Charging System: Diagnosis Dodge Caravan IV

ON-BOARD DIAGNOSTIC SYSTEM

The Powertrain Control Module (PCM) monitors critical input and output circuits of the charging system, making sure they are operational. A Diagnostic Trouble Code (DTC) is assigned to each input and output circuit monitored by the OBD system. Some circuits are checked continuously and some are checked only under certain conditions.

If the OBD system senses that a monitored circuit is bad, it will put a DTC into electronic memory. The DTC will stay in electronic memory as long as the circuit continues to be bad. The PCM is programmed to clear the memory after 40 good trip if the problem does not occur again.

DIAGNOSTIC TROUBLE CODES

A DTC description can be read using the DRBIII(R) scan tool. Refer to POWERTRAIN DIAGNOSTIC PROCEDURES for information.

A DTC does not identify which component in a circuit is bad. Thus, a DTC should be treated as a symptom, not as the cause for the problem. In some cases, because of the design of the diagnostic test procedure, a DTC can be the reason for another DTC to be set. Therefore, it is important that the test procedures be followed in sequence, to understand what caused a DTC to be set.

ERASING DIAGNOSTIC TROUBLE CODES

The DRBIII(R) Scan Tool must be used to erase a DTC.

The following procedures may be used to diagnose the charging system if

1. the check gauges lamp or battery lamp is illuminated with the engine running
2. the voltmeter (if equipped) does not register properly
3. an undercharged or overcharged battery condition occurs.

Remember that an undercharged battery is often caused by

1. accessories being left on with the engine not running
2. a faulty or improperly adjusted switch that allows a lamp to stay on. Refer to Ignition-Off Draw Test under «(ELECTRICAL/BATTERY SYSTEM/BATTERY - STANDARD PROCEDURE)»(ref-248889-S37426460032007022700000)
3. loose generator belt.

INSPECTION

The Powertrain Control Module (PCM) monitors critical input and output circuits of the charging system, making sure they are operational. A Diagnostic Trouble Code (DTC) is assigned to each input and output circuit monitored by the On-Board Diagnostic (OBD) system. Some charging system circuits are checked continuously, and some are checked only under certain conditions.

Refer to Diagnostic Trouble Codes in POWERTRAIN DIAGNOSTIC PROCEDURES for more DTC information. This will include a complete list of DTC's including DTC's for the charging system.

To perform a complete test of the charging system, refer to POWERTRAIN DIAGNOSTIC PROCEDURES and the DRBIII(R) scan tool. Perform the following inspections before attaching the scan tool.

1. Inspect the battery condition. Refer to «BATTERY SYSTEM»(ref-248889) . «(Refer to ELECTRICAL/BATTERY SYSTEM - DIAGNOSIS AND TESTING)»(ref-248889-S09433565692007022700000) for procedures.
2. Inspect condition of battery cable terminals, battery posts, connections at engine block, starter solenoid and relay. They should be clean and tight. Repair as required.
3. Inspect all fuses in both the fuse block and Power Distribution Center (PDC) or IPM (if equipped) for tightness in receptacles. They should be properly installed and tight. Repair or replace as required.
4. Inspect generator mounting bolts for tightness. Replace or tighten bolts if required. Refer to «(Refer to ELECTRICAL/CHARGING - SPECIFICATIONS)»(ref-248919-S06213161382007022700000) for torque specifications .
5. Inspect generator drive belt condition and tension. Tighten or replace belt as required. Refer to «ACCESSORY DRIVE BELT TENSION»(ref-248908-S17956250062007022700000) .
6. Inspect decoupler pulley (if equipped). Ensure decoupler pulley is driving the alternator rotor.
7. Inspect automatic belt tensioner (if equipped). Refer to «COOLING»(ref-248908) for more information.
8. Inspect generator electrical connections at generator field, battery output, and ground terminal (if equipped). Also check generator ground wire connection at engine (if equipped). They should all be clean and tight. Repair as required.

DIAGNOSIS AND TESTING - GENERATOR DECOUPLER PULLEY

Scheme 33

Scheme 34

1. Release hood latch and open hood.
2. Disconnect battery negative cable.
3. Raise vehicle and support.
4. Remove the right front lower splash shield.
5. Remove accessory drive belt, refer to «COOLING»(ref-248908) for proper procedures. (Scheme 33)
6. Lower vehicle.
7. Remove the Air Box. Refer to appropriate ENGINE article for more information.
8. Remove the decoupler pulley cover.
9. Use Special Tool #8433 to loosen the Generator Decoupler. (Scheme 34)and (Scheme 35).
10. Remove the tool.
11. Remove the Generator Decoupler.

Scheme 35

Scheme 36

1. Install the Generator Decoupler to the generator shaft.
2. Use Special Tool #8433 to tighten the Generator Decoupler. (Scheme 35)and (Scheme 36). Refer to «TORQUE»(ref-248919-S34478401402007022700000) for the proper torque.
3. Install a new decoupler pulley cover.
4. Install the Air Box. Refer to appropriate ENGINE article for more information.
5. Raise vehicle and support.
6. Install accessory drive belt, refer to «COOLING»(ref-248908) for proper procedures. (Scheme 33)
7. Install the right front lower splash shield.
8. Lower vehicle.
9. Connect battery negative cable.