Charging System - Generators & Regulators Dodge Grand Caravan IV

GENERATOR APPLICATION

GENERATOR APPLICATION

BATTERY TEMPERATURE SENSOR

The PCM incorporates a Battery Temperature Sensor (BTS) on its circuit board.

The charging system consists of

1. Generator.
2. Decoupler pulley (If equipped).
3. Electronic Voltage Regulator (EVR) circuitry within the Powertrain Control Module (PCM).
4. Ignition switch.
5. Battery.
6. Ambient air temperature (if equipped).
7. Inlet air temperature (calculated battery temperature) (if equipped).
8. Voltmeter.
9. Wiring harness and connections.
10. Accessory drive belt.
11. Battery temperature sensor (if equipped).

The generator is belt-driven by the engine. The generator produces DC voltage at the B+ terminal. If the generator is failed, the generator assembly subcomponents (generator and decoupler pulley) must be inspected for individual failure and replaced accordingly.

GENERATOR DECOUPLER PULLEY

The Generator Decoupler is a one-way clutch. It is attached to the generator and replaces the standard pulley. It is a non-serviceable item and is to be replaced as an assembly. It is a dry operation (no grease or lubricants). The operation of it is not temperature sensitive and has a low sensitivity to electrical load. (Scheme 1)

Scheme 1

VOLTAGE REGULATOR

The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced.

The PCM uses the temperature of the battery area to control the charge system voltage. This temperature, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. The system voltage is higher at cold temperatures and is gradually reduced as temperature around the battery increases.

The PCM maintains the optimal output of the generator by monitoring battery voltage and controlling it to a range of 13.5-14.7 volts based on battery temperature. The system target voltage is 13.5-14.7 volts. However the actual voltage may go below this during heavy electrical loads and generator speeds. Also the actual voltage can be lower than the target voltage between the battery and the battery voltage sense circuit, approximately 0.2-0.3 volts.

The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20°F (-6.7°C).

The charging system is turned on and off with the ignition switch. The system is on when the engine is running and the ASD relay is energized. The ASD relay is energized when the PCM grounds the ASD control circuit. This voltage is connected through the PCM or IPM (Intelligent Power Module) (if equipped) and supplied to one of the generator field terminals (Gen. Source +) at the back of the generator.

The generator is driven by the engine through a serpentine belt and pulley or decoupler pulley arrangement.

The amount of DC current produced by the generator is controlled by the EVR (field control) circuitry contained within the PCM. This circuitry is connected in series with the second rotor field terminal and ground.

An ambient air temperature sensor is used to calculate the temperature near the battery. This temperature data, along with data from monitored line voltage (battery voltage sense circuit), is used by the PCM to vary the battery charging rate. This is done by cycling the ground path to control the strength of the rotor magnetic field. The PCM then compensates and regulates generator current output accordingly to maintain system voltage at the targeted system voltage based on battery temperature.

All vehicles are equipped with On-Board Diagnostics (OBD). All OBD-sensed systems, including EVR (field control) circuitry, are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for certain failures it detects and illuminate the (MIL) lamp.

The Charging system "Battery" light indicates problems with the charging system (voltage too high/low, generator failure, etc.). If an extreme condition is indicated, the lamp will be illuminated. The signal to activate the lamp is sent via the PCI bus circuits. The lamp is located on the instrument panel. Refer to the appropriate ANALOG INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT for additional information.

The PCM uses the ambient air temperature sensor to control the charge system voltage. This temperature, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. The system voltage is higher at cold temperatures and is gradually reduced as the calculated battery temperature increases.

The ambient temperature sensor is used to control the battery voltage based upon ambient temperature (approximation of battery temperature). The PCM maintains the optimal output of the generator by monitoring battery voltage and controlling it to a range of 13.5-14.7 volts based on battery temperature. The system target voltage is 13.5-14.7 volts. However, the actual voltage may go below this during heavy electrical loads and generator speeds. Also, the actual voltage can be lower than the target voltage between the battery and the battery voltage sense circuit, approximately 0.2-0.3 volts.

As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into the windings of the stator coil. Once the generator begins producing sufficient current, it also provides the current needed to energize the rotor.

The Y-type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for rectification. From the diodes, rectified DC current is delivered to the vehicles electrical system through the generator, battery, and ground terminals.

Excessive or abnormal noise emitting from the generator may be caused by

1. Worn, loose or defective bearings.
2. Loose or defective drive pulley (2.4L) or decoupler (3.3l & 3.8L).
3. Incorrect, worn, damaged or misadjusted drive belt.
4. Loose mounting bolts.
5. Misaligned drive pulley.
6. Defective stator or diode.
7. Damaged internal fins.

The generator decoupler is a one-way clutch and should be replaced as an assembly. It is designed to help reduce belt tension fluctuation, reduce fatigue loads, improve belt life, reduce hubloads on components, and reduce noise.

The amount of DC current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground.

Voltage is regulated within the PCM to control the strength of the rotor magnetic field. The EVR circuitry monitors system line voltage at the PDC and calculated battery temperature or inlet air temperature sensor. It then determines a target charging voltage. If sensed battery voltage is lower than the target voltage, the PCM feeds the field winding until sensed battery voltage is at the target voltage. A circuit in the PCM cycles the feed side of the generator field at 250 times per second (250Hz), but has the capability to feed the field control wire 100 percent of the time (full field) to achieve the target voltage. If the charging rate cannot be monitored (limp-in), a duty cycle of 20 percent is used by the PCM in order to have some generator output. Also refer to CHARGING SYSTEM for additional information.

Setting Pinion Factor

Note. This procedure must be performed if the PCM/TCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer.

The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM/TCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain/Transmission Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the pinion factor, it is necessary to use a DRBIII(R) scan tool.

1. Plug the DRBIII(R) scan tool into the diagnostic connector located under the instrument panel.
2. Select the Transmission menu.
3. Select the Miscellaneous menu.
4. Select Pinion Factor. Then follow the instructions on the DRBIII(R) scan tool screen.

Quick Learn Procedure

The quick learn procedure requires the use of the DRBIII(R) scan tool. This program allows the PCM/TCM to recalibrate itself. This will provide the best possible transaxle operation.

Note. The quick learn procedure should be performed if any of the following procedures are performed: Transaxle assembly replacement. Powertrain/Transmission control module replacement. Solenoid/Pressure switch assembly replacement. Clutch plate and/or seal replacement. Valve body replacement or recondition.

To perform the quick learn procedure, the following conditions must be met

1. The brakes must be applied.
2. The engine speed must be above 500 RPM.
3. The throttle angle (TPS) must be less than 3 degrees.
4. The shift lever position must stay until prompted to shift to overdrive.
5. The shift lever position must stay in overdrive until prompted to shift to overdrive.
6. The shift lever position must stay in overdrive after the shift to overdrive prompt, until the DRBIII(R) indicates the procedure is complete.
7. The calculated oil temperature must be above 60 degrees and below 200 degrees.

1. Plug the DRBIII(R) scan too into the diagnostic connector. The connector is located under the instrument panel.
2. Go to the transmission screen.
3. Go to the miscellaneous screen.
4. Select Quick Learn procedure. Follow the instructions of the DRBIII(R) to perform the Quick Learn Procedure.

BELT TENSION

BELT TENSION

TROUBLE SHOOTING

Verify customer's concern by operating system. Inspect for blown fuses, damaged fusible links, wiring or harness connectors. Check for loose or frayed drive belt, loose generator ground wire, or corroded battery terminals. Ensure battery is fully charged and in good condition, battery cables are in good condition with connections clean and secure. Inspect generator and 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

INTERMITTENT CONDITION

Note. The conditions that set the DTC are not present at this time. The following list may help in identifying the intermittent condition.

1. Refer to any TSB's that may apply.
2. Review the DRB Freeze Frame information. If possible, try to duplicate the conditions under which the DTC set.
3. With the engine running at normal operating temperature, monitor the DRB parameters related to the DTC while wiggling the wire harness. Look for parameter values to change and/or a DTC to set.
4. Visually inspect the related wire harness. Look for any chafed, pierced, pinched, partially broken wires and broken, bent, pushed out, or corroded terminals.
5. Inspect and clean all PCM, engine, and chassis grounds.
6. If numerous trouble codes were set, use a wire schematic to help find any common ground or supply circuits.
7. For any relay DTC's, actuate the relay with the DRBIII(R) and wiggle the related wire harness to try to interrupt the actuation.
8. For intermittent Evaporative Emission trouble codes perform a visual and physical inspection of the related parts including hoses and the fuel cap.
9. A co-pilot, data recording, and/or lab scope should be used to help diagnose intermittent conditions.
10. Use the DRBIII(R) to perform a System Test if one applies to failing component.
11. If any problems are found during the above inspections, repair as necessary. If no problems are found, test is complete.

VOLTAGE DROP TEST

Note. 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: The battery is fully charged and load tested. Fully engage the parking brake. 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. Verify that all lamps and accessories are turned off. To prevent the engine from starting, remove the Automatic Shut Down (ASD) relay. The ASD relay is locating in the Intelligent Power Module (IPM), in the engine compartment. See the fuse and relay layout label affixed to the underside of the IPM cover for ASD relay identification and location.

1. Connect the positive lead of the voltmeter to the battery negative cable terminal clamp. Rotate and hold the ignition switch in the START position. Observe the voltmeter. If the 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 cable terminal clamp and the battery positive terminal post.
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 0.2 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 0.2 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 0.2 volt, clean and tighten the battery negative cable eyelet terminal connection to the engine block. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery negative cable.

SELF-DIAGNOSTIC SYSTEM

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

If problem is repaired or ceases to exist, Powertrain Control Module (PCM) automatically clears DTCs after 40 engine warm-up cycles. DTCs can also be cleared using scan tool. See CLEARING DTCS .

RETRIEVING DIAGNOSTIC TROUBLE CODES

Note. For more information on scan tool and PCM diagnostics, see SELF-DIAGNOSTICS - CARAVAN, TOWN & COUNTRY, & VOYAGER article in ENGINE PERFORMANCE.

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

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

With Scan Tool

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. Perform appropriate test in accordance with DTC retrieved. See SCAN TOOL DTC MESSAGES table. Once repairs are made, clear DTCs from PCM. See CLEARING DTCS .

Without Scan Tool

Cycle ignition switch from OFF to ON positions, 3 times within 5 seconds. Odometer will display DTCs. Perform appropriate test in accordance with DTC retrieved. See SCAN TOOL DTC MESSAGES table. If no DTCs are present, odometer will either display DTC P1684 and DONE, or only DONE. DTC P1684 is only a status code and indicates Powertrain Control Module (PCM) memory has been cleared within last 50 ignition switch cycles. DONE indicates no DTCs are present and procedure is complete.

SCAN TOOL DTC MESSAGES

CLEARING 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.
3. Loose generator belt.

NO RESPONSE

If scan tool displays NO RESPONSE FROM PCM, repair communication concern. See PCM MESSAGES NOT RECEIVED under COMMUNICATIONS in BODY CONTROL MODULES - CARAVAN, TOWN & COUNTRY, & VOYAGER article in ACCESSORIES & EQUIPMENT.

DIAGNOSTIC TESTS

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

DTC P0070: AMBIENT TEMP SENSOR STUCK OR DTC P0071: AMBIENT TEMP SENSOR PERFORMANCE

Note. For component location, see SELF-DIAGNOSTICS - 2.4L . For connector identification, see SELF-DIAGNOSTICS - 2.4L . For circuit identification and wiring diagram, see SYSTEM & COMPONENT TESTING . In testing procedures Alpha/Numeric character in parentheses (i.e.; K4) designates circuit. After each repair procedure has been completed, reconnect all components. Perform VERIFICATION TEST VER-5 (2.4L) under VERIFICATION TESTS to ensure system is functioning properly.

When Monitored & Set Conditions

Note. Ambient temperature sensor may also be referred to as battery temperature sensor.

DTC P0070: AMBIENT TEMP SENSOR STUCK - This code is monitored when the engine is running. The DTC is set after 4 warm-up cycles, the PCM did not see a 35°F change in the ambient temperature sensor voltage within 200 miles. This is a two 2-fault.

DTC P0071: AMBIENT TEMP SENSOR PERFORMANCE - This code is monitored when the engine off time has exceeded 480 minutes. Ambient temperature is greater than 39°F. The DTC is set after a calibrated amount of cool down time, the PCM compares the Engine Coolant Temperature (ECT) sensor, Intake Air Temperature (IAT) sensor and the Ambient Air Temperature (AAT) sensor values. If the AAT sensor value is not within 53°F of the other 2 temperature sensors an error is detected. This is a 2-trip fault.

Possible Causes

1. (G31) Ambient Air Temperature (AAT) sensor signal circuit shorted to battery voltage.
2. AAT sensor voltage less than 1.0 volt.
3. (G31) AAT signal circuit open.
4. (K900) sensor ground circuit open.
5. (G31) AAT signal circuit shorted to ground.
6. (G31) AAT signal circuit shorted to (K900) sensor ground.
7. PCM.

Testing

1. Turn the ignition on. With the DRBIII(R) scan tool, read DTCs and record the related freeze frame data. Is the Good Trip Counter displayed and equal to zero? If yes, go to next step. If no, see «INTERMITTENT CONDITION»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators__intermittent-condition) .
2. Turn the ignition off. Disconnect the AAT sensor harness connector. Turn the ignition on. Measure the voltage of the (G31) AAT signal circuit in the AAT sensor harness connector. Is the voltage more than 5.2 volts? If yes, repair the short to battery voltage in the (G31) AAT signal circuit. If no, go to next step.
3. Turn the ignition off. Disconnect the AAT sensor harness connector. Turn the ignition on. With the DRBIII(R) scan tool, read the AAT sensor voltage. Is the voltage more than 4.9 volts? If yes, go to next step. If no, go to step 7 .
4. Turn the ignition off. Disconnect the AAT sensor harness connector. Using a jumper wire, jumper across the AAT sensor harness connector. Turn the ignition on. With the DRBIII(R) scan tool, read the AAT voltage. Is the voltage less than 1.0 volt? If yes, replace the AAT sensor. If no, go to next step.
5. Turn the ignition off. Disconnect the AAT sensor harness connector. Disconnect the PCM harness connectors. Measure the resistance of the (G31) AAT signal circuit from the AAT sensor harness connector to the appropriate terminal of Miller Special Tool (8815). Is the resistance less than 5.0 ohms? If yes, go to next step. If no, repair the open in the (G31) AAT signal circuit.
6. Turn the ignition off. Disconnect the AAT sensor harness connector. Disconnect the PCM harness connectors. Measure the resistance of the (K900) sensor ground circuit from the AAT sensor harness connector to the appropriate terminal of Miller Special Tool (8815). Is the resistance less than 5.0 ohms? If yes, using the wiring diagram as a guide, inspect the wire harness and connectors. Pay particular attention to all power and ground circuits. If there are no possible causes remaining, replace and program the PCM. See «PROGRAMMING»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators) . If no, repair the open in the (K900) sensor ground circuit.
7. Turn the ignition off. Disconnect the AAT sensor harness connector. Disconnect the PCM harness connectors. Measure the resistance between ground and the (G31) AAT signal circuit. Is the resistance less than 100 ohms? If yes, repair the short to ground in the (G31) AAT signal circuit. If no, go to next step.
8. Turn the ignition off. Disconnect the AAT sensor harness connector. Disconnect the PCM harness connectors. Measure the resistance between the (G31) AAT signal circuit and the (K900) sensor ground circuit in the AAT sensor harness connector. Is the resistance less than 100 ohms? If yes, repair the sensor ground shorted to the (G31) AAT signal circuit. If no, using the wiring diagram as a guide, inspect the wire harness and connectors. Pay particular attention to all power and ground circuits. If there are no possible causes remaining, replace and program the PCM. See «PROGRAMMING»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators) .

DTC P0072: AMBIENT TEMP SENSOR LOW

Note. For component location, see SELF-DIAGNOSTICS - 2.4L . For connector identification, see SELF-DIAGNOSTICS - 2.4L . For circuit identification and wiring diagram, see ENGINE PERFORMANCE in appropriate SYSTEM WIRING DIAGRAM article. In testing procedures Alpha/Numeric character in parentheses (i.e.; K4) designates circuit. After each repair procedure has been completed, reconnect all components. Perform VERIFICATION TEST VER-5 (2.4L) under VERIFICATION TESTS to ensure system is functioning properly.

Ambient temperature sensor performance is monitored with ignition on. DTC will set when the ambient temperature sensor is less than 0.0392 volt at the PCM. This is a one trip fault.

1. Ambient Air Temperature (AAT) Sensor Internal Failure
2. (G31) AAT Signal Circuit Shorted To Ground
3. (G31) AAT Signal Circuit Shorted To (K900) Sensor Ground Circuit
4. PCM

1. Turn the ignition on. With the DRBIII(R) scan tool, read the AAT sensor voltage. Is the voltage less than 0.3 volt? If yes, go to next step. If no, see «INTERMITTENT CONDITION»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators__intermittent-condition) .
2. Turn the ignition off. Disconnect the AAT sensor harness connector. Turn the ignition on. With the DRBIII(R) scan tool, read AAT sensor voltage. Is the voltage more than 1.0 volt? If yes, replace the AAT sensor. If no, go to next step.
3. Turn the ignition off. Disconnect the AAT sensor harness connector. Disconnect the PCM harness connectors. Measure the resistance between ground and the (G31) AAT signal circuit in the AAT sensor harness connector. Is the resistance less than 100 ohms? If yes, repair the short to ground in the (G31) AAT signal circuit. If no, go to next step.
4. Turn the ignition off. Disconnect the AAT sensor harness connector. Disconnect the PCM harness connectors. Measure the resistance between the (G31) AAT signal circuit and the (K900) sensor ground circuit in the AAT sensor harness connector. Is the resistance less than 100 ohms? If yes, repair the (K900) sensor ground shorted to the (G31) AAT signal circuit. If no, go to next step.
5. Using the wiring diagram as a guide, inspect the wire harness and connectors. Pay particular attention to all power and ground circuits. If there are no possible causes remaining, replace and program the PCM. See «PROGRAMMING»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators) .

DTC P0073: AMBIENT TEMP SENSOR HIGH

Note. For component location, see SELF-DIAGNOSTICS - 2.4L . For connector identification, see SELF-DIAGNOSTICS - 2.4L . For circuit identification and wiring diagram, see ENGINE PERFORMANCE in appropriate SYSTEM WIRING DIAGRAMS article. In testing procedures Alpha/Numeric character in parentheses (i.e.; K4) designates circuit. After each repair procedure has been completed, reconnect all components. Perform VERIFICATION TEST VER-5 (2.4L) under VERIFICATION TESTS to ensure system is functioning properly.

Ambient Air Temperature (AAT) sensor performance is monitored with ignition on. The DTC will set when the AAT sensor voltage is greater than 4.94 volts. This is a one-trip fault.

1. AAT sensor voltage more than 4.8 volts.
2. (G31) AAT signal circuit shorted to battery voltage.
3. AAT sensor internal failure.
4. (G31) AAT signal circuit open.
5. (K900) sensor ground circuit open.
6. PCM.

1. Turn the ignition on. With the DRBIII(R) scan tool, read the AAT sensor voltage. Is the voltage more than 4.8 volts? If yes, go to next step. If no, see «INTERMITTENT CONDITION»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators__intermittent-condition) .
2. Turn the ignition off. Disconnect the AAT sensor harness connector. Turn the ignition on. Measure the voltage of the (G31) AAT signal circuit in the AAT sensor harness connector. Is the voltage more than 5.2 volts? If yes, repair the short to battery voltage in the (G31) AAT signal circuit. If no, go to next step.
3. Turn the ignition off. Disconnect the AAT sensor harness connector. Connect a jumper wire between the (G31) AAT signal circuit and the (K900) sensor ground circuit in the AAT sensor harness connector. Turn the ignition on. With the DRBIII(R) scan tool, read AAT sensor voltage. Is the voltage less than 1.0 volt? If yes, replace the AAT sensor. If no, go to next step.
4. Turn the ignition off. Disconnect the AAT sensor harness connector. Disconnect the PCM harness connectors. Measure the resistance of the (G31) AAT signal circuit from the AAT sensor harness connector to the appropriate terminal of Miller Special Tool (8815). Is the resistance less than 5.0 ohms? If yes, go to next step. If no, repair the open in the (G31) AAT signal circuit.
5. Turn the ignition off. Disconnect the AAT sensor harness connector. Disconnect the PCM harness connectors. Measure the resistance of the (K900) sensor ground circuit from the AAT sensor harness connector to the appropriate terminal of Miller Special Tool (8815). Is the resistance less than 5.0 ohms? If yes, go to next step. If no, repair the open in the (K900) sensor ground circuit.
6. Using the wiring diagram as a guide, inspect the wire harness and connectors. Pay particular attention to all power and ground circuits. If there are no possible causes remaining, replace and program the PCM. See «PROGRAMMING»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators) .

DTC P0516: BATTERY TEMPERATURE SENSOR LOW

Note. For component location, see SELF-DIAGNOSTICS - 2.4L . For connector identification, see SELF-DIAGNOSTICS - 2.4L . For circuit identification and wiring diagram, see appropriate SYSTEM WIRING DIAGRAMS article. In testing procedures Alpha/Numeric character in parentheses (i.e.; K4) designates circuit. After each repair procedure has been completed, reconnect all components. Perform VERIFICATION TEST VER-5 (2.4L) under VERIFICATION TESTS to ensure system is functioning properly.

Battery temperature sensor is monitored with ignition on. DTC will set if the battery temperature sensor voltage is less than 0.5 volt.

1. Battery Temperature Sensor Internal Failure
2. Battery Temperature Signal Shorted To Ground
3. Battery Temperature Signal Shorted To Sensor Ground Circuit
4. PCM

1. Turn the ignition on. With the DRBIII(R) scan tool, read the battery temperature sensor voltage. Is the voltage less than 0.5 volt? If yes, go to next step. If no, see «INTERMITTENT CONDITION»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators__intermittent-condition) .
2. Turn the ignition off. Disconnect the battery temperature sensor harness connector. Turn the ignition on. With the DRBIII(R) scan tool, read battery temperature sensor voltage. Does the battery temperature sensor voltage read approximately 5.0 volts? If yes, replace the battery temperature sensor. If no, go to next step.
3. Turn the ignition off. Disconnect the battery temperature sensor harness connector. Disconnect the PCM harness connectors. Measure the resistance between ground and the battery temperature signal circuit in the battery temperature sensor harness connector. Is the resistance less than 100 ohms? If yes, repair the short to ground in the battery temperature signal circuit. If no, go to next step.
4. Turn the ignition off. Disconnect the battery temperature sensor harness connector. Disconnect the PCM harness connectors. Measure the resistance between the battery temperature signal circuit and the sensor ground circuit in the battery temperature sensor harness connector. Is the resistance less than 100 ohms? If yes, repair the sensor ground shorted to the battery temperature sensor signal circuit. If no, go to next step.
5. Before continuing, check the PCM harness connector terminals for corrosion, damage, or terminal push out. Repair as necessary. If there are no possible causes remaining, replace and program the PCM. See «PROGRAMMING»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators) .

DTC P0517: BATTERY TEMPERATURE SENSOR HIGH

Note. For component location, see SELF-DIAGNOSTICS - 2.4L . For connector identification, see SELF-DIAGNOSTICS - 2.4L . For circuit identification and wiring diagram, see appropriate SYSTEM WIRING DIAGRAMS articel. In testing procedures Alpha/Numeric character in parentheses (i.e.; K4) designates circuit. After each repair procedure has been completed, reconnect all components. Perform VERIFICATION TEST VER-5 (2.4L) under VERIFICATION TESTS to ensure system is functioning properly.

Battery temperature sensor is monitored with ignition on. DTC will set if the battery temperature voltage is more than 4.8 volts.

1. Battery Temperature Signal Circuit Shorted To Battery Voltage
2. Battery Temperature Sensor Internal Failure
3. Battery Temperature Signal Circuit Open
4. Sensor Ground Circuit Open
5. PCM

1. Turn the ignition on. With the DRBIII(R) scan tool, read the battery temperature sensor voltage. Is the voltage more than 4.8 volts? If yes, go to next step. If no, see «INTERMITTENT CONDITION»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators__intermittent-condition) .
2. Turn the ignition off. Disconnect the battery temperature sensor harness connector. Turn the ignition on. Measure the voltage of the battery temperature signal circuit in the battery temperature sensor harness connector. Is the voltage more than 5.2 volts? If yes, repair the short to battery voltage in the battery temperature signal circuit. If no, go to next step.
3. Turn the ignition off. Disconnect the battery temperature harness connector. Connect a jumper wire between the battery temperature signal circuit and the sensor ground circuit in the battery temperature harness connector. Turn the ignition on. With the DRBIII(R) scan tool, read the battery temperature sensor voltage. Is the voltage less than 1.0 volt? If yes, replace the battery temperature sensor. If no, go to next step.
4. Turn the ignition off. Disconnect the battery temperature sensor harness connector. Disconnect the PCM harness connectors. Measure the resistance of the battery temperature signal circuit from the battery temperature sensor harness connector to the appropriate terminal of Miller Special Tool (8815). Is the resistance less than 5.0 ohms? If yes, go to next step. If no, repair the open in the battery temperature signal circuit.
5. Turn the ignition off. Disconnect the battery sensor harness connector. Disconnect the PCM harness connectors. Measure the resistance of the sensor ground circuit from the battery temperature sensor harness connector to the appropriate terminal of Miller Special Tool (8815). Is the resistance less than 5.0 ohms? If yes, go to next step. If no, repair the open in the sensor ground circuit.
6. Before continuing, check the PCM harness connector terminals for corrosion, damage, or terminal push out. Repair as necessary. If there are no possible causes remaining, replace and program the PCM. See «PROGRAMMING»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators) .

DTC P0562: BATTERY VOLTAGE LOW

Note. For component location, see SELF-DIAGNOSTICS - 2.4L . For connector identification, see SELF-DIAGNOSTICS - 2.4L . For circuit identification and wiring diagram, see appropriate SYSTEM WIRING DIAGRAMS article. In testing procedures Alpha/Numeric character in parentheses (i.e.; K4) designates circuit. After each repair procedure has been completed, reconnect all components. Perform VERIFICATION TEST VER-3 (2.4L) under VERIFICATION TESTS to ensure system is functioning properly.

Battery voltage is monitored with engine running and engine speed is greater than 1150 RPM. DTC will set if the battery sensed voltage is one volt less than the charging goal for 13.47 seconds. The PCM senses the battery voltage turns off the field driver and senses the battery voltage again. If the voltages are the same, the code is set. This is a one-trip fault.

1. B+ circuit high resistance.
2. Generator ground high resistance.
3. Generator operation.
4. (Z1) generator field ground circuit open.
5. (K20) generator field control circuit shorted to ground.
6. (K20) generator field control circuit open
7. PCM.

1. Ensure the battery is in good condition. Test the battery before continuing. Inspect the vehicle for aftermarket accessories that may exceed the generator system output. Turn the ignition off. Ensure the generator drive belt is in good operating condition. Inspect the fuses in the PDC. If a fuse is found to be open use the wiring diagram/schematic as a guide, inspect the wiring and connectors for damage. Turn the ignition on. With the DRBIII(R) scan tool, read DTCs and record the related freeze frame data. Is the Good Trip Counter displayed and equal to zero? If yes, go to next step. If no, see «INTERMITTENT CONDITION»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators__intermittent-condition) .
2. Turn the ignition on. Ensure all wires are clear of the engines moving parts. Measure the voltage between the generator B+ terminal and the battery positive post. Start the engine. Is the voltage more than 0.4 volt? If yes, repair the B+ circuit for high resistance between the generator and battery. If no, go to next step.
3. Start the engine. Allow the engine to reach normal operating temperature. Ensure all wires are clear of the engines moving parts. Measure the voltage between the generator case and battery ground post. Is the voltage more than 0.1 volt? If yes, repair generator ground for high resistance, generator case to battery ground side. If no, 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. With the DRBIII(R) scan tool, actuate the generator field driver circuit. Does the test light illuminate brightly and flash on and off? If yes, replace the generator. If no, go to next step.
5. Turn the ignition off. Disconnect the generator field harness connector. Using a 12-volt test connected to battery voltage, probe the generator (Z1) ground circuit in the generator field harness connector. Does the test light illuminate brightly? If yes, go to next step. If no, repair the open in the (Z1) generator field ground circuit.
6. Turn the ignition on. Disconnect the generator field harness connector. Disconnect the PCM harness connectors. Measure the resistance between ground and the (K20) generator field control circuit in the generator field harness connector. Is the resistance less than 100 ohms? If yes, repair the (K20) generator field control circuit for a short to ground. If no, go to next step.
7. Turn the ignition off. Disconnect the generator field harness connector. Disconnect the PCM harness connectors. Measure the resistance of the (K20) generator field control circuit from the generator field harness connector to the appropriate terminal of the Miller Special Tool (8815). Is the resistance less than 5.0 ohms? If yes, go to next step. If no, repair the open in the (K20) generator field control circuit.
8. Before continuing, disconnect the PCM harness connector and check the related wiring terminals for corrosion, damage or terminal push out. Repair as necessary. Pay particular attention to all power and ground circuits. If there are no possible causes remaining, replace and program the PCM. See «PROGRAMMING»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators) .

DTC P0563: BATTERY VOLTAGE HIGH

Note. For component location, see SELF-DIAGNOSTICS - 2.4L . For connector identification, see SELF-DIAGNOSTICS - 2.4L . For circuit identification and wiring diagram, see appropriate SYSTEM WIRING DIAGRAMS article. In testing procedures Alpha/Numeric character in parentheses (i.e. K4) designates circuit. After each repair procedure has been completed, reconnect all components. Perform VERIFICATION TEST VER-3 (2.4L) under VERIFICATION TESTS to ensure system is functioning properly.

Battery voltage is monitored with engine running and the engine speed is greater than 380 RPM. DTC will set if the battery voltage is one volt greater than desired system voltage. This is a one-trip fault.

1. Generator
2. (K20) Generator Field Control Circuit Shorted To Battery Voltage
3. PCM

1. Before continuing with test, ensure that the battery cables and posts are tight and free from corrosion. Verify that the battery is fully charged and capable of passing a load test. Ensure the battery is in good condition. Inspect the vehicle for aftermarket accessories that may exceed the generator system output. Turn the ignition off. Ensure the generator drive belt is in good operating condition. Inspect the fuses in the PDC. If a fuse is found to be open use the wiring diagram/schematic as a guide, inspect the wiring and connectors for damage. Turn the ignition on. With the DRBIII(R) scan tool, read DTCs and record the related freeze frame data. Is the Good Trip Counter displayed and equal to zero? If yes, go to next step. If no, see «INTERMITTENT CONDITION»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators__intermittent-condition) .
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. With the DRBIII(R) scan tool, actuate the generator field driver circuit. Does the test light illuminate brightly and flash on and off? If yes, go to step 4 . If no, go to next step.
3. Turn the ignition off. Disconnect the generator field harness connector. Disconnect the PCM harness connectors. Measure the voltage on the (K20) generator field control circuit at the generator field harness connector. Is the voltage more than 1.0 volt? If yes, repair the short to voltage in the (K20) generator field control circuit. If no, go to next step.
4. Before continuing, disconnect the PCM harness connector and check the related wiring terminals for corrosion, damage or terminal push out. Repair as necessary. Pay particular attention to all power and ground circuits. If there are no possible causes remaining, replace and program the PCM. See «PROGRAMMING»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators) .

DTC P0622: GENERATOR FIELD CONTROL CIRCUIT (2.4L)

Note. For component location, see SELF-DIAGNOSTICS - 2.4L . For connector identification, see SELF-DIAGNOSTICS - 2.4L . For circuit identification and wiring diagram, see appropriate SYSTEM WIRING DIAGRAMS articel. In testing procedures Alpha/Numeric character in parentheses (i.e.; K4) designates circuit. After each repair procedure has been completed, reconnect all components. Perform VERIFICATION TEST VER-3 (2.4L) under VERIFICATION TESTS to ensure system is functioning properly.

Generator field control circuit is monitored with the ignition on, engine running. DTC will set when the PCM tries to regulate the generator field with no result during monitoring. This is a one-trip fault.

1. Generator
2. (Z1) Generator Field Ground Circuit Open
3. (K20) Generator Field Control Circuit Shorted To Battery Voltage
4. (K20) Generator Field Control Circuit Shorted To Ground
5. (K20) Generator Field Control Circuit Open
6. PCM

1. Turn the ignition on. With the DRBIII(R) scan tool, read DTCs and record the related freeze frame data. Is the Good Trip Counter displayed and equal to zero? If yes, see «INTERMITTENT CONDITION»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators__intermittent-condition) . If no, go to next step.
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. With the DRBIII(R) scan tool, actuate the generator field driver circuit. Does the test light illuminate brightly and flash on and off? If yes, replace the generator. If no, go to next step.
3. Turn the ignition off. Disconnect the generator field harness connector. Using a 12-volt test connected to battery voltage, probe the (Z1) generator ground circuit in the generator field harness connector. Does the test light illuminate brightly? If yes, go to next step. If no, repair the open in the (Z1) generator field ground circuit.
4. Turn the ignition off. Disconnect the generator field harness connector. Disconnect the PCM harness connectors. Measure the voltage on the (K20) generator field control circuit in the generator field harness connector. Is the voltage more than 1.0 volt? If yes, repair the short to voltage in the (K20) generator field control circuit. If no, go to next step.
5. Turn the ignition on. Disconnect the generator field harness connector. Disconnect the PCM harness connectors. Measure the resistance between ground and the (K20) generator field control circuit in the generator field harness connector. Is the resistance less than 100 ohms? If yes, repair the (K20) generator field control circuit for a short to ground. If no, go to next step.
6. Turn the ignition off. Disconnect the generator field harness connector. Disconnect the PCM harness connectors. Measure the resistance of the (K20) generator field control circuit from the generator field harness connector to the appropriate terminal of the Miller Special Tool (8815). Is the resistance less than 5.0 ohms? If yes, go to next step. If no, repair the open in the (K20) generator field control circuit.
7. Before continuing, disconnect the PCM harness connector and check the related wiring terminals for corrosion, damage or terminal push out. Repair as necessary. Pay particular attention to all power and ground circuits. If there are no possible causes remaining, replace and program the PCM. See «PROGRAMMING»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators) .

This DTC is monitored with the ignition on and the engine running. This DTC sets when the PCM tries to regulate the generator field with no result during monitoring.

1. Generator operation.
2. (K342) ASD relay output circuit open.
3. (K20) generator field driver circuit shorted to ground.
4. (K20) generator field driver circuit open.
5. Generator field coil open.
6. Generator field coil shorted.
7. PCM.

1. Turn the ignition on. Record all DTC's and the related Freeze Frame data. Using a 12-volt test light connected to ground, backprobe the (K20) generator field driver circuit in the back of the generator. With the DRBIII(R), actuate the generator field driver circuit. If the test light illuminates brightly and flashes, see «INTERMITTENT CONDITION»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators__intermittent-condition) . Perform «VERIFICATION TEST VER-3 (3.3/3.8L)»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators__verification-test-ver-3-33l-38l) . If the test light does not illuminate brightly or flash, go to next step.
2. Disconnect the generator field harness connector. Turn the ignition on. With the DRBIII(R), actuate the generator field driver circuit. Using a 12-volt test light connected to ground, probe the (K342) ASD relay output circuit. If the test light illuminates, go to next step. If the test light does not illuminate, repair the (K342) ASD relay output circuit. Perform «VERIFICATION TEST VER-3 (3.3L & 3.8L)»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators__verification-test-ver-3-33l-38l) .
3. Turn the ignition off. Disconnect the PCM harness connector. Disconnect the generator shield harness connector. Measure the resistance of the (K20) generator field driver circuit from the PCM harness connector to ground. If the resistance is below 100 ohms, repair the (K20) generator field driver circuit for a short to ground. If the resistance is not below 100 ohms, go to next step.
4. Turn the ignition off. Disconnect the PCM harness connector. Disconnect the generator field harness connector. Measure the resistance of the (K20) generator field driver circuit from the PCM harness connector to the generator field harness connector. If the resistance is below 5 ohms, go to next step. If the resistance is not below 5 ohms, repair the (K20) generator field driver circuit for an open. Perform «VERIFICATION TEST VER-3 (3.3L & 3.8L)»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators__verification-test-ver-3-33l-38l) .
5. Turn the ignition off. Disconnect the generator field harness connector. Measure the resistance across the generator field terminals at the generator. If the resistance is above 15 ohms, replace the generator. Perform «VERIFICATION TEST VER-3 (3.3L & 3.8L)»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators__verification-test-ver-3-33l-38l) . If the resistance is not above 15 ohms, go to next step.
6. Turn the ignition off. Disconnect the generator field harness connector. Measure the resistance across the generator field terminals at the generator. If the resistance is below 0.5 ohms, replace the generator. Perform «VERIFICATION TEST VER-3 (3.3L & 3.8L)»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators__verification-test-ver-3-33l-38l) . If the resistance is not below 0.5 ohms, go to next step.
7. Using schematics as a guide, inspect the wire harness and connectors. Pay particular attention to all power and ground circuits. If there is not more possible causes remaining, replace and program the PCM. See «PROGRAMMING»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators) . Perform «VERIFICATION TEST VER-3 (3.3L & 3.8L)»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators__verification-test-ver-3-33l-38l) .

DTC P1478: BATTERY TEMP SENSOR VOLTS OUT OF LIMIT

Note. For component location, see SELF-DIAGNOSTICS - 3.3L & 3.8L . For connector identification, see SELF-DIAGNOSTICS - 3.3L & 3.8L . For circuit identification and wiring diagram, see appropriate SYSTEM WIRING DIAGRAMS article. In testing procedures Alpha/Numeric character in parenthesis (i.e.; K4) designates circuit. After each repair procedure has been completed, reconnect all components. Perform VERIFICATION TEST VER-5 (3.3/3.8L) under VERIFICATION TESTS to ensure system is functioning properly.

Battery temp is monitored with ignition on. DTC will set if the battery temperature sensor, internal to the PCM, goes above 4.9 volts or below 0.1 volt for more than 3.2 seconds.

Possible Cause

PCM

The PCM has detected a fault with the battery temperature sensor which is internal to the Powertrain Control Module. If there are no possible causes remaining, replace and program the PCM. See PROGRAMMING .

Charging system voltage is monitored with the engine running. With the engine speed greater than 380 RPM. DTC will set if the battery voltage is 1 volt greater than desired system voltage.

1. Target Voltage Differs From Battery Voltage
2. Intermittent Condition
3. (K20) Generator Field Driver Circuit Shorted To Ground
4. Generator Field
5. PCM

Note. Battery must be fully charged.

Note. Generator belt tension and condition must be checked before continuing.

1. Turn the ignition on. With DRBIII(R) scan tool, actuate the generator field driver. With a 12-volt test light connected to ground, backprobe the (K20) Generator Field Driver circuit in the back of Generator harness connector. Does the test light illuminate brightly and flash? If yes, go to next step. If no, go to step 5 .
2. With DRBIII(R) scan tool, stop all actuation. Turn the ignition on. With DRBIII(R) scan tool, read the target charging voltage. Is the target charging voltage above 13 volts? If yes, go to next step. If no, go to step 4 .
3. Start the engine. With the DRBIII(R) scan tool, manually set the engine speed to 1600 RPM. With DRBIII(R) scan tool, read both the battery voltage and the target charging voltage. Compare the target charging voltage to the battery voltage reading. Monitor voltage for 5 minutes, if necessary. Look for a 1.0 volt difference or more. Was there more than a 1.0 volt difference? If yes, replace and program the PCM. See «PROGRAMMING»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators) . If no, go to next step.
4. The conditions that set the DTC are not present at this time. The following list may help in identifying the intermittent condition. With the engine running at normal operating temperature, monitor the DRBIII(R) scan tool parameters related to the DTC while wiggling the wiring harness. Look for parameter values to change and/or a DTC to set. Review the DRBIII(R) scan tool freeze frame information. If possible, try to duplicate the conditions under which the DTC was set. Refer to any Technical Service Bulletins (TSB) that may apply. Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or partially broken wires. Visually inspect the related wiring harness connectors. Look for broken, bent, pushed out, or corroded terminals. Were any of the above conditions present? If yes, repair as necessary If no, the test is complete.
5. Turn the ignition off. Disconnect the PCM harness connector. Disconnect the generator field harness connector. Measure the resistance of the (K20) generator field driver circuit from the PCM harness connector to ground. Is the resistance below 5.0 ohms? If yes, repair the short to ground in the (K20) generator field driver circuit. If no, go to next step.
6. Turn the ignition off. Disconnect the generator field harness connector. Measure resistance of the generator field driver terminal pin of the generator to ground. Is the resistance below 5.0 ohms? If yes, repair or replace the shorted generator as necessary. If no, go to next step.
7. Using the wiring diagram as a guide, inspect the wire harness and connectors. Pay particular attention to all power and ground circuits. If there are no possible causes remaining, replace and program the PCM. See «PROGRAMMING»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators) .

This DTC is monitored with the ignition on. Engine RPM greater than 1152 RPM. With no other charging system codes set. This DTC will set when the battery sense voltage is 1 volt below the charging goal for 13.47 seconds. The PCM senses the battery voltage turns off the field driver and senses the battery voltage again. If the voltages are the same, the code is set.

1. B+ circuit high resistance.
2. Generator ground high resistance.
3. Intermittent condition.
4. (K20) generator field driver circuit open.
5. (K342) ASD relay output circuit open.
6. Generator.

1. Turn the ignition off. Start the engine. Allow the idle to stabilize. With the DRBIII(R), read the target charging voltage. If the target charging voltage is above 15.1 volts, go to step 8 . If the target charging voltage is not above 15.1 volts, go to next step.
2. Turn the ignition on. Measure the voltage between the generator B+ terminal and the Battery+ post. Start the engine. If the voltage is above 0.4 volt, repair the B+ circuit for high resistance between the generator and battery. See «VERIFICATION TEST VER-3 (3.3L & 3.8L)»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators__verification-test-ver-3-33l-38l) . If the voltage is not above 0.4 volt, go to next step.
3. Start the engine. Warm the engine to operating temperature. Measure the voltage between the generator case and Battery ground post. If the voltage is above 0.1 volt, repair generator case ground for high resistance between the generator case and battery ground terminal. See «VERIFICATION TEST VER-3 (3.3L & 3.8L)»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators__verification-test-ver-3-33l-38l) . If the voltage is not above 0.1 volt, go to next step.
4. Start the engine. Turn on all accessories, manually set engine speed to 1600 RPM. With the DRBIII(R), read target charging and charging voltage. Compare the 2 readings. If there is more than a 1 volt difference go to next step. If there is not more than a 1 volt difference, go to step 8 .
5. Turn the ignition off. Disconnect the PCM harness connector. Disconnect the generator field harness connector. Measure the resistance of the (K20) generator harness connector. Measure the resistance of the (K20) generator field driver circuit from the PCM harness connector to generator 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 (K20) generator field driver circuit. Perform «VERIFICATION TEST VER-3 (3.3L & 3.8L)»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators__verification-test-ver-3-33l-38l) .
6. Disconnect the generator field harness connector. Turn the ignition on. With the DRBIII(R), actuate the generator field driver. Using a 12-volt test light connected to ground, probe the ASD relay output circuit in the generator harness connector. If the test light illuminates, go to next step. If the test light does not illuminate, repair the (K342) ASD relay output circuit. See «VERIFICATION TEST VER-3 (3.3L & 3.8L)»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators__verification-test-ver-3-33l-38l) .
7. If there is no possible causes remaining, repair or replace the generator as necessary. See «VERIFICATION TEST VER-3 (3.3L & 3.8L)»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators__verification-test-ver-3-33l-38l) .
8. With the engine running at normal operating temperature, monitor the DRBIII(R) parameters related to the DTC while wiggling the wiring harness. Look for parameter values to change and/or a DTC to set. Refer to any TSB's that may apply. Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or partially broken wires. Visually inspect the related wiring harness connectors. Look for broken, bent, pushed out, or corroded terminals. If any of these conditions are present, repair as necessary. See «VERIFICATION TEST VER-3 (3.3L & 3.8L)»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators__verification-test-ver-3-33l-38l) . If none of these conditions were present, the test is complete.

DTC P2503: CHARGING SYSTEM VOLTAGE LOW

Note. For component location, see SELF-DIAGNOSTICS - 2.4L . For connector identification, see SELF-DIAGNOSTICS - 2.4L . For circuit identification and wiring diagram, see appropriate SYSTEM WIRING DIAGRAMS article. In testing procedures Alpha/Numeric character in parentheses (i.e.; K4) designates circuit. After each repair procedure has been completed, reconnect all components. Perform VERIFICATION TEST VER-3 (2.4L) under VERIFICATION TESTS to ensure system is functioning properly.

Charging system is monitored with engine running and engine speed greater than 1157 RPM. DTC will set if the battery sensed voltage is one volt less than the charging goal for 13.47 seconds. The PCM senses the battery voltage turns off the field driver and senses the battery voltage again. If the voltages are the same, the code is set.

1. (A11) B+ Circuit High Resistance
2. Generator Ground High Resistance
3. Generator
4. (Z1) Generator Field Ground Circuit Open
5. (K20) Generator Field Control Circuit Shorted To Battery Voltage
6. (K20) Generator Field Control Circuit Shorted To Ground
7. (K20) Generator Field Control Circuit Open
8. PCM

1. Inspect the vehicle for aftermarket accessories that may exceed the generator system output. Turn the ignition off. The battery must be fully charged. The generator belt tension and condition must be checked before continuing. Start the engine. Allow the idle to stabilize. With the DRBIII(R) scan tool, read the target charging voltage. Is the target charging voltage more than 15.1 volts? If yes, see «INTERMITTENT CONDITION»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators__intermittent-condition) . If no, go to next step.
2. Turn the ignition on. Ensure all wires are clear of the engines moving parts. Start the engine. Measure the voltage between the (All) generator B+ terminal and the battery positive post. Is the voltage more than 0.4 volt? If yes, repair the (All) B positive circuits for high resistance between the generator and battery. If no, go to next step.
3. Start the engine. Warm the engine to operating temperature. Ensure all wires are clear of the engines moving parts. Measure the voltage between the generator case and battery ground post. Is the voltage more than 0.1 volt? If yes, repair generator ground for high resistance, generator case to battery ground side. If no, 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. With the DRBIII(R) scan tool, actuate the generator field control circuit. Does the test light illuminate brightly and flash on and off? If yes, replace the generator. If no, go to next step.
5. Turn the ignition off. Disconnect the generator field harness connector. Using a 12-volt test connected to battery voltage, probe the (Z1) generator field ground circuit in the generator field harness connector. Does the test light illuminate brightly? If yes, go to next step. If no, repair the open in the (Z1) generator field ground circuit.
6. Turn the ignition off. Disconnect the generator field harness connector. Disconnect the PCM harness connectors. Measure the voltage on the (K20) generator field control circuit at the generator field harness connector. Is the voltage more than 1.0 volt? If yes, repair the short to voltage in the (K20) generator field control circuit. If no, go to next step.
7. Turn the ignition on. Disconnect the generator field harness connector. Disconnect the PCM harness connectors. Measure the resistance between ground and the (K20) generator field control circuit in the generator field harness connector. Is the resistance less than 100 ohms? If yes, repair the (K20) generator field control circuit for a short to ground. If no, go to next step.
8. Turn the ignition off. Disconnect the generator field harness connector. Disconnect the PCM harness connectors. Measure the resistance of the (K20) generator field control circuit from the generator field harness connector to the appropriate terminal of the Miller Special Tool (8815). Is the resistance less than 5.0 ohms? If yes, go to next step. If no, repair the open in the (K20) generator field control circuit.
9. Before continuing, disconnect the PCM harness connector and check the related wiring terminals for corrosion, damage or terminal push out. Repair as necessary. Pay particular attention to all power and ground circuits. If there are no possible causes remaining, replace and program the PCM. See «PROGRAMMING»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators) .

TRANSMISSION VERIFICATION TEST VER-1

1. Connect the DRBIII(R) to the Data Link Connector (DLC).
2. Reconnect any disconnected components.
3. With the DRBIII(R), erase all Transmission DTC's, also erase the PCM DTC's.
4. With the DRBIII(R), display transmission temperature.
5. 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 DRBIII(R) Quick Learn Procedure and reset the "Pinion Factor".
6. Road test the vehicle. With the DRBIII(R), 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.
7. 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.
8. For specific DTC, drive the vehicle to the Symptom's When Monitored/When Set Conditions to verify the DTC repair.
9. Check for Diagnostic Trouble Codes (DTC's) during the road test. If a DTC sets during the road test, return to the symptom list and follow the path.
10. Erase P0700 DTC in the PCM to turn the MIL light off after making transmission repairs. This will turn the MIL off.
11. If any DTC's were set during the road test, refer to symptom list for appropriate diagnostic tests. If no DTC's were set, repair is complete.

VERIFICATION TEST VER-3 (2.4L)

1. After completing this test, see «TRANSMISSION VERIFICATION TEST VER-1»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators__transmission-verification-test-ver-1) . This test must be performed.
2. 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.
3. If the vehicle is equipped with a Sentry Key Immobilizer System, Secret Key data must be updated. See «PROGRAMMING»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators) .
4. Inspect the vehicle to ensure that all components related to the repair are connected properly.
5. With the DRBIII(R), 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 DRBIII(R), read the DTC's. If the DTC returns, or any other symptom or DTC is present, see appropriate symptom.
10. If there are no DTC's present and all components are functioning properly, the repair is complete. If there are DTC's present, repair is not complete, refer to appropriate symptom.

VERIFICATION TEST VER-3 (3.3L & 3.8L)

1. 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.
2. If the vehicle is equipped with a Sentry Key Immobilizer System, Secret Key data must be updated. See «PROGRAMMING»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators) .
3. Inspect the vehicle to ensure that all components related to the repair are connected properly.
4. With the DRBIII(R), clear DTC's.
5. Perform generator output test.
6. Start the engine and set engine speed to 2000 RPM for at least 30 seconds.
7. Cycle the ignition key off and on.
8. With the DRBIII(R), read the DTC's. If the DTC returns, or any other symptom or DTC is present, refer to appropriate category and perform the corresponding symptom.
9. If there are no DTC's present and all components are functioning properly, the repair is complete. If there are DTC's repair is not complete, refer to appropriate symptom.

VERIFICATION TEST VER-5 (2.4L)

1. After completing this test, see «TRANSMISSION VERIFICATION TEST VER-1»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators__transmission-verification-test-ver-1) . The Transmission Verification test must be performed.
2. 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.
3. If the vehicle is equipped with Sentry Key Immobilizer, Secret Key data must be updated. See «PROGRAMMING»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators) .
4. Inspect the vehicle to ensure that all engine components are properly installed and connected. Reassemble and reconnect components as necessary.
5. Connect the DRBIII(R) to data link connector.
6. Ensure the fuel tank has at least a quarter tank of fuel. Turn off all accessories.
7. If a Comprehensive Component DTC was repaired, perform steps 5 - 8 . If a major OBDII Monitor DTC was repaired skip those steps and continue verification.
8. After the ignition has been off for at least 10 seconds, restart the vehicle and run 2 minutes.
9. If the good trip counter changed to one or more and there are no new DTC's, the repair was successful and is now complete. Erase DTC's and disconnect the DRBIII(R).
10. 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 TSB's or flash updates and return to symptom list.
11. If another DTC has set, return to the symptom list and follow the path specified for that DTC.
12. If any DTC's are present, repair is not complete. Refer to appropriate symptom list. If there are not DTC's present, repair is complete.

VERIFICATION TEST VER-5 (3.3L & 3.8L)

1. 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.
2. If the vehicle is equipped with a Sentry Key Immobilizer System, Secret Key data must be updated. See «PROGRAMMING»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators) .
3. Inspect the vehicle to ensure that all engine components are properly installed and connected. Reassemble and reconnect components as necessary.
4. Connect the DRBIII(R) to the Data Link Connector.
5. Ensure the fuel tank has at least a quarter tank of fuel. Turn off all accessories.
6. If a comprehensive component DTC was repaired, perform steps 5 - 8 . 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. If the Good Trip Counter changed to one or more and there are no new DTC's, the repair was successful and is now complete. Erase DTC's and disconnect the DRBIII(R).
9. If the repaired DTC has reset, the repair is not complete. Check for any related TSB's or flash updates and return to the symptom list.
10. If another DTC has set, return to the symptom list and follow the path specified for that DTC.
11. With the DRBIII(R), 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).
12. If the monitor ran, and the Good Trip counter changed to one or more, the repair was successful and is now complete. Erase DTC's and disconnect the DRBIII(R).
13. 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 symptom list.
14. If another DTC has set, return to the symptom list and follow the path specified for that DTC.
15. If any DTC's are present, repair is not complete. See appropriate symptom list. If not DTC's are present, repair is complete.

The battery temperature sensor is not serviced separately. If replacement is necessary, the PCM must be replaced.

Removal & Installation

Disconnect negative battery cable. Raise and support vehicle. Remove right front lower splash shield. Remove accessory drive belt. Lower vehicle. Remove air cleaner assembly. Using Generator Decoupler Tool (8433), loosen generator decoupler. (Scheme 2) Remove generator decoupler tool and generator decoupler. To install, reverse removal procedure, using generator decoupler tool. Tighten fasteners to specification. See TORQUE SPECIFICATIONS.

Scheme 2

Removal - 2.4L

1. Release hood latch and open hood.
2. Disconnect battery negative cable.
3. Disconnect the Inlet Air Temperature sensor.
4. Remove the Air Box.
5. Remove the EVAP Purge solenoid from its bracket and reposition.
6. Disconnect the push-in field wire connector from back of generator.
7. Remove nut holding B+ wire terminal to back of generator.
8. Separate B+ terminal from generator.
9. Remove accessory drive belt.
10. Remove the generator.

Scheme 3

Scheme 4

1. Release hood latch and open hood.
2. Disconnect battery negative cable.
3. Disconnect the push-in field wire connector from back of generator.
4. Remove nut holding B+ wire terminal to back of generator.
5. Separate B+ terminal from generator.
6. Raise vehicle and support.
7. Remove the right front lower splash shield.
8. Remove accessory drive belt.
9. Remove the lower oil dipstick tube bolt. (Scheme 3)
10. Remove wiring harness from the oil dipstick tube. (Scheme 3)
11. Remove the 3 mounting bolts.
12. Lower vehicle.
13. Remove oil dipstick tube from vehicle.
14. Roll and remove the generator from vehicle. (Scheme 4)

Installation - 2.4L

1. Install the generator.
2. Install the accessory drive belt.
3. Connect B+ terminal to generator.
4. Install nut holding B+ wire terminal to back of generator.
5. Connect the push-in field wire connector to back of generator.
6. Install the EVAP Purge solenoid to its bracket.
7. Install the air box.
8. Connect the Inlet Air Temperature sensor.
9. Connect battery negative cable.

Installation - 3.3L & 3.8L

1. Roll and place generator in position on vehicle.
2. Install upper bolts to hold generator in place.
3. Lubricate the O-ring. Install oil dipstick tube.
4. Install the upper oil dipstick tube bolt.
5. Place B+ terminal in position on generator.
6. Install nut to hold B+ wire terminal to back of generator.
7. Connect the push-in field wire connector into back of generator.
8. Raise vehicle and support.
9. Install the lower mounting bolt and tighten.
10. Install the lower oil dipstick tube bolt and tighten.
11. Install accessory drive belt. See «SPECIFICATIONS & DRIVE BELT ROUTING»(/dodge/grand-caravan/iv-2000-2007/remont/accessory-drive-belts/#engine-cooling-system-specifications-drive-belt-routing) .
12. Install the right front lower splash shield.
13. Lower vehicle.
14. Install wiring harness to the oil dipstick tube
15. Connect battery negative cable.
16. Verify generator output rate.

Removal

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.
6. Lower vehicle.
7. Remove the air box.
8. Remove the decoupler pulley cover.
9. Use Special Tool (8433) to loosen the generator decoupler. (Scheme 5)
10. Remove the tool.
11. Remove the generator decoupler.

Scheme 5

Installation

1. Install the Generator Decoupler to the generator shaft.
2. Use Special Tool (8433) to tighten the generator decoupler. (Scheme 6) See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iv-2000-2007/remont/charging-system/#charging-system-generators-regulators__torque-specifications).
3. Install a new decoupler pulley cover.
4. Install the air box.
5. Raise vehicle and support.
6. Install accessory drive belt.
7. Install the right front lower splash shield.
8. Lower vehicle.
9. Connect battery negative cable.

Scheme 6

OVERHAUL

Information is not available from manufacturer. Manufacturer recommends replacing generator if defective.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

WIRING DIAGRAMS

See STARTING/CHARGING in appropriate SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

See also:
• COMPUTER RELEARN PROCEDURES
• SYSTEM & COMPONENT TESTING
• SELF-DIAGNOSTICS - 3.3L & 3.8L
• SPECIFICATIONS & DRIVE BELT ROUTING
• CHARGING SYSTEM
• SELF-DIAGNOSTIC SYSTEM
• CLEARING DTCS
• ON-VEHICLE TESTING
• P0070
• P0072
• P0073
• P0516
• P0517
• P0562
• P0563
• P0622
• P1478
• P2503
• VERIFICATION TEST VER-5 (2.4L)
• INTERMITTENT CONDITION
• VERIFICATION TEST VER-3 (2.4L)
• VERIFICATION TEST VER-3 (3.3/3.8L)
• VERIFICATION TEST VER-5 (3.3/3.8L)
• TRANSMISSION VERIFICATION TEST VER-1
• TORQUE SPECIFICATIONS