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Generators & Regulators: Diagnosis Dodge Durango II

Charging System ~6585 words

TROUBLE SHOOTING

Verify customer's concern by operating system. Inspect for blown fuses, 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 in good condition, 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 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.

VOLTAGE DROP TEST

WARNINGIf the battery shows signs of freezing, leaking, loose posts, or low electrolyte level, DO NOT test, assist boost, or charge. The battery may arc internally and explode. Personal injury and/or vehicle damage may result.
WARNINGExplosive hydrogen gas forms in and around the battery. DO NOT smoke, use flame, or create sparks near the battery. Personal injury and/or vehicle damage may result.
WARNINGThe battery contains sulfuric acid, which is poisonous and caustic. Avoid contact with the skin, eyes, or clothing. In the event of contact, flush with water and call a physician immediately. Keep out of the reach of children.
WARNINGIf the battery is equipped with removable cell caps, be certain that each of the cell caps is in place and tight before the battery is returned to service. Personal injury and/or vehicle damage may result from loose or missing cell caps.

The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing this test, be certain that the following procedures are accomplished

  1. The battery is fully-charged and tested.
  2. Fully engage the parking brake.
  3. If the vehicle is equipped with an automatic transmission, place the gearshift selector lever in the Park position. If the vehicle is equipped with a manual transmission, place the gearshift selector lever in the Neutral position and block the clutch pedal in the fully depressed position.
  4. Verify that all lamps and accessories are turned off.
  5. To prevent the engine from starting, remove the proper fuse in the PDC.
  1. Connect the positive lead of the voltmeter to the battery negative terminal post. Connect the negative lead of the voltmeter to the negative cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery negative cable terminal clamp and the battery negative terminal post.
  2. Connect the positive lead of the voltmeter to the battery positive terminal post. Connect the negative lead of the voltmeter to the battery positive cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery positive terminal post and battery positive cable terminal clamp.
  3. Connect the voltmeter to measure between the battery positive cable terminal clamp and the starter solenoid B+ terminal stud. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above .2 volt, clean and tighten the battery positive cable eyelet terminal connection at the starter solenoid B+ terminal stud. Repeat the test. If the reading is still above .2 volt, replace the faulty battery positive cable.
  4. Connect the voltmeter to measure between the battery negative cable terminal clamp and a good clean ground on the engine block. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above .2 volt, clean and tighten the battery negative cable eyelet terminal connection to the engine block. Repeat the test. If the reading is still above .2 volt, replace the faulty battery negative cable.

IGNITION-OFF DRAW TEST

  1. Verify that all electrical accessories are off. Turn off all lamps, remove the ignition key, and close all doors. If the vehicle is equipped with an illuminated entry system or an electronically tuned radio, allow the electronic timer function of these systems to automatically shut off (time out). This may take up to 3 minutes.
  2. Determine that the underhood lamp is operating properly, then disconnect the lamp wire harness connector or remove the lamp bulb.
  3. Disconnect the battery negative cable.
  4. Set an electronic digital multimeter to its highest amperage scale. Connect the multimeter between the disconnected battery negative terminal post and negative cable terminal clamp. Make sure that the doors remain closed so that the illuminated entry system is not activated. The multimeter amperage reading may remain high for up to 3 minutes, or may not give any reading at all while set in the highest amperage scale, depending upon the electrical equipment in the vehicle. The multimeter leads must be securely clamped to the battery negative cable terminal post and negative cable terminal clamp. If continuity between the battery negative terminal post and the negative cable terminal clamp is lost during any part of the IOD test, the electronic timer function will be activated and all of the tests will have to be repeated.
  5. After about 3 minutes, the high-amperage IOD reading on the multimeter should become very low or nonexistent, depending upon the electrical equipment in the vehicle. If the amperage reading remains high, remove and replace each fuse or circuit breaker in the Power Distribution Center (PDC) and then in the Junction Block (JB), one at a time until the amperage reading becomes very low, or nonexistent. Refer to the appropriate wiring information for complete PDC and JB fuse, circuit breaker, and circuit identification. This will isolate each circuit and identify the circuit that is the source of the high-amperage IOD. If the amperage reading remains high after removing and replacing each fuse and circuit breaker, disconnect the wire harness from the generator. After the high-amperage IOD has been corrected, switch the multimeter to progressively lower amperage scales and, if necessary, repeat the fuse and circuit breaker remove-and-replace process to identify and correct all sources of excessive IOD. It is now safe to select the lowest milliampere scale of the multimeter to check the low amperage IOD.
  6. Observe the multimeter reading. The low-amperage IOD should not exceed 35 milliamperes (0.035 ampere). If the current draw exceeds 35 milliamperes, isolate each circuit using the fuse and circuit breaker remove-and-replace process in step 5 . The multimeter reading will drop to within the acceptable limit when the source of the excessive current draw is disconnected. Repair this circuit as required; whether a wiring short, incorrect switch adjustment, or a component failure is at fault.

OPEN CIRCUIT VOLTAGE TEST

A battery open-circuit voltage (no load) test will show the approximate state-of-charge of a battery. This test can be used in place of the hydrometer test when a hydrometer is not available, or for maintenance free batteries with non-removable cell caps.

Note. Before proceeding with this test, completely charge the battery.

  1. Before measuring the open-circuit voltage, the surface charge must be removed from the battery. Turn on the headlamps for 15 seconds, then allow up to 5 minutes for the battery voltage to stabilize.
  2. Disconnect and isolate both battery cables, negative cable first.
  3. Using a voltmeter connected to the battery posts (see the instructions provided by the manufacturer of the voltmeter), measure the open-circuit voltage.

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.

If a problem is sensed in a monitored circuit, a DTC will be stored in Powertrain Control Module (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 engine warm-up cycles. DTCs can also be cleared using scan tool. See CLEARING DIAGNOSTIC TROUBLE CODES .

RETRIEVING DIAGNOSTIC TROUBLE CODES

CAUTIONBefore entering self-diagnostics, check charging system for other problems. See TROUBLE SHOOTING . DO NOT connect scan tool to vehicle if battery charger is connected, as scan tool damage will result.

Note. Powertrain Control Module (PCM) cannot diagnose every charging system problem. If fault still exists after performing self-diagnostic procedures, perform ON-VEHICLE TESTING .

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

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

Ensure battery is fully charged. Connect scan tool to Data Link Connector (DLC). DLC is located below instrument panel, near steering column. Using scan tool, retrieve and record DTCs. If scan tool does not communicate with all modules, repair communication concerns. See appropriate BODY CONTROL MODULES article in ACCESSORIES & EQUIPMENT. 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 Powertrain Control Module (PCM) memory. See CLEARING DIAGNOSTIC TROUBLE CODES .

DTC (1)Scan Tool Display
P0071AMBIENT TEMP SENSOR PERFORMANCE
P0072AMBIENT TEMP SENSOR CIRCUIT LOW
P0073AMBIENT TEMP SENSOR CIRCUIT HIGH
P0516BATTERY TEMPERATURE SENSOR CIRCUIT LOW
P0517BATTERY TEMPERATURE SENSOR CIRCUIT HIGH
P0562BATTERY VOLTAGE LOW
P0563BATTERY VOLTAGE HIGH
P0622GENERATOR FIELD CONTROL CIRCUIT
P2503CHARGING SYSTEM OUTPUT 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.
(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.

SCAN TOOL DTC MESSAGES

CLEARING DIAGNOSTIC TROUBLE CODES

Powertrain Control Module (PCM) automatically clears DTCs from memory after 40 engine warm-up cycles. DTCs can also be cleared by using scan tool. Follow scan tool manufacturer's instructions.

DIAGNOSTIC TESTS

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

Testing

  1. Turn ignition on, engine not running. With a scan tool, read DTC's. If any DTC's are active at this time, go to next step. If there are no active DTC's, see «INTERMITTENT CONDITION»(ref-166557-S32099919242004092300000) under SYSTEM TESTS. Perform «POWERTRAIN VERIFICATION TEST VER-5»(ref-166557-S35640678772004092300000) under VERIFICATION TESTS.
  2. Turn the ignition off. Disconnect the C2 FCM harness connector. Disconnect the AAT sensor harness connector. Turn ignition on, engine not running. Measure the voltage on the (G31) AAT sensor signal circuit in the AAT sensor harness connector. If the voltage is above 5.2 volts, repair the short to voltage in the (G31) AAT sensor signal circuit. Perform «POWERTRAIN VERIFICATION TEST VER-5»(ref-166557-S35640678772004092300000) under VERIFICATION TESTS. If the voltage is not above 5.2 volts, go to next step.
  3. Turn the ignition off. Connect the C2 FCM harness connectors. Turn ignition on, engine not running. With a scan tool, read the AAT voltage. If the voltage is above 4.6 volts, go to next step. If the voltage is not above 4.6 volts, go to step 7 .
  4. Connect a jumper wire between the (G31) AAT sensor signal circuit and the (G931) sensor ground circuit in the AAT sensor harness connector. With a scan tool, read the AAT sensor voltage. If the voltage is below one volt with the jumper wire installed, replace the AAT sensor. Perform «POWERTRAIN VERIFICATION TEST VER-5»(ref-166557-S35640678772004092300000) under VERIFICATION TESTS. If the voltage is not below one volt, go to next step.
  5. Turn the ignition off. Disconnect the C2 FCM harness connector. Measure the resistance of the (G31) AAT sensor signal circuit from the AAT sensor harness connector to the C2 FCM harness connector. If the resistance is below 5.0 ohms, go to next step. If the resistance is not below 5 ohms, repair the open in the (G31) AAT sensor signal circuit. Perform «POWERTRAIN VERIFICATION TEST VER-5»(ref-166557-S35640678772004092300000) under VERIFICATION TESTS.
  6. Measure the resistance of the (G931) Sensor ground circuit from the AAT sensor harness connector to the C2 FCM harness connector. If the resistance is below 5.0 ohms go to step 9 . If the resistance is not below 5 ohms, repair the open in the (G931) sensor ground circuit. Perform «POWERTRAIN VERIFICATION TEST VER-5»(ref-166557-S35640678772004092300000) under VERIFICATION TESTS.
  7. Turn the ignition off. Disconnect the C2 FCM harness connector. Measure the resistance between ground and the (G31) AAT sensor signal circuit in the AAT sensor harness connector. If the resistance is below 100 ohms, repair the short to ground in the (G31) AAT sensor signal circuit. Perform «POWERTRAIN VERIFICATION TEST VER-5»(ref-166557-S35640678772004092300000) under VERIFICATION TESTS. If the resistance is not below 100 ohms, go to next step.
  8. Measure the resistance between the (G31) AAT sensor signal circuit and the (G931) sensor ground circuit in the AAT sensor harness connector. If the resistance is below 5.0 ohms, repair the short between the (G931) Sensor ground circuit and the (G31) AAT sensor signal circuit. Perform «POWERTRAIN VERIFICATION TEST VER-5»(ref-166557-S35640678772004092300000) under VERIFICATION TESTS. If the resistance is not below 5.0 ohms, go to next step.
  9. Using the schematics as a guide, inspect the wire harness and connectors. See Fig.1 . Pay particular attention to all Power and Ground circuits. If any problems were found, repair as necessary. Perform «BODY VERIFICATION TEST VER-1»(ref-166557-S25087236092004092300000) under VERIFICATION TESTS. If there were no problems found, replace the Front Control Module. Perform «BODY VERIFICATION TEST VER-1»(ref-166557-S25087236092004092300000) under VERIFICATION TESTS.
  1. Turn ignition on, engine not running. With a scan tool, read ambient temperature sensor voltage. If the voltage is below .078 volt, go to next step. If the voltage is not below .078 volt, see «INTERMITTENT CONDITION»(ref-166557-S32099919242004092300000) under SYSTEM TESTS. Perform «POWERTRAIN VERIFICATION TEST VER-5»(ref-166557-S35640678772004092300000) under VERIFICATION TESTS.
  2. Turn the ignition off. Disconnect the ambient air temperature sensor harness connector. Turn the ignition on, engine not running. With a scan tool, reset the ATT sensor voltage. If the voltage is above 4.6 volts, replace the ambient temperature sensor. Perform «POWERTRAIN VERIFICATION TEST VER-5»(ref-166557-S35640678772004092300000) under VERIFICATION TESTS. If the voltage is not above 4.6 volts, go to next step.
  3. Turn the ignition off. Disconnect the C2 FCM harness connectors. Measure the resistance between ground and the (G31) AAT sensor signal circuit in the IAT sensor harness connector. If the resistance is below 100 ohms, repair the short to ground in the (G31) AAT sensor signal circuit. Perform «POWERTRAIN VERIFICATION TEST VER-5»(ref-166557-S35640678772004092300000) under VERIFICATION TESTS. If the resistance is not below 100 ohms, go to next step.
  4. Measure the resistance between the (G931) sensor ground circuit and the (G31) AAT sensor signal circuit in the AAT sensor harness connector. If the resistance is below 5 ohms, repair the short between the (G931) sensor ground circuit and the (G31) AAT sensor signal circuit. Perform «POWERTRAIN VERIFICATION TEST VER-5»(ref-166557-S35640678772004092300000) under VERIFICATION TESTS. If the resistance is not below 5 ohms, go to next step.
  5. Using the schematics as a guide, inspect the wire harness and connectors. See Fig.1 . Pay particular attention to all power and ground circuits. If there were any problems found, repair as necessary. Perform «BODY VERIFICATION TEST VER-1»(ref-166557-S25087236092004092300000) under VERIFICATION TESTS. If no problems were found, replace and program the Front Control Module. Perform «BODY VERIFICATION TEST VER-1»(ref-166557-S25087236092004092300000) under VERIFICATION TESTS.
  1. Turn the ignition on, engine not running. With a scan tool, read the ambient air temperature sensor voltage. If the voltage is above 4.98 volts, go to next step. If the voltage is not above 4.98 volts, see «INTERMITTENT CONDITION»(ref-166557-S32099919242004092300000) under SYSTEM TESTS. Perform «POWERTRAIN VERIFICATION TEST VER-5»(ref-166557-S35640678772004092300000) under VERIFICATION TESTS.
  2. Turn the ignition off. Disconnect the ambient air temperature sensor harness connector. Connect a jumper wire between the (G31) AAT sensor signal circuit and the (G931) sensor ground circuit in the AAT sensor harness connector. Turn the ignition on, engine not running. With a scan tool, read AAT sensor voltage. If the voltage is below one volt with a jumper wire installed, replace the ambient air temperature sensor. Perform «POWERTRAIN VERIFICATION TEST VER-5»(ref-166557-S35640678772004092300000) under VERIFICATION TESTS. If the voltage is not below one volt, go to next step.
  3. Turn the ignition off. Disconnect the C2 FCM harness connector. Turn the ignition on, engine not running. Measure the voltage on the (G31) AAT sensor signal circuit in the AAT sensor harness connector. If the voltage is above 5.2 volts, repair the short to battery voltage in the (G31) AAT sensor signal circuit. Perform «POWERTRAIN VERIFICATION TEST VER-5»(ref-166557-S35640678772004092300000) under VERIFICATION TESTS. If the voltage is not 5.2 volts, go to next step.
  4. Turn the ignition off. Measure the resistance of the (G31) AAT sensor signal circuit from the AAT sensor harness connector to the C2 FCM harness connector. If the resistance is below 5 ohms, go to next step. If the resistance is not below 5 ohms, repair the open in the (G31) AAT sensor signal circuit. Perform «POWERTRAIN VERIFICATION TEST VER-5»(ref-166557-S35640678772004092300000) under VERIFICATION TESTS.
  5. Measure the resistance of the (G931) sensor ground circuit from the AAT sensor harness connector to the C2 FCM harness connector. If the resistance is below 5 ohms, go to next step. If the resistance is not below 5 ohms, repair the open in the (G931) sensor ground circuit. Perform «POWERTRAIN VERIFICATION TEST VER-5»(ref-166557-S35640678772004092300000) under VERIFICATION TESTS.
  6. Using the schematics as a guide, inspect the wire harness and connectors. See Fig.1 . Pay particular attention to all power and ground circuits. If there were any problems found, repair as necessary. Perform «BODY VERIFICATION TEST VER-1»(ref-166557-S25087236092004092300000) under VERIFICATION TESTS. If there were no problems found, replace the front control module. Perform «BODY VERIFICATION TEST VER-1»(ref-166557-S25087236092004092300000) under VERIFICATION TESTS.
  1. Turn ignition on, engine not running. With a scan tool, monitor Battery Temperature Sensor voltage. If the voltage is below .5 volt, go to next step. If the voltage is not below .5 volt, see «INTERMITTENT CONDITION»(ref-166557-S32099919242004092300000) under SYSTEM TESTS. Perform «POWERTRAIN VERIFICATION TEST VER-2»(ref-166557-S27254237822004092300000) under VERIFICATION TESTS.
  2. Turn ignition on, engine not running. With the scan tool, read the battery temp sensor voltage value. Disconnect the battery temperature sensor harness connector. If the battery temperature voltage value changes from below one volt to above 4.5 volts, replace the battery temperature sensor. Perform «POWERTRAIN VERIFICATION TEST VER-2»(ref-166557-S27254237822004092300000) under VERIFICATION TESTS. If the voltage value did not change from one volt to above 4.5 volts, go to next step.
  3. Turn the ignition off. Disconnect the C1 FCM harness connector. Measure the resistance between ground and the (K25) batt temp signal circuit in the battery temp sensor harness connector. If the resistance is below 100 ohms, repair the short to ground in the (K25) batt temp signal circuit. Perform «POWERTRAIN VERIFICATION TEST VER-2»(ref-166557-S27254237822004092300000) under VERIFICATION TESTS. If the resistance is not below 100 ohms, go to next step.
  4. Measure the resistance between the (K25) batt temp signal circuit and the (K91) batt temp return circuit in the battery temp sensor harness connector. If the resistance is below 5 ohms, repair the short between the (K91) batt temp return circuit and the (K25) batt temp circuit. Perform «POWERTRAIN VERIFICATION TEST VER-2»(ref-166557-S27254237822004092300000) under VERIFICATION TESTS. If the resistance is not below 5 ohms, go to next step.
  5. Using the schematics as a guide, inspect the wire harness and connectors. See Fig.2 . Pay particular attention to all power and ground circuits. If there were any problems found, repair as necessary. Perform «BODY VERIFICATION TEST VER-1»(ref-166557-S25087236092004092300000) under VERIFICATION TESTS. If no problems were found, replace and program the front control module. Perform «BODY VERIFICATION TEST VER-1»(ref-166557-S25087236092004092300000) under VERIFICATION TESTS.$
  1. Turn ignition on, engine not running. With a scan tool, monitor the battery temperature sensor voltage. If the voltage is above 4.9 volts, go to next step. If the voltage is not above 4.9 volts, see «INTERMITTENT CONDITION»(ref-166557-S32099919242004092300000) under SYSTEM TESTS. Perform «POWERTRAIN VERIFICATION TEST VER-2»(ref-166557-S27254237822004092300000) under VERIFICATION TESTS.
  2. Turn the ignition off. Disconnect the battery temperature sensor harness connector. Turn ignition on, engine not running. With the scan tool, read the battery temp voltage value. Connect a jumper wire between the (K25) batt temp signal circuit and the (K91) batt temp return circuit in the battery temp sensor harness connector. If the battery temp voltage value changed from greater than 4.5 volts to less than one volt with a jumper wire installed, replace the battery temperature sensor. Perform «POWERTRAIN VERIFICATION TEST VER-2»(ref-166557-S27254237822004092300000) under VERIFICATION TESTS. If the voltage did not change as specified, go to next step.
  3. Turn the ignition off. Disconnect the C1 FCM harness connector. Measure the voltage on the (K25) batt temp signal circuit in the battery temp sensor harness connector. If the voltage is above 5.2 volts, repair the short to battery voltage in the (K25) batt temp signal circuit. Perform «POWERTRAIN VERIFICATION TEST VER-2»(ref-166557-S27254237822004092300000) under VERIFICATION TESTS. If the voltage is not above 5.2 volts, go to next step.
  4. Turn the ignition off. Measure the resistance of the (K25) batt temp signal circuit from the battery temp sensor harness connector to the C1 FCM harness connector. If the resistance is below 5 ohms, go to next step. If the resistance is not below 5 ohms, repair the open in the (K25) batt temp signal circuit. Perform «POWERTRAIN VERIFICATION TEST VER-2»(ref-166557-S27254237822004092300000) under VERIFICATION TESTS.
  5. Measure the resistance in the (K91) batt temp return circuit from the sensor connector to the C1 FCM harness connector. If the resistance is below 5 ohms, go to next step. If the resistance is not below 5 ohms, repair the open in the (K91) batt temp return circuit. Perform «POWERTRAIN VERIFICATION TEST VER-2»(ref-166557-S27254237822004092300000) under VERIFICATION TESTS.
  6. Using the schematics as a guide, inspect the wire harness and connectors. See Fig.2 . Pay particular attention to all power and ground circuits. If problems were found, repair as necessary. Perform «POWERTRAIN VERIFICATION TEST VER-5»(ref-166557-S35640678772004092300000) under VERIFICATION TESTS. If no problems were found, replace and program the front control module. Perform «BODY VERIFICATION TEST VER-1»(ref-166557-S25087236092004092300000) under VERIFICATION TESTS.

Note. Make sure the battery is in good condition. Using the Midtronics battery tester, test the battery before continuing.

Note. Inspect the vehicle for aftermarket accessories that may exceed the generator system output.

  1. Turn the ignition off. Make sure the generator drive belt is in good operating condition. Inspect the fuses in the IPM. If an open fuse is found, use the wire diagram/schematic as a guide, inspect the wiring and connectors for damage. Turn ignition on, engine not running. With the scan tool, read DTC's. If the DTC is active at this time, go to next step. If there are no active DTC's, see «INTERMITTENT CONDITION»(ref-166557-S32099919242004092300000) under SYSTEM TESTS. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS.
  2. Measure the voltage between the (A1) B+ terminal at the generator and the battery positive post. Start the engine. If the voltage is above .4 volt, repair the excessive resistance in the (A1) B+ circuit between the generator and battery. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS. If the voltage is not above .4 volt, go to next step.
  3. Start the engine. Allow the engine to reach normal operating temperature. Make sure all wires are clear of the engine's moving parts. Measure the voltage between the generator case and battery ground post. If the voltage is above .1 volt, repair excessive resistance in the generator ground between the generator case and battery ground side. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS. If the voltage is not above .1 volt, go to next step.
  4. Turn the ignition off. Disconnect the generator field harness connector. Using a 12-volt test light, jumper it across the generator field harness connector. Turn the ignition on, engine not running. With the scan tool, actuate the gen field control circuit. If the test light illuminate brightly and flashes on and off, replace the generator. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS. If the test light does not illuminate or flash, go to next step.
  5. Turn the ignition off. Disconnect the PCM harness connectors. Measure the resistance of the (K20) gen field control circuit from the generator harness connector to the appropriate terminal of the Miller Special Tool (8815). If the resistance is below 5 ohms, go to next step. If the resistance is not below 5 ohms, repair the open in the (K20) gen field control circuit. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS.
  6. Measure the resistance between ground and the (K20) gen field control circuit in the generator field harness connector. If the resistance is below 100 ohms, repair the short to ground in the (K20) gen field control circuit. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS. If the resistance is not below 100 ohms, go to next step.
  7. Using a 12-volt test light connected to 12-volts, probe the (Z20) ground circuit in the generator field harness connector. If the test light illuminates, go to next step. If the test light does not illuminate, repair the open in the (Z20) ground circuit. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS.
  8. Using the schematics as a guide, inspect the wire harness and connectors. See Fig.3 . Pay particular attention to all power and ground circuits. If there were any problems found, repair as necessary. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS. If no problems were found, replace and program the PCM. See «PROGRAMMING»(ref-166557-S29154505932004092300000) . Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS.

Note. Make sure the battery is in good condition. Using the Midtronics Battery Tester, test the battery before counting.

Note. Inspect the vehicle for aftermarket accessories that may exceed the generator system output.

  1. Turn the ignition off. Make sure the generator drive belt is in good operating condition. Inspect the fuse in the IPM. If a fuse is open, using the wiring diagram/schematic as a guide, inspect the wiring and connectors for damage. See Fig.3 . Turn ignition on, engine not running. With a scan tool, read DTC's. If any DTC's are active, go to next step. If no DTC's are active, see «INTERMITTENT CONDITION»(ref-166557-S32099919242004092300000) under SYSTEM TESTS. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS.
  2. Turn the ignition off. Disconnect the generator field harness connector. Using a 12-volt test light, jumper across the generator field harness connector. Turn ignition on, engine not running. With the scan tool, actuate the generator field driver. If the test light illuminates or flashes on and off, replace the generator. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS. If the test light does not illuminate or flash, go to next step.
  3. Turn the ignition off. Disconnect the PCM harness connectors. Turn ignition on, engine not running. Measure the voltage on the (K20) gen field control circuit at the generator field harness connector. If the voltage is above one volt, repair the short to battery voltage in the (K20) gen field control circuit. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS. If the voltage is not above one volt, go to next step.
  4. Using the schematics as a guide, inspect the wire harness and connectors. See Fig.3 . Pay particular attention to all power and ground circuits. If any problems were found, repair as necessary. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS. If there were no problems found, replace and program the PCM. See «PROGRAMMING»(ref-166557-S29154505932004092300000) . Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS.
  1. Turn ignition on, engine not running. With a scan tool, read DTC's. If there are any active DTC's, go to next step. If there are no active DTC's, see «INTERMITTENT CONDITION»(ref-166557-S32099919242004092300000) under SYSTEM TESTS. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS.
  2. Turn the ignition off. Disconnect the generator field harness connector. Using a 12-volt test light, jumper it across the generator field harness connector. Turn the ignition on, engine not running. With a scan tool, actuate the generator field control circuit. If the test light illuminates or flashes on and off, replace the generator. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS. If the test light does not illuminate or flash on and off, go to next step.
  3. Turn the ignition off. Disconnect the PCM harness connectors. Turn the ignition on, engine not running. Measure the voltage on the (K20) gen field control circuit in the generator field harness connector. If the voltage is above one volt, repair the short to battery voltage in the (K20) gen field control circuit. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS. If the voltage is not above one volt, go to next step.
  4. Turn the ignition off. Measure the resistance of the (K20) gen field control circuit from the generator field harness connector to appropriate terminal of the Special Tool (8815). If the resistance is below 5 ohms, go to next step. If the resistance is not below 5 ohms, repair the open in the (K20) gen field control circuit. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS.
  5. Measure the resistance between ground and the (K20) gen field control circuit in the generator field harness connector. If the resistance is below 100 ohms, repair the short to ground in the (K20) gen field control circuit. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS. If the resistance is not below 100 ohms, go to next step.
  6. Using a 12-volt test light connected to battery voltage, probe the (Z20) ground circuit in the gen field harness connector. If the test illuminates brightly, go to next step. If the test light does not illuminate, repair the open in the (Z20) ground circuit. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS.
  7. Using the schematic as a guide, inspect the wire harness and connectors. See Fig.4 . Pay particular attention to all power and ground circuits. If there were any problems found, repair as necessary. Perform «POWERTRAIN VERIFICATION TEST VER-2»(ref-166557-S27254237822004092300000) under VERIFICATION TESTS. If there were no problems found, replace and program the PCM. See «PROGRAMMING»(ref-166557-S29154505932004092300000) . Perform «POWERTRAIN VERIFICATION TEST VER-2»(ref-166557-S27254237822004092300000) under VERIFICATION TESTS.

Note. Inspect the vehicle for aftermarket accessories that may exceed the generator system output.

  1. Turn the ignition on, engine not running. The battery must be fully charged. The generator belt tension and condition must be checked before continuing. With a scan tool, read DTC's. With a scan tool, erase DTC's. Start the engine. Allow the engine idle to stabilize. Turn engine off. Turn the ignition on, engine not running. With the scan tool, read DTC's. If there is an active DTC, go to next step. If there are no DTC's, see «INTERMITTENT CONDITION»(ref-166557-S32099919242004092300000) under SYSTEM TESTS. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS.
  2. Turn ignition on, engine not running. Make sure all wires are clear of the engine's moving parts. Measure the voltage between the generator B+ output terminal and the battery positive post. Start the engine. If the voltage is above .4 volt, repair the excessive resistance in the battery positive circuit between the generator and battery. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS. If the voltage is not above .4 volt, go to next step.
  3. Start the engine. Warm the engine to operating temperature. Make sure all wires are clear of the engine's moving parts. Measure the voltage between the generator case and battery ground post. If the voltage is above .1 volt, repair the excessive resistance in the generator case ground. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS. If the voltage is not above .1 volt, go to next step.
  4. Turn the ignition off. Disconnect the generator field harness connector. Using a 12-volt test light, jumper across the generator field harness connector. Turn ignition on, engine not running. With a scan tool, actuate the generator field driver. If the test light illuminates brightly or flashes on and off, replace the generator. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS. If the test light does not illuminate or flash on and off, go to next step.
  5. Turn the ignition off. Disconnect the PCM harness connectors. Turn ignition on, engine not running. Measure the voltage on the (K20) gen field control circuit in the generator field harness connector. If the voltage is above one volt, repair the short to battery voltage in the (K20) gen field control circuit. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS. If the voltage is not above one volt, go to next step.
  6. Turn the ignition off. Measure the resistance of the (K20) gen field control circuit from the generator field harness connector to the appropriate terminal of Miller Special Tool (8815). If the resistance is below 5 ohms, go to next step. If the resistance is not below 5 ohms, repair the open in the (K20) gen field control circuit. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS.
  7. Measure the resistance between ground and the (K20) gen field control circuit in the generator field harness connector. If the resistance is below 100 ohms, repair the short to ground in the (K20) gen field control circuit. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS. If the resistance is not below 100 ohms, go to next step.
  8. Using a 12-volt test light connected to battery voltage, probe the (Z346) ground circuit in the generator field harness connector. If the test light illuminates brightly, go to next step. If the test light does not illuminate, repair the open in the (Z346) generator ground circuit. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS.
  9. Using the schematics as a guide, inspect the wire harness and connectors. See Fig.5 . Pay particular attention to all power and ground circuits. If there were any problems found, repair as necessary. Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS. If there were no problems found, replace and program the PCM. See «PROGRAMMING»(ref-166557-S29154505932004092300000) . Perform «POWERTRAIN VERIFICATION TEST VER-3»(ref-166557-S12552749072004092300000) under VERIFICATION TESTS.

BODY VERIFICATION TEST VER-1

  1. Disconnect all jumper wires and reconnect all previously disconnected components and connectors.
  2. Ensure that all accessories are turned off.
  3. Ensure that the battery is fully charged.
  4. Turn the ignition on.
  5. With the scan tool, record and erase DTC's from all modules.
  6. If repairs are made to any of the HVAC door actuator circuits, with the scan tool in HVAC mode, select System Tests and then select actuator DTC detection. The test must pass before proceeding to the next step.
  7. If repairs were made to any of the HVAC doors, linkage, door actuators, or door actuator circuits, with the scan tool in HVAC mode, select System Tests and then select Actuator Calibration Test. The test must pass before proceeding to the next step.
  8. Turn the ignition off, wait 10 seconds, and then turn the ignition on.
  9. Operate all functions of the system that caused the original concern.
  10. With the scan tool, select ECU view.
  11. Check for DTC's in the modules.
  12. If any DTC's are present in any of the modules or if the original condition is still present, the repair is not complete. If no DTC's are present, repair is complete.

POWERTRAIN VERIFICATION TEST VER-2

Note. If this vehicle is equipped with a Electronic Throttle Control system, and the APP sensors, PCM, or Throttle Body Assembly have been replaced, use a scan tool to perform the ETC RELEARN function.

Note. After completing this test, perform TRANSMISSION VERIFICATION TEST .

Note. If the PCM has been replaced and the correct VIN and mileage have not been programmed, a DTC will set in the ABS Module, Air bag Module and the SKIM.

Note. If the vehicle is equipped with a Sentry Key Immobilizer System, Secret Key data must be updated. See PROGRAMMING .

  1. Inspect the vehicle to make sure that all components related to the repair are properly installed and connected.
  2. With a scan tool, clear DTC's and reset memory for all engine values.
  3. Run the engine for one warm-up cycle to verify proper operation.
  4. Road test the vehicle. Use all accessories that may be related to this repair.
  5. With the scan tool, confirm that no DTC's or secondary indicators are present and that all components are functioning properly.
  6. If this test is being performed after a NO TROUBLE CODE test, verify the symptom is no longer present.
  7. If there are any DTC's or symptoms remaining, check for any related TSB's and/or see appropriate diagnostic procedure. See «SCAN TOOL DTC MESSAGES»(ref-166557-S37019597202004092300000) table. If no DTC's or symptoms remain, repair is complete.

POWERTRAIN VERIFICATION TEST VER-3

Note. After completing this test, perform TRANSMISSION VERIFICATION TEST .

  1. If this vehicle is equipped with an Electronic Throttle Control system, and the APP Sensors, PCM, or Throttle Body Assembly has been replaced, use a scan tool to perform the ETC RELEARN function.
  2. If the PCM has been replaced and the correct VIN and mileage have not been programmed, a DTC will set in the ABS Module, Air bag module and the SKIM.
  3. If the vehicle is equipped with a Sentry Key Immobilizer System, Secret Key data must be updated. See «PROGRAMMING»(ref-166557-S29154505932004092300000) .
  4. Inspect the vehicle to make sure that all components related to the repair are properly installed and connected.
  5. With the scan tool, clear DTC's.
  6. Perform generator output test.
  7. Start the engine and set engine speed to 2000 RPM for at least 30 seconds.
  8. Cycle the ignition key off and on.
  9. With the scan tool, read the DTC's.
  10. If any DTC's or symptoms are remaining, check for any TSB's and/or see the «SCAN TOOL DTC MESSAGES»(ref-166557-S37019597202004092300000) table. If no DTC's or symptoms are remaining, repair is complete.

POWERTRAIN VERIFICATION TEST VER-5

Note. After completing this test, perform TRANSMISSION VERIFICATION TEST .

Note. If the PCM has been replaced and the correct VIN and mileage have not been programmed, a DTC will be set in the ABS Module, Air bag module and the SKIM.

Note. If the vehicle is equipped with a Sentry Key Immobilizer System, Secret Key data must be updated. See PROGRAMMING .

Note. If this vehicle is equipped with an Electronic Throttle Control system, and the APP sensors, PCM, or throttle body assembly have been replaced, use the scan tool to perform the ETC RELEARN function.

Note. When replacing an O2 sensor, the PCM RAM memory must be cleared, either by disconnecting the PCM C-1 connector or momentarily disconnecting the negative battery cable.

  1. The NGC learns the characteristics of each O2 heater element and these old values should be cleared when installing a new O2 sensor. The customer may experience driveability issues if this is not performed.
  2. Inspect the vehicle to ensure that all engine components are properly installed and connected. Reassemble and reconnect components as necessary.
  3. Connect the scan tool to the data link connector.
  4. Make sure the fuel tank has at least a quarter tank of fuel. Turn off all accessories.
  5. If the catalyst was replaced, with the scan tool go to the MISCELLANEOUS menu option "CATALYST REPLACED" and press enter.
  6. If a comprehensive component DTC was repaired, perform steps 7 - 9 . If a major OBDII monitor DTC was repaired, skip those steps and continue verification.
  7. After the ignition has been off for at least 10 seconds, restart the vehicle and run 2 minutes.
  8. With the scan tool, monitor the appropriate pre-test enabling conditions until all conditions have been met. Once the conditions have been met, switch screen to the appropriate OBDII monitor, (Audible beeps when the monitor is running).
  9. If the repaired OBDII trouble code has reset or was seen in the monitor while on the road test, the repair is not complete. Check for any related technical service bulletins or flash updates and return to «SCAN TOOL DTC MESSAGES»(ref-166557-S37019597202004092300000) table.
  10. If the conditions cannot be duplicated, erase all DTC's with the DRBIII(R).
  11. If another DTC has set, return to the «SCAN TOOL DTC MESSAGES»(ref-166557-S37019597202004092300000) table and follow the path specified for that DTC.
  12. If the OBDII monitor ran successfully and has a good trip counter changed to one or more, repair is complete. If the counter did not change, check for any TSB's and/or appropriate diagnostic procedure. See «SCAN TOOL DTC MESSAGES»(ref-166557-S37019597202004092300000) table.

TRANSMISSION VERIFICATION TEST

  1. Connect the scan tool to the DLC.
  2. Reconnect any disconnected components.
  3. With the scan tool, erase all transmission DTC's, and erase all PCM DTC's.
  4. Using scan tool, perform PRNDL FAULT CLEARING PROCEDURE after completion of repairs for DTC P0706: CHECK SHIFTER SIGNAL. For DTC repair procedure, see appropriate AUTOMATIC TRANSMISSIONS article.
  5. With the scan tool, display transmission temperature. Start and run the engine until the transmission temperature is HOT, above 110°F (43°C).
  6. Check the transmission fluid and adjust if necessary.
  7. If the Transmission Control Module (TCM) or torque converter has been replaced, or if the transmission has been repaired or replaced, it is necessary to perform the scan tool Quick Learn Procedure and reset the "Pinion Factor".
  8. Road test the vehicle. With the scan tool, monitor the engine RPM. Make 15-20; 1-2, 2-3, 3-4 upshifts. Perform these shifts from a standing start to 45 MPH with a constant throttle opening of 20-25 degrees.
  9. Below 25 MPH, make 5-8 wide open throttle kickdowns to 1st gear. Allow at least 5 seconds each in 2nd and 3rd gear between each kickdown.
  10. For a specific DTC, drive the vehicle to the Symptom's When Monitored/When Set conditions to verify the DTC is repaired.
  11. If equipped with AutoStick(R), upshift and downshift several times using the AutoStick(R) feature during the road test.
  12. Use the EATX OBDII task manager to run Good Trip time in each gear. This will confirm the repair and ensure that the DTC has not re-matured.
  13. Check for Diagnostic Trouble Codes (DTC's) during the road test. If no codes are set, repair is complete. If a DTC sets during the road test, diagnose as necessary. See appropriate AUTOMATIC TRANSMISSIONS article. After repair is complete, repeat this test.

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