started since faults were last set, erased, or battery was disconnected. This helps determine if fault is intermittent. Memory space limits start counter to first 3 faults. Start counter of zero equals a hard fault. Start counter of more than zero indicates an intermittent fault. Start counter will count up to 255 starts. If no fault messages are stored, DRB-II will display NO FAULTS DETECTED and start counter will show 0 STARTS SINCE ERS.

STATE DISPLAYS Mode

1. This function allows user to read states or values of a variety of sensors, inputs/outputs and components.
2. The SBEC can only recognize high and low states on switch circuits. SBEC cannot differentiate between an open or short circuit or a defective switch. If DRB-II displays a change between INPUT HIGH and INPUT LOW, it can be assumed that the entire switch circuit to the SBEC is functioning.

ACTUATOR TEST Mode

1. This function allows the user to check for proper operation of output circuits or devices, which the SBEC cannot internally recognize. DRB-II allows SBEC to activate these outputs or devices, allowing an observer to verify proper operation.
2. Most of the tests available in this mode provide an audible or visual indication of device operation (click of relay contacts, fuel spray, etc.). With the exception of an intermittent condition, if a device functions properly during its test, it can be assumed that the device, wiring and its driver circuit are functioning properly.

ADJUSTMENTS Mode

This function allows the user to erase fault codes. Function also allows user to reset Emission Maintenance Reminder (EMR) light and mileage (trucks only).

DRB-II Volt/Ohmmeter Mode

1. To access volt/ohmmeter mode of DRB-II, connect Red volt/ohmmeter test lead to Red port, located on right-top side of DRB-II. NOTE: Because DRB-II is grounded through engine diagnostic connector, only one volt/ohmmeter test lead is required when using volt/ohmmeter option. DRB-II volt/ohmmeter should only be used when diagnostic procedures require the use of this option.
2. To access voltmeter, press VOLT/OHM key once. DRB-II is now in voltmeter mode. Touch test probe to connector or wire to be measured. Read voltage on DRB-II display. When voltage testing is complete, press VOLT/OHM key 3 times to exit voltmeter mode.
3. To access ohmmeter, press VOLT/OHM key twice. DRB-II is now in ohmmeter mode. Touch test probe to connector or wire to be measured. Read resistance to circuit ground on DRB-II display. When resistance testing is complete, press VOLT/OHM key twice to exit ohmmeter mode.

DRB-II Continuity Meter Mode

Press VOLT/OHM key 3 times. Display will read NO CONTINUITY. Touch test probe to connector or wire to be measured. Read continuity on DRB-II display. When continuity testing is complete, press VOLT/OHM key once to exit continuity meter mode.

VEHICLES TESTED Mode

1. Mode is used to show what vehicles are covered by DRB-II cartridge. To access vehicles tested mode, turn ignition off. Attach DRB-II to engine diagnostic connector. Connector is located in engine compartment, near SBEC.
2. Turn ignition switch to RUN position. All DRB-II character positions will illuminate and copyright information will appear on screen. After several seconds DRB-II menu will appear.
3. At DRB-II menu, press "1" (VEHICLES TESTED) key. Press ENTER key. DRB-II will display vehicles covered by cartridge. Screen will display for 5 seconds and return to DRB-II menu.

HOW TO USE Mode

Enter DRB-II menu display. Refer to steps 1) and 2) under VEHICLES TESTED MODE. At DRB-II menu, press "2" (HOW TO USE) key. Press ENTER key. A series of screens will be displayed explaining the use of DRB-II keys used to move through engine diagnostic program.

CONFIGURE Mode

1. Configure option allows user to customize DRB-II display. For example, if metric system is more useful to use, simply select METRIC from the appropriate menu.
2. All selections made under CONFIGURE option remain active until user changes selection. To enter configure mode, enter DRB-II menu display. Refer to steps 1) and 2) under VEHICLES TESTED MODE. At DRB-II menu, press "3" (CONFIGURE) key. Press ENTER key. DRB-II will display CONFIGURE menu.

Blank Message Screen

1. Connect DRB-II to a different vehicle. If message screen is still blank, DRB-II or cable adapter is faulty. Substitute to find faulty component.
2. If message screen is not blank, DRB-II and cable adapter are functioning properly. Inspect diagnostic connector for proper wire placement, damaged terminals or pushed out pins. Repair as necessary.
3. If diagnostic connector is okay, using an ohmmeter, check resistance between Black/White or Black/Yellow wire and ground at engine diagnostic connector. If resistance is greater than 10 ohms, repair open in Black/White or Black/Yellow wire.

NO RESPONSE Message

1. Connect DRB-II to another vehicle. If DRB-II displays NO RESPONSE message again, DRB-II or cable adapter is faulty. Substitute to find faulty component. If message screen does not display NO RESPONSE, DRB-II and cable adapter are functioning properly. Go to next step.
2. Turn ignition off. Disconnect DRB-II. Using an ohmmeter, check Pink or Black/Red wire for resistance between SBEC and engine diagnostic connectors. If resistance is more than 10 ohms, repair open in Pink or Black/Red wire.
3. If resistance is less than 10 ohms, check Light Green/Orange or Black/Pink wire for resistance between SBEC and engine diagnostic connectors. If resistance is more than 10 ohms, repair open in Light Green/Orange or Black/Pink wire.

RAM TEST FAILURE Message

Replace DRB-II.

CARTRIDGE ERROR Message

Replace DRB-II cartridge.

KEY PAD TEST FAILURE Message

Power up DRB-II again with fingers off keypad. If error message returns, replace DRB-II.

HIGH OR LOW BATTERY Message

Correct condition of vehicle battery and reconnect DRB-II.

Note. For more information on SBEC diagnostic capabilities and using DRB-II, see appropriate G - TEST W/CODES article in the ENGINE PERFORMANCE Section.

OVERHAUL

Overhaul information is not available.

ALTERNATOR SSPECIFICATIONS

ALTERNATOR MINIMUM OUTPUT

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS (ALTERNATOR MOUNTING BOLTS)

See also:
• TROUBLE SHOOTING - BASIC PROCEDURES
• COMPUTER RELEARN PROCEDURES
• ALTERNATOR MINIMUM OUTPUT
• TEST CH-VER, CHARGING VERIFICATION
• TEST CH-2, ALTERNATOR FIELD NOT SWITCHING PROPERLY
• TEST CH-3, CHARGING SYSTEM VOLTAGE LOW
• TEST CH-4, CHARGING SYSTEM VOLTAGE HIGH
• TEST CH-5, CHECKING FOR INTERMITTENT PROBLEMS
• TEST CH-1, BATTERY TEST
• ENTERING ON-BOARD DIAGNOSTICS
• TESTING (ON-VEHICLE)
• INITIAL CHECKS