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Charging System - Generators & Regulators Dodge Grand Caravan III

Charging System 2 illustrations ~4656 words

DESCRIPTION

Chrysler Corp. minivans use a Denso generator. The generator consists of a rotor, stator, rectifiers, front and rear covers and drive pulley. Generator is serviced as a complete unit only. Voltage regulation is controlled by the Powertrain Control Module (PCM). Electronic Voltage Regulator (EVR) is not a separate component, but a circuit located within the PCM. If EVR circuit is defective, PCM must be replaced.

ApplicationCase No. (1)Minimum Amps
90-Amp468609886
120-Amp468609998
(1) Part number is located on side of generator case.
(1)Part number is located on side of generator case.

GENERATOR APPLICATION

OPERATION

The amount of amperage produced by the generator is controlled by Electronic Voltage Regulator (EVR) circuitry within the PCM. EVR circuitry is connected in series with the generator field driver terminal and ground. A Battery Temperature Sensor (BTS), located within PCM, is used to sense battery temperature. Sensed battery temperature and data from monitored line voltage is used by PCM to adjust battery charging rate. This is accomplished by cycling the ground path to control the strength of generator rotor magnetic field. PCM then compensates and regulates generator amperage output accordingly. The PCM monitors critical input to control fuel injection, ignition, emission and other engine management functions. The PCM is also programmed to monitor charging system related circuits.

  1. Battery feed to PCM.
  2. Generator field control.
  3. Battery charging voltage (high & low).

If a problem is sensed in a monitored circuit, a Diagnostic Trouble Code (DTC) will be stored in PCM memory and Malfunction Indicator Light (MIL) will come on, provided specific criteria have been met. DTCs can be read using MIL or Chrysler's Diagnostic Readout Box (DRB-III).

Note. DTC is erased from memory if failure does not reoccur after 50 engine starts.

Certain DTCs cause MIL to illuminate and engine controller to 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

ApplicationNew: Lbs. (kg)Used: Lbs. (kg)
2.4L190 (86)115 (52)
3.0L, 3.3L & 3.8L(1)(1) *
(1) Dynamic tensioner is used. No adjustment is required.
(1)Dynamic tensioner is used. No adjustment is required.

BELT TENSION

INITIAL CHECKS

Before proceeding with charging system diagnosis, ensure following conditions are met.

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

UNSTEADY OR LOW CHARGING

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

OVERCHARGING

Check for grounded generator field wiring or faulty generator.

NOISY GENERATOR

Check for worn or frayed drive belt, loose generator mounting, or faulty generator.

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

SELF-DIAGNOSTIC SYSTEM

If a problem is sensed in a monitored circuit, a DTC will be stored in PCM and MIL will come on, provided specific criteria are met. PCM will then enter limp-in mode, substituting information from other sources to compensate for component failure. Vehicle is operational in limp-in mode, but driveability may not be optimal.

A specific DTC results from a particular system failure. DTC only indicates problem circuit. It does not identify specific component failure in the circuit.

If problem is repaired or ceases to exist, PCM automatically clears DTCs after 50 ignition on-off cycles. DTCs can also be cleared using scan tool. See CLEARING DTCs.

PRECAUTIONS

Before proceeding with diagnosis, observe following precautions.

  1. Ensure battery is fully charged and charging system is functional.
  2. Probe PCM connector from pin side. DO NOT backprobe PCM connector.
  3. DO NOT cause short circuits when performing electrical tests. This will set additional DTCs, making diagnosis of original problem more difficult.
  4. DO NOT use a test light in place of a voltmeter.
  5. Always begin repair with lowest DTC number (MIL) or first fault displayed (DRB).
  6. Always perform verification test after repairs are made.
  7. Always disconnect scan tool after use.
  8. Always disconnect scan tool before charging battery.

ON-BOARD DIAGNOSTICS

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

Note. Self-diagnostic tests are written specifically for Chrysler's Diagnostic Readout Box (DRB-III) scan tool, which will be referred to as scan tool during testing procedures. A generic scan tool should may also be used for system diagnostics, but has limited diagnostic capability.

Note. PCM cannot diagnose every charging system problem. If fault still exists after performing self-diagnostic procedures, proceed to ON-VEHICLE TESTING .

Faults may be retrieved using Malfunction Indicator Light (MIL) on instrument panel or scan tool. To activate MIL, turn ignition key on-off-on-off-on within 5 seconds. Count number of times MIL flashes on and off. This represents the DTC. Following is a brief description of DTCs and conditions.

  1. DTC 12 - Battery feed to PCM has been interrupted within last 50-100 engine starts. PCM monitors this circuit whenever ignition is on.
  2. DTC 41 - Generator field control fails to switch properly. PCM monitors this circuit whenever ignition is on.
  3. DTC 44 - Battery temperature sensor voltage is out of range. PCM monitors this circuit whenever ignition is on.
  4. DTC 46 - Charging system voltage is more than one volt above desired control voltage for more than 20 seconds. PCM monitors this signal whenever engine is running.
  5. DTC 47 - Charging system voltage is at least one volt less than desired control voltage for more than 20 seconds. No significant change in voltage is detected during active test of generator. PCM monitors this signal whenever engine speed is more than 1500 RPM.

CLEARING DTCS

PCM automatically clears DTCs from PCM memory after 50 ignition on-off cycles. DTC's can also be cleared using scan tool by following scan tool manufacturer's instructions.

NO RESPONSE Message

See TEST NS-2A in TESTS W/CODES article.

Note. For more information on scan tool and PCM diagnostics, see the appropriate TESTS W/CODES article. Refer to the G - TESTS W/CODES ARTICLE MENU & LINKS table.

G - TESTS W/CODES ARTICLE MENU & LINKS

SELF-DIAGNOSTIC TESTS

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.

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

DTC TEST - CHECKING FOR DTCS

Note. For connector terminal identification, see CONNECTOR IDENTIFICATION in the appropriate TESTS W/CODES article. See the G - TESTS W/CODES ARTICLE MENU & LINKS table.

  1. Attempt to start engine. If necessary, crank engine for up to 10 seconds. Connect scan tool to Data Link Connector (DLC). Record scan tool trouble codes. If scan tool screen shows no response, go to TEST NS-2A in TESTS W/CODES article.
  2. If DTCs are displayed, see «SCAN TOOL DTC MESSAGES»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators) table. Only DTCs relating to charging system are listed. For all other DTCs, see appropriate TESTS W/CODES article in the ENGINE PERFORMANCE section. See the «G - TESTS W/CODES ARTICLE MENU & LINKS»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators) table. If no DTCs are displayed, go to «TEST CH-1A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ch-1a-charging-system-no) - CHARGING SYSTEM NO CODE TEST.
Scan Tool DisplayDTCPerform Test
BATTERY TEMP SENSOR VOLTS TOO HIGHP1492TEST TC-153A
BATTERY TEMP SENSOR VOLTS TOO LOWP1493TEST TC-153A
CHARGING SYSTEM VOLTAGE HIGHN/ATEST TC-6A
CHARGING SYSTEM VOLTAGE LOWN/ATEST TC-5A
GEN. FIELD NOT SWITCHING PROPERLYN/ATEST TC-11A

SCAN TOOL DTC MESSAGES

TEST TC-5A - CHARGING SYSTEM VOLTAGE TOO LOW

Note. For connector terminal identification, see CONNECTOR IDENTIFICATION in appropriate TESTS W/CODES article. See the G - TESTS W/CODES ARTICLE MENU & LINKS table.

  1. Ensure battery is fully charged and generator belt is in good condition and properly adjusted before proceeding. Using scan tool, read target charging voltage. If target charging voltage is 15.1 volts or less, go to step 4). If target charging voltage is more than 15.1 volts, go to next step.
  2. Using scan tool temperature probe, measure underhood temperature near the Powertrain Control Module (PCM). The PCM is located between driver's side front fender and power distribution center, near battery. Using scan tool, read the Battery Temperature Sensor (BTS) temperature.
  3. If BTS temperature is not within 10 degrees of the underhood temperature, replace Powertrain Control Module (PCM). Perform «TEST VER-2A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-2a-road-test-verification). If BTS temperature is within 10 degrees of the underhood temperature, go to next step.
  4. Connect voltmeter between positive B+ lead (large single battery terminal) on rear of generator and positive battery terminal. Start engine and note voltage reading on voltmeter. If voltage is.4 volt or less, go to next step. If voltage is more than.4 volt, repair B+ circuit between battery and generator for high resistance. Perform «TEST VER-2A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-2a-road-test-verification).
  5. Turn ignition off. Connect voltmeter between generator case and negative battery terminal. Start engine and note voltage reading on voltmeter. If voltage is.1 volt or less, go to next step. If voltage is more than.1 volt, repair generator ground circuit for high resistance. Perform «TEST VER-2A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-2a-road-test-verification).
  6. Remove voltmeter. Maintain engine RPM at 1600 RPM. Using scan tool, read target charging voltage and charging voltage. Compare the 2 readings.
  7. If difference between the 2 readings is one volt or less, go to next step. If difference between the 2 readings is more than one volt, go to step 9).
  8. Allow engine to idle. Shut engine off. Turn ignition on. Using scan tool, clear Diagnostic Trouble Codes (DTCs) from Powertrain Control Module (PCM). Perform «TEST CH-1A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ch-1a-charging-system-no) - CHARGING SYSTEM NO CODE TEST.
  9. Ensure ignition is off. Disconnect PCM connectors. The PCM is located between driver's side front fender and power distribution center, near battery. Disconnect round 2-wire connector from rear of generator.
  10. Using ohmmeter, check resistance of Dark Green/Orange wire between PCM connector terminal No. 6 and round 2-wire connector on rear of generator. (Scheme 1) If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open circuit in the Dark Green/Orange wire between the PCM and generator. Perform «TEST VER-2A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-2a-road-test-verification).
  11. Using ohmmeter, check resistance of Dark Green wire between PCM connector terminal No. 4 and round 2-wire connector on rear of generator. If resistance is less than 5 ohms, replace generator. Perform «TEST VER-2A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-2a-road-test-verification). If resistance is 5 ohms or more, repair open circuit on Dark Green wire between PCM and generator. Perform «TEST VER-2A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-2a-road-test-verification).

Scheme 1

Scheme 1
Scheme 1

TEST TC-6A - CHARGING SYSTEM VOLTAGE TOO HIGH

Note. For connector terminal identification, see CONNECTOR IDENTIFICATION in appropriate TESTS W/CODES article. See the G - TESTS W/CODES ARTICLE MENU & LINKS table.

  1. Ensure battery is fully charged and generator belt is in good condition and properly adjusted before proceeding. Turn ignition on.
  2. Using scan tool, actuate generator field driver. Using voltmeter, check voltage by backprobing terminal No. 2 (Dark Green wire) at round 2-wire connector on back of generator.
  3. If voltage cycles from low voltage to high voltage, perform TEST TC-6B. If voltage does not cycle from low voltage to high voltage, go to next step.
  4. Using scan tool, stop actuation of generator field driver. Turn ignition off. Disconnect connectors from Powertrain Control Module (PCM). The PCM is located between driver's side front fender and power distribution center, near battery.
  5. Disconnect round 2-wire connector from rear of generator. Using ohmmeter, check resistance between ground and PCM connector terminal No. 4 (Dark Green wire). (Scheme 1)
  6. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair generator field driver circuit for short to ground in Dark Green wire between PCM and generator. Perform «TEST VER-2A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-2a-road-test-verification).
  7. Using ohmmeter, check resistance between ground and generator field driver terminal (Dark Green wire) at generator. If resistance is less than 5 ohms, short circuit exists in generator. Replace generator. Perform «TEST VER-2A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-2a-road-test-verification). If resistance is 5 ohms or more, replace PCM. Perform «TEST VER-2A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-2a-road-test-verification).

TEST TC-6B - CHARGING SYSTEM VOLTAGE TOO HIGH

Note. Perform TEST TC-6A before proceeding. For connector terminal identification, see CONNECTOR IDENTIFICATION in appropriate TESTS W/CODES article. See the G - TESTS W/CODES ARTICLE MENU & LINKS table.

  1. Using scan tool, stop actuation of generator field driver. Note target charging voltage. If target charging voltage is 13 volts or less, go to next step. If target charging voltage is more than 13 volts, go to step 4).
  2. Using scan tool temperature probe, measure underhood temperature near the Powertrain Control Module (PCM). The PCM is located between driver's side front fender and power distribution center, near battery. Using scan tool, read Battery Temperature Sensor (BTS) temperature.
  3. If BTS temperature is not within 10 degrees of underhood temperature, replace PCM. Perform «TEST VER-2A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-2a-road-test-verification) . If BTS temperature is within 10 degrees of underhood temperature, go to next step.
  4. Start engine and maintain engine speed at 1600 RPM. Using scan tool, read target charging voltage and charging voltage. Compare voltage readings for 5 minutes.
  5. If difference between the 2 readings is more than one volt, replace PCM. Perform «TEST VER-2A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-2a-road-test-verification) . If difference between the 2 readings is one volt or less, allow engine to idle. Shut engine off. Turn ignition on. Using scan tool, clear Diagnostic Trouble Codes (DTCs) from Powertrain Control Module (PCM). Perform «TEST CH-1A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ch-1a-charging-system-no) - CHARGING SYSTEM NO CODE TEST.

TEST TC-11A - GENERATOR FIELD NOT SWITCHING PROPERLY

Note. For connector terminal identification, see CONNECTOR IDENTIFICATION in appropriate TESTS W/CODES article. See the G - TESTS W/CODES ARTICLE MENU & LINKS table.

  1. Using scan tool, clear Diagnostic Trouble Codes (DTCs) from Powertrain Control Module (PCM). Turn ignition on. Using scan tool, actuate generator field driver. Using voltmeter, check voltage by backprobing terminal No. 1 (Dark Green/Orange wire) at round 2-wire connector on rear of generator.
  2. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open circuit in Dark Green/Orange wire between generator and Auto Shutdown (ASD) relay. The ASD relay is located in power distribution center at driver's side front corner of engine compartment, near battery. Perform «TEST VER-3A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-3a-charging-verification).
  3. Using voltmeter, check voltage by backprobing terminal No. 2 (Dark Green wire) at round 2-wire connector on rear of generator. If voltage cycles from low voltage to high voltage, go to next step. If voltage does not cycle from low voltage to high voltage, go to step 9).
  4. Conditions required to set DTC are not present at this time. The PCM regulates charging system voltage at 12.9-15.0 volts. Charging system voltage determined by PCM is referred to as the control voltage. Control voltage is determined from the Battery Temperature Sensor (BTS) input signal to PCM. Control voltage is compared to the sensed voltage so PCM may control field circuit ground to obtain correct voltage.
  5. DTC may be stored in PCM when the PCM tries to regulate generator field with no result. Possible causes are: field driver circuit open or shorted, generator internal open or short, defective PCM, defective connector terminals or wiring. Go to next step.
  6. Check for defective wiring or connections at rear of generator, PCM and ASD relay. The PCM is located between driver's side front fender and power distribution center, near battery. The ASD relay is located in power distribution center at driver's side front corner of engine compartment, near battery.
  7. If defective wiring or connections exist, repair as necessary. Perform «TEST VER-3A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-3a-charging-verification). If no defective wiring or connections exist, using scan tool, check for DTCs with generator field driver still actuated. Wiggle wiring harness from generator to the PCM and note if DTC is set to indicate generator field is not switching properly.
  8. If DTC for generator field not switching properly is set, repair wiring harness as necessary. Perform «TEST VER-3A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-3a-charging-verification). If DTC was not set, no problem is indicated at this time. Perform «TEST VER-3A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-3a-charging-verification).
  9. Using scan tool, stop actuation of generator field driver. Turn ignition off. Disconnect PCM connectors. The PCM is located between driver's side front fender and power distribution center, near battery.
  10. Disconnect round 2-wire connector from rear of generator. Using ohmmeter, check resistance of Dark Green wire between terminal No. 2 at round 2-wire connector and PCM connector terminal No. 4. (Scheme 1)
  11. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair generator field driver circuit for open circuit in Dark Green wire between PCM and generator. Perform «TEST VER-3A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-3a-charging-verification).
  12. Using ohmmeter, check resistance between generator field driver terminals at rear of generator. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, replace generator. Perform «TEST VER-3A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-3a-charging-verification).
  13. Using ohmmeter, check resistance between ground and terminal No. 2 (Dark Green wire) in the round 2-wire connector that was disconnected from rear of generator.
  14. If resistance is less than 5 ohms, repair short to ground in Dark Green wire between generator and PCM. Perform «TEST VER-3A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-3a-charging-verification). If resistance is 5 ohms or more, replace PCM. Perform «TEST VER-3A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-3a-charging-verification).

TEST TC-153A - BATTERY TEMP SENSOR VOLTAGE TOO LOW/TOO HIGH

Note. For connector terminal identification, see CONNECTOR IDENTIFICATION in appropriate TESTS W/CODES article. See the G - TESTS W/CODES ARTICLE MENU & LINKS table.

  1. Using scan tool, check for stored Diagnostic Trouble Codes (DTCs). If scan tool displays BATTERY TEMPERATURE SENSOR VOLTAGE with a run count of zero, replace Powertrain Control Module (PCM). Perform «TEST VER-2A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-2a-road-test-verification) . If scan tool does not display BATTERY TEMPERATURE SENSOR VOLTAGE with a run count of zero, go to next step.
  2. Conditions required to set DTC are not present at this time. Battery Temperature Sensor (BTS) is built internally in the PCM. The BTS voltage signal is used by PCM to determine what charging system goal should be.
  3. The PCM uses charging system goal to determine charging system output level. DTC will be set when PCM senses voltage from BTS is less than .5 volt or more than 4.9 volts for 3 seconds. Check wiring harness and charging circuit related connectors for loose, corroded or damaged terminals. Repair as necessary. Perform «TEST VER-2A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-2a-road-test-verification) .

TEST CH-1A - CHARGING SYSTEM NO CODE TEST

Note. Perform DTC TEST , TEST TC-5A or TEST TC-6A before proceeding. Ensure battery is fully charged and in good condition before proceeding. For connector terminal identification, refer to CONNECTOR IDENTIFICATION in the appropriate TESTS W/CODES article. Refer to the G - TESTS W/CODES ARTICLE MENU & LINKS table.

  1. Inspect generator belt for proper tension and good condition. If generator belt is okay, go to next step. If generator belt tension is incorrect or belt is damaged, repair as necessary. Perform «TEST VER-3A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-3a-charging-verification) .
  2. Start engine. Using scan tool, set engine speed at 1600 RPM for 30 seconds. Using scan tool, return engine speed to idle and read Diagnostic Trouble Codes (DTCs). If any DTCs exist pertaining to charging system, go to appropriate test. See «DTC TEST»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__dtc-test-checking-for-dtcs) . If no DTCs exist pertaining to charging system, go to next step.
  3. Turn ignition off. Turn ignition on with engine off. Using scan tool, actuate generator field. Using scan tool in voltmeter mode, backprobe terminal No. 2 (Dark Green) at round 2-wire connector on rear of generator. Voltage should cycle from zero volts to battery voltage every 1.4 seconds.
  4. While monitoring voltage display on scan tool, wiggle wiring from round 2-pin connector on rear of alternator back to Powertrain Control Module (PCM) and Auto Shutdown (ASD) relay. The PCM is located between driver's side front fender and power distribution center, near battery. The ASD relay is located at rear of power distribution center at driver's side front corner of engine compartment, near battery.
  5. If no interruption of normal voltage cycle exists when wiggling wiring, go to next step. If interruption of normal voltage cycle exists when wiggling wiring, repair wiring as necessary. Perform «TEST VER-3A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-3a-charging-verification) .
  6. Using scan tool, read DTCs. If any DTCs exist pertaining to charging system, perform appropriate test. If no DTCs exist pertaining to charging system, go to next step.
  7. Using external voltmeter, connect voltmeter positive lead on B+ (battery) terminal on rear of generator. Connect voltmeter negative lead to positive battery terminal.
  8. Start engine and note voltage reading on voltmeter. If voltage is .4 volt or less, go to next step. If voltage is more than .4 volt, repair B+ circuit between battery and generator for high resistance. Perform «TEST VER-3A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-3a-charging-verification) .
  9. Turn ignition off. Using external voltmeter, connect voltmeter positive lead on generator case. Connect voltmeter negative lead to negative battery terminal.
  10. Start engine and note voltage reading on voltmeter. If voltage is .4 volt or less, go to next step. If voltage is more than .4 volt, repair generator ground circuit from generator case to negative battery terminal for high resistance. Perform «TEST VER-3A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-3a-charging-verification) .
  11. Remove external voltmeter. Using scan tool, read battery voltage. Record this voltage reading. Using external voltmeter, measure battery voltage between positive and negative battery terminals. Record this voltage reading.
  12. Compare both voltage readings obtained in step 11). If the difference between both voltage readings is less than one volt, test is complete. Perform «TEST VER-3A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-3a-charging-verification) . If the difference between both voltage readings is one volt or more, go to next step.
  13. Ensure ignition is off. Disconnect connectors from PCM. Using external voltmeter, check voltage at PCM connector terminal No. 46 (Red/White wire). Compare this voltage reading to voltage reading obtained using scan tool in step 11).
  14. If this voltage reading is not within one volt of voltage reading obtained using scan tool in step 11), replace PCM. Perform «TEST VER-3A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-3a-charging-verification) . If this voltage reading is within one volt of voltage reading obtained using scan tool in step 11), repair high resistance on Red/White wire between PCM connector terminal No. 46 and battery. Perform «TEST VER-3A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-ver-3a-charging-verification) .

TEST VER-2A - ROAD TEST VERIFICATION

Note. For connector terminal identification, see CONNECTOR IDENTIFICATION in appropriate TESTS W/CODES article. See the G - TESTS W/CODES ARTICLE MENU & LINKS table.

  1. Inspect vehicle to ensure all engine components are connected. Reassemble and reconnect components as necessary.
  2. Check if initial symptom still exists. If initial or another symptom exists, repair is not complete. Check for Technical Service Bulletins (TSBs) that apply to the symptom and return to «DTC TEST»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__dtc-test-checking-for-dtcs) if necessary.
  3. If any DTCs have not been diagnosed, go to «DTC TEST»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__dtc-test-checking-for-dtcs) and finish diagnosing remaining DTCs as necessary. If all DTCs have been diagnosed, go to next step.
  4. If Powertrain Control Module (PCM) has not been changed, using scan tool, clear DTCs from PCM. Using scan tool, reset all values in adaptive memory. Disconnect scan tool. To ensure no other DTCs remain, go to next step.
  5. Using scan tool, check for stored DTCs. If repaired DTC has reset, repair is not complete. Check for related Technical Service Bulletins (TSBs) and return to «DTC TEST»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__dtc-test-checking-for-dtcs) if necessary. If another DTC exists, return to DTC TEST and follow path specified by other DTC. If no other DTCs exist, repair is now complete.

TEST VER-3A - CHARGING VERIFICATION

Note. For connector terminal identification, see CONNECTOR IDENTIFICATION in appropriate TESTS W/CODES article. See the G - TESTS W/CODES ARTICLE MENU & LINKS table.

  1. Inspect vehicle to ensure all engine components are connected. Reassemble and reconnect components as necessary. If Powertrain Control Module (PCM) has been changed, go to next step. If PCM has not been changed, go to step 3).
  2. If vehicle is equipped with factory vehicle theft security system, start vehicle at least 20 times so vehicle theft security system can be activated when desired. Using scan tool, clear DTCs from PCM. Go to next step.
  3. To ensure no charging system problem exists, start engine. Increase engine speed to 2000 RPM for at least 30 seconds. Allow engine to idle. Turn engine off.
  4. Turn ignition on with engine off. Using scan tool, check for stored DTCs. If repaired DTC has reset, repair is not complete. Check for related Technical Service Bulletins (TSBs) and return to «DTC TEST»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__dtc-test-checking-for-dtcs) if necessary. If another DTC exists, return to DTC TEST and follow specified procedure specified by other DTC. If no other DTCs exist, repair is now complete.

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.

VOLTAGE DROP TEST

Note. VOLTAGE DROP TEST determines amount of resistance in circuits between generator and battery.

  1. Ensure battery is in condition and is fully charged. Clean battery terminals (if necessary). Using external voltmeter, connect positive lead to generator B+ terminal stud (not the nut). Connect voltmeter negative lead to positive battery post. 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, A/C-heater blower motor to high speed and headlights on high beam. Increase engine speed to 2400 RPM. Voltmeter reading should not be more than 0.6 volt.
  3. If voltage drop is more than 0.6 volt, inspect, clean and tighten all connections between generator B+ terminal and positive battery post. 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.

CURRENT OUTPUT TEST

CAUTIONGenerator has 2 field terminals: generator field driver (Dark Green wire) and ASD relay output (Dark Green/Orange wire). DO NOT connect generator ASD relay output terminal to ground.

Note. Perform VOLTAGE DROP TEST before continuing with this test. Perform test soon after starting engine, as charging amperage will drop quickly. A volt/amp tester equipped with both a battery load control (carbon pile rheostat) and an inductive type pick-up clamp is required to perform the 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. NOTE: Depending on volt/amp tester manufacturer, load may be applied automatically. Refer to volt/amp tester manufacturer's instructions.
  3. Note reading on ammeter. Generator amperage reading should be more than the minimum amperage rating specification. See «GENERATOR APPLICATION»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators) table under DESCRIPTION. If amperage reading is less than minimum specification, go to step 5). If amperage reading is more than 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 circuitry is okay and charging system is functioning properly. It may take several minutes for amperage to change. If output amperage does not change to less than 20-amps, perform «TEST TC-11A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-tc-11a-generator-field-not) - GENERATOR FIELD NOT SWITCHING PROPERLY under SELF-DIAGNOSTIC TESTS.
  5. Connect a jumper wire between ground and generator field driver terminal (Dark Green wire) on back of generator. Start engine, and immediately 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 exceed 16 volts.
  6. Note reading on volt/amp tester. Generator amperage reading should be more than the minimum amperage rating specification. See «GENERATOR APPLICATION»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators) table under DESCRIPTION. If amperage reading is less than minimum specification, replace generator. If amperage reading is more than minimum specification, a fault exists in EVR circuitry. Perform «TEST TC-11A»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__test-tc-11a-generator-field-not) - GENERATOR FIELD NOT SWITCHING PROPERLY under SELF-DIAGNOSTIC TESTS.

REMOVAL & INSTALLATION

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.

REMOVAL & INSTALLATION (2.4L)

  1. Disconnect negative battery cable. Remove accessory drive belt. Disconnect chassis wiring connector. Remove nut holding B+ cable to back of generator and disconnect B+ cable.
  2. Remove generator mounting bolts. Remove generator. To install, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__torque-specifications) .

REMOVAL & INSTALLATION (3.0L)

  1. Disconnect negative battery cable. Remove windshield wiper housing. Remove accessory drive belt. Remove generator mounting bolts.
  2. Disconnect chassis wiring connector. Remove B+ terminal nut and disconnect B+ cable. Remove wire connectors. Remove generator from vehicle. To install, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators__torque-specifications) .

REMOVAL & INSTALLATION (3.3L & 3.8L)

  1. Disconnect negative battery cable. Remove windshield wiper housing. Remove accessory drive belt. Remove generator mounting bolts. Remove generator mount bracket.
  2. Disconnect chassis wiring connector. Remove B+ terminal nut and disconnect B+ cable. Remove generator. To install, reverse removal procedure. Tighten fasteners to specification. Refer to the «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/charging-system/#charging-system-generators-regulators) table.

Charging System Wiring Diagram. Scheme 2

Scheme 2: Charging System Wiring Diagram
Scheme 2: Charging System Wiring Diagram

TORQUE SPECIFICATIONS

ApplicationFt. Lbs. (N.m)
Generator Mounting Bolts40 (54)
INCH Lbs. (N.m)
Battery Hold-Down Bolt/Nut125 (14)
Field Terminal Nuts25 (3)
B+ & Ground Terminal Nuts75 (9)

TORQUE SPECIFICATIONS