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Charging System - Generators & Regulators Dodge Pickup R1500

Charging System 9 illustrations ~17665 words

IDENTIFICATION

Note. Generator rating information for the 8.3L, is not available from the manufacturer.

EnginesPart NumberTypeSAE Amps
3.7/4.7L56029700AADenso136
3.7/4.7L5601120ACBosch136
5.7L Gas/5.9L Diesel56028696AADenso136
5.7L Gas/5.9L Diesel56028699AABosch136

GENERATOR RATINGS

The charging system consists of

  1. Generator.
  2. Electronic Voltage Regulator (EVR) circuitry within the Powertrain Control Module (PCM) for gasoline engnines or Electronic Control Module (ECM) for diesel engines.
  3. Ignition switch.
  4. Battery.
  5. Battery temperature sensor.
  6. Check gauges lamp (if equipped).
  7. Voltmeter.
  8. Wiring harness and connections.

BATTERY TEMPERATURE SENSOR

The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery.

The generator is belt-driven by the engine using a serpentine type drive belt. It is serviced only as a complete assembly. If the generator fails for any reason, the entire assembly must be replaced.

VOLTAGE REGULATOR

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

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. When the ASD relay is on, voltage is supplied to the ASD relay sense circuit at the PCM (ECM on diesel). This voltage is connected through the PCM (ECM on diesel) and supplied to one of the generator field terminals (Gen. Source +) at the back of the generator.

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

A battery temperature sensor, located in the battery tray housing, is used to sense battery temperature. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM on diesel) 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.

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

The Check Gauges Lamp (if equipped) monitors: Charging system voltage, engine coolant temperature and engine oil pressure. If an extreme condition is indicated, the lamp will be illuminated. this is done as a reminder to check the 3 gauges. The signal to activate the lamp is sent via the CCD bus circuits. The lamp is located on the instrument panel.

The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM on diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures.

The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases.

The BTS is also used for OBDII diagnostics. Certain faults and OBDII monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBDII monitors are disabled below 20°F (-6.7°C).

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 stator winding connections deliver the induced alternating current to 3 positive and 3 negative diodes for rectification. From the diodes, rectified direct current is delivered to the vehicle electrical system through the generator battery terminal.

Although the generators appear the same externally, different generators with different output ratings are used on this vehicle. Be certain that the replacement generator has the same output rating and part number as the original unit.

Noise emitting from the generator may be caused by: worn, loose or defective bearings; a loose or defective drive pulley; incorrect, worn, damaged or misadjusted fan drive belt; loose mounting bolts; a misaligned drive pulley or a defective stator or diode.

The amount of direct 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 by cycling the ground path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line voltage (B+) and battery temperature. It then determines a target charging voltage. If sensed battery voltage is .5 volt or lower than the target voltage, the PCM grounds the field winding until sensed battery voltage is .5 volts above target voltage. A circuit in the PCM cycles the ground side of the generator field up to 100 times per second (100 Hz), but has the capability to ground 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 25 percent is used by the PCM in order to have some generator output.

PCM (NGC) OR ECM (CUMMINS)

Note. There are 2 procedures for transferring the secret key to the SKIM. When ONLY the SKIM module is replaced, the secret key is transferred from the PCM (NGC-gasoline engine) or ECM (Cummins-diesel engine) to the SKIM. The ORIGINAL KEYS may then be programmed to the SKIM. When ONLY the PCM/ECM is replaced, then the secret key is transferred from the SKIM to the PCM/ECM. The ORIGINAL KEYS may be used. When BOTH the SKIM and the PCM/ECM are replaced the secret key is transferred from the SKIM to the PCM/ECM, and NEW KEYS must be programmed.

Note. Before replacing the PCM/ECM (depending on engine application), for a failed driver, control circuit, or ground circuit, or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM/ECM driver/control circuit features are caused be internal component failures (i.e.; relay and solenoids) and shorted circuits (i.e.; pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one Diagnostic Trouble Code (DTC) has set.

When a PCM/ECM and Sentry Key Immobilizer Module (SKIM) are replaced at the same time perform the following steps in order

  1. Program the new PCM/ECM.
  2. Program the new SKIM.
  3. Replace all ignition keys and program them to the new SKIM.

The Sentry Key Immobilizer System (SKIS) Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, PCM/ECM and transponder chip (ignition keys). When replacing the PCM/ECM it is necessary to program the secret key into the new PCM/ECM using the DRBIII(R) scan tool. Perform the following steps to program the secret key into the PCM/ECM.

  1. Turn the ignition switch on (transmission in Park/Neutral).
  2. Use the DRBIII(R) scan tool and select THEFT ALARM, SKIM then MISCELLANEOUS.
  3. Select PCM REPLACED (GAS ENGINE) or CUMMINS ECM REPLACED (DIESEL ENGINE).
  4. Enter secured access mode by entering the vehicle 4-digit PIN.
  5. Select ENTER to update PCM/ECM VIN.
  6. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM/ECM).
  7. Press PAGE BOOK to get to the SELECT SYSTEM menu and select ENGINE, MISCELLANEOUS, and SRI MEMORY CHECK.
  8. The DRBIII(R) scan tool will ask, "Is odometer reading between XX and XX? Select the YES or NO button on the DRBIII(R) scan tool. If NO is selected, the DRBIII(R) scan tool will read, ENTER ODOMETER READING (FROM I.P. ODOMETER). Enter odometer reading from the instrument cluster and press ENTER.

SKIM

  1. Turn the ignition switch on (transmission in Park/Neutral).
  2. Use the DRBIII(R) scan tool and select THEFT ALARM, SKIM then MISCELLANEOUS.
  3. Select SKIM REPLACED.
  4. Program the vehicle 4-digit PIN into SKIM.
  5. Select COUNTRY CODE and enter the correct country.
  6. Select YES to update the VIN (the SKIM will learn the VIN from the PCM/ECM).
  7. Press ENTER to transfer the secret key (the PCM/ECM will send the secret key information to the SKIM).
  8. Program ignition keys to the SKIM.

IGNITION KEYS TO SKIM

  1. Turn the ignition switch on (transmission n Park/Neutral).
  2. Use the DRBIII(R) scan tool and select THEFT ALARM, SKIM then MISCELLANEOUS.
  3. Select PROGRAM IGNITION KEY'S.
  4. Enter secured access mode by entering the vehicle 4-digit PIN.
  5. If ignition key programmed is unsuccessful, the DRBIII(R) scan tool will display one of the following messages: Programming Not Attempted The DRBIII(R) scan tool attempts to read the programmed key status and there are no keys programmed into SKIM memory. Programming Key Failed (Possible Used Key From Wrong Vehicle) SKIM is unable to program key due to a faulty ignition key transponder or ignition key is programmed to another vehicle. 8 Keys Already Learned, Programming Not Done SKIM transponder ID memory is full. Learned Key In Ignition Ignition key transponder ID is currently programmed in SKIM memory.
  6. Obtain ignition keys to be programmed from customer (8 keys maximum).
  7. Using the DRBIII(R) scan tool, erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CURRENT IGN. KEYS.
  8. Program all ignition keys.

BELT TENSION

ApplicationNew Belt - Lbs. (kg)(1) Used Belt - Lbs. (kg)
Cab & Chassis & Pickup
All Engines(2)(2)
(1) Belt is considered used after 15 minutes of service. (2) Automatic belt tensioner is used. Belt tension adjustment is not required.
(1)Belt is considered used after 15 minutes of service.
(2)Automatic belt tensioner is used. Belt tension adjustment is not required.

BELT ADJUSTMENT SPECIFICATIONS

TROUBLE SHOOTING

Verify customer's concern by operating system. Inspect for blown fuses, wiring or harness connectors. Check for loose or frayed drive belt, loose generator ground wire, or corroded battery terminals. Ensure battery is fully charged and in good condition, battery cables are in good condition with connections clean and secure. Inspect generator and PCM/ECM harness connections. Check engine ground strap. If fault is found, repair as necessary. If no fault is found, perform self-diagnostics. See SELF-DIAGNOSTIC SYSTEM .

ON-VEHICLE TESTING

CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

VOLTAGE DROP TEST

A voltage drop test will determine if there is excessive resistance in the battery cable terminal connections or the battery cables. If excessive resistance is found in the battery cable connections, the connection point should be disassembled, cleaned of all corrosion or foreign material, then reassembled. Following reassembly, check the voltage drop for the battery cable connection and the battery cable again to confirm repair.

When performing the voltage drop test, it is important to remember that the voltage drop is giving an indication of the resistance between the 2 points at which the voltmeter probes are attached. For example; when testing the resistance of the battery positive cable, touch the voltmeter leads to the battery positive cable terminal clamp and to the battery positive cable eyelet terminal at the starter solenoid B+ terminal stud. If you probe the battery positive terminal post and the battery positive cable eyelet terminal at the starter solenoid B+ terminal stud, you are reading the combined voltage drop in the battery positive cable terminal clamp-to-terminal post connection and the battery positive cable.

WARNINGModels equipped with a diesel engine have an automatic shutdown (ASD) relay located in the Power Distribution Center (PDC). Removal of the ASD relay may not prevent the diesel engine from starting. Be certain to disconnect the fuel shutdown solenoid wire harness connector to prevent the engine from starting. Failure to do so may result in personal injury.

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

  1. The battery is fully-charged and tested.
  2. Fully engage the parking brake.
  3. If the vehicle is equipped with an automatic transmission. Place the gearshift selector lever in the Park position. If the vehicle is equipped with a manual transmission, place the gearshift in Neutral position and block the clutch pedal in the fully depressed position.
  4. Verify that all lamps and accessories are turned off.
  5. To prevent a gasoline engine from starting, remove the Automatic Shutdown (ASD) relay. The ASD relay is located in the Integrated Power Module (IPM), in the engine compartment. See the fuse and relay layout label on the underside of the IPM cover for ASD relay identification and location.
  1. Connect the positive lead of the voltmeter to the battery negative terminal post. Connect the negative lead of the voltmeter to the battery negatve 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 .2 volt, clean and tighten the battery positive cable eyelet terminal connection at the starter solenoid B+ terminal stud. Repeat the test. If the reading is still above .2 volt, replace the faulty battery positive cable.
  4. Connect the voltmeter to measure between the battery negative cable terminal clamp and a good clean ground on the engine block. Rotate and hold the ignition switch in the START position. Observe the voltmeter. If the reading is above .2 volt, clean and tighten the battery negative cable eyelet terminal connection to the engine block. Repeat the test. If the reading is still above .2 volt, replace the faulty battery negative cable.

SELF-DIAGNOSTIC SYSTEM

CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

If a problem is sensed in a monitored circuit, a DTC will be stored in PCM/ECM memory. Voltage indicator light and Malfunction Indicator Light (MIL) will illuminate, provided specific criteria are met. A specific DTC results from a particular system failure. DTC only indicates problem in circuit, it does not identify specific component failure in circuit.

If problem is repaired or ceases to exist, PCM automatically clears DTC after 40 engine warm-up cycles. DTCs can also be cleared using scan tool. See CLEARING DIAGNOSTIC TROUBLE CODES .

RETRIEVING DIAGNOSTIC TROUBLE CODES

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

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

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

Note. For more information on scan tool and PCM/ECM diagnostics, see appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.

Ensure battery is fully charged. Connect scan tool to Data Link Connector (DLC). DLC is located below instrument panel, near steering column. Using scan tool, retrieve and record DTCs. If scan tool does not communicate with all modules, repair communication concerns See appropriate BODY CONTROL MODULES article in ACCESSORIES & EQUIPMENT. If any DTCs are retrieved, perform appropriate test procedure in accordance with DTCs retrieved. See SCAN TOOL DTC MESSAGES table. Once repairs are made, clear DTCs from Powertrain Control Module (PCM) memory. See CLEARING DIAGNOSTIC TROUBLE CODES . If no DTCs are retrieved, perform INTERMITTENT CONDITION under SYSTEM TESTS.

DTC (1)Scan Tool Display
P0071AMBIENT/BATTERY TEMP SENSOR PERFORMANCE
P0514BAT TEMPERATURE SENSOR RATIONALITY (DIESEL)
P0516LOW VOLTAGE AT THE BAT TEMP SENSOR (DIESEL)
P0516BATTERY TEMPERATURE SENSOR LOW (NGC)
P0517BATTERY TEMPERATURE SENSOR HIGH
P0562BATTERY VOLTAGE LOW (DIESEL)
P0562BATTERY VOLTAGE LOW (NGC)
P0563BATTERY VOLTAGE TOO HIGH (DIESEL)
P0563BATTERY VOLTAGE TOO HIGH (NGC)
P0622GENERATOR FIELD NOT SWITCHING PROPERLY (DIESEL)
P0622GENERATOR FIELD CONTROL CIRCUIT (NGC)
P0622GENERATOR FIELD NOT SWITCHING PROPERLY (GAS)
P1492AMBIENT BATTERY TEMPERATURE SENSOR VOLTAGE TOO HIGH
P1493AMBIENT/BATTERY TEMPERATURE SENSOR VOLTAGE TOO LOW
P1594CHARGING SYSTEM VOLTAGE TOO HIGH
P1682CHARGING SYSTEM VOLTAGE TOO LOW
P2503CHARGING SYSTEM OUTPUT LOW
(1) DTCs listed in this table are only testing procedure covered in this article. For a complete listing of PCM DTCs, see appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.
(1)DTCs listed in this table are only testing procedure covered in this article. For a complete listing of PCM DTCs, see appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.

SCAN TOOL DTC MESSAGES

CLEARING DIAGNOSTIC TROUBLE CODES

PCM/ECM automatically clears DTCs from memory after 40 engine warm-up cycles. DTCs can also be cleared by using scan tool.

Blank Message Screen

Check for loose cable connections or faulty cable. If cable connections and cable are okay, check voltage at Data Link Connector (DLC) terminal No. 16 (Pink wire). Voltage should be at least 11 volts. If voltage is not as specified, check wiring circuit and necessary fuses.

NO RESPONSE Message

If scan tool displays NO RESPONSE from PCM/ECM, repair communication concern. See appropriate BODY CONTROL MODULES article in ACCESSORIES & EQUIPMENT.

DIAGNOSTIC TESTS

CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

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

When Monitored & Set Condition

This code is monitored with the ignition ON and no battery temperature sensor open or short faults present. DTC P0071 sets after 5 warm-up cycles have occurred (coolant increases at least 40°F (22°C) to a minimum of 160°F (71°C) and the odometer mileage has increased 196.6 miles and the battery temperature has changed less than 7.2°F (4°C) change in temperature. One trip fault.

Possible Causes

  1. Good trip equal to zero.
  2. (K118) battery temp signal circuit shorted to voltage.
  3. Battery temperature sensor.
  4. Resistance in the (K118) battery temp sensor signal circuit.
  5. Resistance in the (K4) sensor ground circuit.
  6. (K118) battery temp sensor signal circuit shorted to ground.
  7. PCM.

Testing

  1. Turn ignition on, engine not running. With the DRBIII(R), read DTC's and record the related Freeze Frame data. If the good trip counter is equal to zero, go to next step. If the good trip counter is not equal to zero, see «INTERMITTENT CONDITION»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . Perform «POWERTRAIN VERIFICATION TEST VER-5 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-gas) .
  2. Turn the ignition off. Disconnect the battery temp sensor harness connector. Turn ignition on, engine not running. Measure the voltage on the (K118) battery temp signal circuit at the sensor connector. If the voltage is above 5.2 volts, repair the short to voltage on the (K118) batt temp signal circuit. See «POWERTRAIN VERIFICATION TEST VER-5 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-gas) . If the voltage is not above 5.2 volts, go to next step.
  3. With the DRBIII(R), read the battery temp sensor voltage with the battery temp sensor still disconnected. If the voltage is above 4.6 volts, go to next step. If the voltage is not above 4.6 volts, go to step 7 .
  4. Connect a jumper wire between the (K118) battery temp signal circuit and the (K4) sensor ground circuit at the sensor harness connector. With the DRBIII(R), read the battery temp sensor voltage. If the voltage is below 1 volt, replace the battery temperature sensor. See «POWERTRAIN VERIFICATION TEST VER-5 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-gas) . If the voltage is not below 1 volt, go to next step.
  5. Turn the ignition off. Connect the battery temp sensor harness connector. Ensure the voltmeter leads meet the terminals in the connector and that there is good terminal to wire connection. Ensure the voltmeter leads are connected for positive polarity. Backprobe the (K118) battery temp sensor signal circuit at the sensor harness connector and the PCM harness connector with both voltmeter leads. Start the engine. Allow the engine to idle. If the voltage is below .10 volt, go to next step. If the voltage is not below .10 volt, repair the excessive resistance in the (K118) battery temp sensor signal circuit. See «POWERTRAIN VERIFICATION TEST VER-5 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-gas) .
  6. Turn the ignition off. Ensure the voltmeter leads meet the terminals in the connector and that there is good terminal to wire connection. Ensure the voltmeter leads are connected for positive polarity. Backprobe the (K4) sensor ground circuit at the battery temperature sensor harness connector and the PCM harness connector using both voltmeter leads. Start the engine. Allow the engine to idle. If the voltage is below .10 volt, go to next step. If the voltage is not below .10 volt, repair the excessive resistance in the (K4) sensor ground circuit. See «POWERTRAIN VERIFICATION TEST VER-5 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-gas) .
  7. Turn the ignition off. Disconnect the battery temp sensor harness connector. Disconnect the PCM harness connectors. Measure the resistance between ground and the (K118) battery temp signal circuit. If the resistance is below 100 ohms, repair the short to ground in the (K118) battery temp signal circuit. If the resistance is not below 100 ohms, go to next step.
  8. Using the schematics 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/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . Perform «POWERTRAIN VERIFICATION TEST VER-5 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-gas) .

When Monitored & Set Conditions

This code is monitored when the engine off time is greater than 480 minutes and ambient temperature is greatre than 39°F (4°C). DTC P0071 sets after a calibrated amount of cool down time, the PCM compares the ECT sensor, IAT sensor and the ambient air temperature sensor values. If the ambient air temperature sensor value is not within 18°F (-10°C) of the other 2 temperature sensor's. Two trip fault. Three good trips to turn off the MIL.

  1. Good trip equal to zero.
  2. (G31) AAT signal circuit shorted to battery voltage.
  3. AAT sensor.
  4. (G31) AAT signal circuit open.
  5. (K900) sensor ground circuit open.
  6. (G31) AAT signal circuit shorted to ground.
  7. (G31) AAT signal circuit shorted to (K900) sensor ground.
  8. PCM.
  1. Turn the ignition on, engine not running. With the DRBIII(R), read DTC's and record the related Freeze Frame data. If the good trip counter displayed is equal to zero, go to next step. If the good trip counter is not equal to zero, see «INTERMITTENT CONDITION»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . See «POWERTRAIN VERIFICATION TEST VER-5 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-ngc) .
  2. Turn the ignition off. Disconnect the PCM harness connectors. Disconnect the Ambient Air Temp (AAT) sensor harness connector. Turn the ignition on, engine not running. Using a 12-volt test light connected to ground, probe the (G31) AAT signal circuit in the ambient temp sensor harness connector. If the test light illuminates, repair the short to voltage in the (G31) AAT signal circuit. See «POWERTRAIN VERIFICATION TEST VER-5 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-ngc) . If the test light does not illuminate, go to next step.
  3. Turn the ignition off. Connect the PCM harness connectors. Turn the ignition on, engine not running. With the DRBIII(R), read the ambient air temperature sensor voltage. If the voltage is above 4.6 volts, go to next step. If the voltage is not above 4.6 volts, go to step 7 .
  4. Turn the ignition off. Connect the PCM harness connectors. Turn the ignition on, engine not running. With the DRBIII(R), read the Ambient Air Temperature (AAT) sensor voltage. If the voltage is below 1 volt, replace the AAT sensor. See «POWERTRAIN VERIFICATION TEST VER-5 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-ngc) . If the voltage is not below 1 volt, go to next step.
  5. Turn the ignition off. Disconnect the PCM harness connectors. Measure the resistance of the (G31) AAT signal circuit from the AAT sensor harness connnector to the appropriate terminal of Miller Special Tool (8815). If the resistance is below 5 ohms, go to next step. If the resistance is not below 5 ohms, repair the open in the (G31) AAT signal circuit. See «POWERTRAIN VERIFICATION TEST VER-5 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-ngc) .
  6. Measure the resistance of the (K900) AAT sensor ground circuit from the AAT sensor harness connector to the appropriate terminal of Miller Special Tool (8815). If the resistance is below 5 ohms, go to step 9 . If the resistance is not below 5 ohms, repair the open in the (K900) sensor ground circuit. See «POWERTRAIN VERIFICATION TEST VER-5 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-ngc) .
  7. Turn the ignition off. Diconnect the PCM harness connectors. Measure the resisitance between ground and the (G31) AAT signal circuit in the AAT sensor harness connector. If the resistance is below 100 ohms, repair the short to ground in the (G31) AAT signal circuit. See «POWERTRAIN VERIFICATION TEST VER-5 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-ngc) . If the resisitance is not below 100 ohms, go to next step.
  8. Measure the resistance between the (G31) AAT signal circuit and the (K900) sensor ground circuit in the AAT sensor harness connector. If the resistance is below 100 ohms, repair the short between the (K900) sensor ground circuit and the (G31) AAT signal circuit. See «POWERTRAIN VERIFICATION TEST VER-5 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-ngc) . If the resistance is not below 100 ohms, go to next step.
  9. Using the schematics 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/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . See «POWERTRAIN VERIFICATION TEST VER-5 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-ngc) .

This code is monitored with the ignition key on. DTC P0072 is set when ambient temperature sensor is less than .0392 volt at the PCM for 4.8 seconds. One trip fault. Three good trips to turn off the MIL.

  1. AAT sensor voltage below .3 volt.
  2. AAT sensor.
  3. (G31) AAT signal circuit shorted to ground.
  4. (G31) AAT signal circuit shorted to the (K900) sensor ground.
  5. PCM.
  1. Turn the ignition on, engine not running. With the DRBIII(R), read the ambient air temperature sensor voltage. If the voltage is below .3 volt, go to next step. If the voltage is not below .3 volt, see «INTERMITTENT CONDITION»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . See «POWERTRAIN VERIFICATION TEST VER-5 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-ngc) .
  2. Turn the ignition off. Disconnect the ambient air temperature sensor harness connector. Turn the ignition on, engine not running. With the DRBIII(R), read AAT sensor voltage. If the voltage is above 4.6 volts, replace the ambient temperature sensor. See «POWERTRAIN VERIFICATION TEST VER-5 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-ngc) . If the voltage is not above 4.6 volts, go to next step.
  3. Turn the ignition off. Disconnect the PCM harness connectors. Measure the resistance between ground and the (G31) AAT signal circuit in the AAT sensor harness connector. If the resistance is below 100 ohms, repair the short to ground in the (G31) AAT signal circuit. See «POWERTRAIN VERIFICATION TEST VER-5 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-ngc) . If the resistance is not below 100 ohms, go to next step.
  4. Measure the resistance between the (G31) AAT signal circuit and the (K900) senosr ground circuit at the AAT sensor harness connector. If the resistance is below 100 ohms, repair the short between the (K900) sensor ground circuit and the (G31) AAT signal circuit. If the resisitance is not below 100 ohms, go to next step.
  5. Using the schematices 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/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . Perform «POWERTRAIN VERIFICATION TEST VER-5 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-ngc)

This code is monitored with the ignition key on. DTC P0073 sets when the ambient temperature sensor voltage is greater than 4.9 volts at the PCM for 4.8 seconds. One trip fault. Three good trips to turn off the MIL.

  1. AAT sensor voltage above 4.8 volts.
  2. AAT sensor.
  3. (G31) AAT signal circuit shorted to battery voltage.
  4. (G31) AAT signal circuit open.
  5. (K900) sensor ground circuit open.
  6. PCM.
  1. Turn the ignition on, engine not running. With the DRBIII(R), read the ambient air temperature sensor voltage. If the voltage is above 4.8 volts, go to next step. If the voltage is not above 4.8 volts, see «INTERMITTENT CONDITION»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . See «POWERTRAIN VERIFICATION TEST VER-5 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-ngc) .
  2. Turn the ignition off. Disconnect the ambient air temperature sensor harness connector. Connect a jumper wire between the (G31) AAT signal circuit and the (K900) sensor ground circuit at the AAT sensor harness connector. Turn the ignition on, engine not running. With the DRBIII(R), read ambient air temperature sensor voltage. If the voltage is below 1 volt, replace the ambient temperature sensor. See «POWERTRAIN VERIFICATION TEST VER-5 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-ngc) . If the voltage is not below 1 volt, go to next step.
  3. Turn the ignition off. Disconnect the PCM harness connectors. Turn the ignition on, engine not running. Using a 12-volt test light connected to ground, probe the (G31) AAT signal circuit in the AAT sensor harness connector. If the test light illuminates, repair the short to voltage in the (G31) AAT signal circuit. See «POWERTRAIN VERIFICATION TEST VER-5 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-ngc) . If the test light does not illuminate, go to next step.
  4. Turn the ignition off. Measure the resistance of the (G31) AAT signal circuit from the AAT sensor harness connector to the appropriate terminal of Special Tool (8815). If the resistance is below 5 ohms, go to next step. If the resistance is not below 5 ohms, repair the open in the (G31) AAT signal circuit. See «POWERTRAIN VERIFICATION TEST VER-5 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-ngc) .
  5. Measure the resisitance of the (K900) sensor ground circuit from the AAT sensor harness connector to the appropriate terminal of Miller Special Tool (8815). If the resistance is below 5 ohms, go to next step. If the resistance is not below 5 ohms, repair the open in the (K900) sensor ground circuit. See «POWERTRAIN VERIFICATION TEST VER-5 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-ngc) .
  6. Using the schematics 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/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . Perform «POWERTRAIN VERIFICATION TEST VER-5 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-ngc) .

This code is monitored while the engine is running. This code sets when the ECM does not read a change in value from the sensor over time.

  1. Battery temperature sensor.
  2. Intermittent condition.
  1. Remove the temperature sensor and reconnect the wiring harness connector to the sensor.
  2. Monitor DRBIII(R), while heating the sensor with an external heat source (DO NOT use an open flame).
  3. If the reading from the sensor increases at least 5°F on the DRBIII(R), see «INTERMITTENT CONDITION»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . See «POWERTRAIN VERIFICATION TEST VER-4 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-4-diesel) . If the temperature did not increase at least 5°F, replace the battery temperature sensor. See «POWERTRAIN VERIFICATION TEST VER-4 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-4-diesel) .

This code is monitored with the ignition on and battery voltage greater than 10.4 volts. This code sets when the circuit voltage to the ECM falls below a calibrated threshold for a certain period of time.

  1. Battery temperature sensor.
  2. Signal circuit shorted to ground.
  3. Signal circuit shorted.
  4. Intermittent condition.
  5. ECM.
  1. Turn the ignition off. Disconnect the battery temp sensor harness connector. Check connectors. Clean and repair as necessary. Measure the resistance of the battery temp sensor. If the resistance is between 300 and 90K ohms, go to next step. If the resistance is not as specified, replace the battery temp sensor. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) .
  2. Disconnect the ECM harness connectors. Check connectors. Clean and repair as necessary. Measure the resistance between the engine ground and the temperature sensor signal wire at the sensor connector. If the resistance is more than 100K ohms, go to next step. If the resistance is not as specified, repair the battery temp sensor signal circuit shorted to ground. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) .
  3. Measure the resistance between the battery temp sensor signal circuit and all other circuits in the ECM harness connector of the engine harness. If the resistance is more than 100K ohms, go to next step. If the resistance is not as specified, repair the signal circuit shorted to another circuit. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) .
  4. Reconnect the disconnected battery temp sensor harness connector. While monitoring with DRBIII(R), disconnect the temperature sensor harness connector. If DTC P0517 set, see «INTERMITTENT CONDITION»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . Perform «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) . If DTC P0517 did not set, replace the ECM. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) .

This code is monitored with the ignition on and battery voltage greater than 10 volts. DTC P0516 is set when battery temperature sensor voltage is below .039 volt. One trip fault. Three good trips to turn off the MIL.

  1. Battery temp volts below .5 volt.
  2. Battery temperature sensor.
  3. (K118) batt temp signal circuit shorted to ground.
  4. (K118) batt temp signal circuit shorted to (K4) sensor ground circuit.
  5. PCM.
  1. Turn ignition on, engine not running. With the DRBIII(R), record all DTC's and the related freeze frame data. With the DRBIII(R), monitor battery temperature sensor volts. If the voltage is below .5 volt, go to next step. If the voltage is not below .5 volt, see «INTERMITTENT CONDITION»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . Perform «POWERTRAIN VERIFICATION TEST VER-2 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-2-ngc) .
  2. Turn ignition on, engine not running. With the DRBIII(R) in sensors, read the battery temp sensor voltage value. Disconnect the battery temperature sensor harness connector. If the battery temperature voltage value changed from below 1 volt to above 4.5 volts, replace the battery temperature sensor. If the voltage did not change as specified, go to next step.
  3. Turn the ignition off. Disconnect the PCM harness connectors. Measure the resistance between ground and the (K118) batt temp signal circuit at the battery temp sensor harness connector. If the resistance is below 100 ohms, repair the short to ground in the (K118) batt temp signal circuit. See «POWERTRAIN VERIFICATION TEST VER-2 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-2-ngc) . If the resistance is not below 100 ohms, go to next step.
  4. Measure the resistance between the (K118) batt temp signal circuit and the (K4) sensor ground circuit at the battery temp sensor harness connector. If the resistance is below 5 ohms, repair the short between the (K4) sensor ground and the (K118) batt temp signal circuit. See «POWERTRAIN VERIFICATION TEST VER-2 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-2-ngc) . If the resistance is not below 5 ohms, go to next step.
  5. Using the schematics as a guide, inspect the wire harness and connectors. Pay particular attention to all power and ground circuits. If there are no possible causes remaining, replace and program the PCM. See «PROGRAMMING»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . See «POWERTRAIN VERIFICATION TEST VER-2 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-2-ngc) .

This code is monitored with the ignition on and battery voltage greater than 10.4 volts. DTC P0517 is set when the circuit voltage to the ECM is above a calibrated threshold for a certain period of time.

  1. Battery temp sensor.
  2. Signal circuit open.
  3. Return circuit open.
  4. Signal circuit shorted.
  5. ECM.
  6. Intermittent condition.
  1. Disconnect the battery temp sensor harness connector. Check the connectors and clean or repair as necessary. Measure the resistance of the battery temp sensor. If the resistance is between 300 and 90K ohms, go to next step. If the resistance is not as specified, replace the battery temp sensor. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) .
  2. Reconnect the disconnected battery temp sensor harness connector. Disconnect the ECM harness connectors. Check connectors and clean or repair as necessary. Measure the resistance between the temperature sensor signal and return circuits at the ECM harness connector. If the resistance is between 300 and 90K ohms, go step 5 . If the resistance is not as specified, go to next step.
  3. Disconnect the battery temp sensor harness connector. Measure the resistance of the sensor signal circuit between the sensor harness connector and the ECM harness connector. If the resistance is less than 10 ohms, go to step 5 . If the resistance is not as specified, go to next step.
  4. Measure the resistance of the sensor return circuit between the sensor harness connector and the ECM harness connector. If the resistance is less than 10 ohms, go to next step. If the resistance is not as specified, repair the open return circuit. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) .
  5. Check for a short circuit from signal circuit to all other circuits at the ECM harness connector. If the resistance is more than 100K ohms, go to next step. If the resistance is not as specified, repair the shorted signal circuit. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) .
  6. Reconnect the ECM harness connectors. While monitoring the DRBIII(R), use a jumper wire and connect the sensor signal circuit to the sensor return circuit at the sensor harness connector. If DTC P0516 set, see «INTERMITTENT CONDITION»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . Perform «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) . If the DTC did not set, replace the ECM. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) .

This code is monitored with ignition on and battery voltage greater than 10 volts. DTC P0517 sets when battery temperature voltage is above 4.94 volts for 4.8 seconds. One trip fault. Three good trips to turn off the MIL.

  1. Battery temp sensor voltage above 4.8 volts.
  2. Battery temperature sensor.
  3. (K25) batt temp signal circuit shorted to voltage.
  4. (K25) batt temp signal circuit open.
  5. (K900) sensor ground circuit open.
  6. PCM.
  1. Turn ignition on, engine not running. Record all DTC's and the related Freeze Frame data. With the DRBIII(R), monitor the battery temperature sensor voltage. If the voltage is above 4.8 volts, go to next step. If the voltage is not above 4.8 volts, see «INTERMITTENT CONDITION»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . See «POWERTRAIN VERIFICATION TEST VER-2 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-2-ngc) .
  2. Turn the ignition off. Disconnect the battery temperature sensor harness connector. Turn ignition on, engine not running. With the DRBIII(R) in sensors, read the battery temp voltage value. Connect a jumper wire between the (K25) batt temp signal circuit and the (K900) sensor ground circuit at the battery temp sensor harness connector. If the battery temp voltage value changed from greater than 4.5 volts to less than 1 volt, replace the battery temperature sensor. See «POWERTRAIN VERIFICATION TEST VER-2 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-2-ngc) . If the voltage did not change as specified, go to next step.
  3. Turn the ignition off. Disconnect the PCM harness connectors. Turn the ignition on, engine not running. Using a 12-volt test light connected to ground, probe the (K25) batt temp signal circuit at the battery temp sensor harness connector. If the test light illuminates, repair the short to voltage in the (K25) batt temp signal circuit. See «POWERTRAIN VERIFICATION TEST VER-2 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-2-ngc) . If the voltage is not above 5.2 volts, go to next step.
  4. Turn the ignition off. Measure the resistance of the (K25) batt temp signal circuit from the battery temp sensor harness connector to the appropriate terminal of Miller Special Tool (8815). If the resistance is below 5 ohms, go to next step. If the resistance is not below 5 ohms, repair the open in the (K25) sensor ground circuit. See «POWERTRAIN VERIFICATION TEST VER-2 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-2-ngc) .
  5. Measure the resistance in the (K900) sensor ground circuit from the sensor connector to the appropriate terminal of Miller Special Tool (8815). If the resistance is below 5 ohms, go to next step. If the resistance is not below 5 ohms, repair the open in the (K900) sensor ground circuit. See «POWERTRAIN VERIFICATION TEST VER-2 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-2-ngc) .
  6. Using the schematics 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/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . See «POWERTRAIN VERIFICATION TEST VER-2 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-2-ngc) .

This code is monitored with the key on or the engine running. DTC P0562 is set when battery voltage detected by the ECM is less than a calibrated value.

  1. P0622 present.
  2. P2502 present.
  3. P2503 present.
  4. Battery terminal connections.
  5. Accessory wiring.
  6. Battery.
  7. High resistance in wire harness.
  8. ECM.
  9. Intermittent condition.
  1. Read the DTC's with DRBIII(R). If P0622 is set, repair first. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) . If the code is not set, go to next step.
  2. Read the DTC's with DRBIII(R). If P2502 is set, repair first. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) . If the code is not set, go to next step.
  3. Read the DTC's with DRBIII(R). If P2503 is set, repair first. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) . If the code is not set, go to next step.
  4. Visually inspect the positive and negative connections at the batteries and inspect the battery negative connections at the engine block. If the connections are free of corrosion and are tight, go to next step. If not, repair the poor connections. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) .
  5. Check for add-on or accessory wiring at positive (+) terminal of the battery. If there are any damaged wires at the battery, repair accessory wiring. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) . If there is no damage, go to next step.
  6. Perform battery load test using the Midtronics Micro 420 battery system tester. If the battery passed the test, go to next step. If the battery did not pass the test, replace the weak battery or batteries. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) .
  7. Turn the ignition off. Disconnect the ECM harness connectors. Disconnect the battery terminals. Measure the resistance from the positive and negative battery posts to the appropriate circuits in the ECM harness connector. If the resistance is less than 10 ohms, go to next step. If the resistance is not more than 10 ohms, repair the high resistance in the wire harness. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) .
  8. Reconnect the battery terminals. Measure and record the voltage between battery positive pins of the ECM connector and the battery negative circuits of the ECM harness connector. Reconnect the ECM harness connectors. Use the DRBIII(R) to measure and record battery voltage. If the readings are within 3 volts of each other, see «INTERMITTENT CONDITION»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . Perform «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) . If the readings are not within 3 volts or each other, replace the ECM. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) .

This code is monitored with the engine running. The engine speed greater than 1000 RPM. DTC P0562 sets when battery voltage is 1 volt less than desired voltage for a set period of time. One trip fault. ETC light is flashing. Three good trips to clear the MIL.

  1. Good trip equal to zero.
  2. Resistance in the battery positive circuit.
  3. Resistance in the generator ground.
  4. Generator operation.
  5. (K20) gen field control circuit open.
  6. (K20) gen field control circuit shorted to ground.
  7. Ground circuit open.
  8. PCM.
WARNINGWhen the engine is operating, DO NOT stand in a direct line with the fan. DO NOT put your hands near the pulleys, belts or fan. DO NOT wear loose clothing.

Note. Ensure all wires are clear of the engine's moving parts.

Note. Ensure the battery is in good condition. Using the Midtronics Battery Tester, test the battery before continuing.

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

  1. Turn the ignition off. Ensure the generator drive belt is in good operating condition. Inspect the fuses in the IPM. If an open fuse is found, use the wire diagram/schematic as a guide, inspect the wiring and connectors for damage. Turn the ignition on, engine not running. With the DRBIII(R), read the DTC's and record the related Freeze Frame data. If the good trip counter displays an equal to zero count, go to next step. If it does not display equal to zero, see «INTERMITTENT CONDITION»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) .
  2. Measure the voltage between the generator B+ terminal and the battery + post. Start the engine. If the voltage is above .4 volt, repair the excessive resistance in the battery positive circuit between the generator and battery. See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) . If the voltage is not above .4 volt, go to next step.
  3. Turn ignition on, engine not running. Start the engine. Allow the engine to reach normal operating temperature. Measure the voltage between the generator case and battery ground post. If the voltage is above .1 volt, repair the excessive resistance in the generator ground between the generator case and battery ground. See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) . If the voltage is not above .1 volt, go to next step.
  4. Turn the ignition off. Disconnect the generator field harness connector. Using a 12-volt test light, jump it across the generator field harness connector. Turn the ignition on, engine not running. With the DRBIII(R), actuate the gen field control circuit. If the test light illuminates and flashes on and off, replace the generator. See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) . If the light does not illuminate or flash on and off, go to the next step.
  5. Turn the ignition off. Disconnect the PCM harness connectors. Measure the resistance of the (K20) gen field control circuit from the generator harness connector to the appropriate terminal of the Miller Special Tool (8815). If the resistance is below 5 ohms, go to next step. If the resistance is not below 5 ohms, repair the open in the (K20) gen field control circuit. Perform «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) .
  6. Measure the resistance between ground and the (K20) fen field control circuit in the gen field harness connector. If the resistance is below 100 ohms, repair the short to ground in the (K20) gen field control circuit. See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) . If the resistance is not below 100 ohms, go to next step.
  7. Using a 12-volt test light connected to 12-volts, probe the ground circuit in the generator field harness connector. If the test light illuminates, go to next step. If the test light does not illuminate, repair the open in the ground circuit. See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) .
  8. Using the schematics 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/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) .

This code is monitored with the key ON or the engine running. DTC P0563 sets when the battery voltage detected by the ECM is greater than a calibrated value.

  1. P0622 present.
  2. P2502 present.
  3. P2504 present.
  4. Batteries improperly installed.
  5. ECM.
  6. Intermittent condition.
  1. With the DRBIII(R), read DTC's. If P0622 is set, repair first. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) . If P0622 is not set, go to next step.
  2. With the DRBIII(R), read DTC's. If P2502 is set, repair first. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) . If P2502 did not set, go to next step.
  3. With the DRBIII(R), read DTC's. If P2504 is set, repair first. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) . If P2504 did not set, go to next step.
  4. Disconnect the ECM harness connectors. Measure the battery voltage between the battery positive pins of the ECM harness connector. If the voltage is less than 19 volts, go to next step. If the voltage is not below 19 volts, install the battery system correctly. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) .
  5. Reconnect the battery terminals. Measure and record the voltage between battery positive pins of the ECM connector and the battery negative circuits of the ECM harness connector. Reconnect the ECM harness connectors. Use DRBIII(R) to measure and record battery voltage. If the readings are within 3 volts of each other, see «INTERMITTENT CONDITION»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . Perform «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) . If the readings are not within 3 volts, replace the ECM. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) .

This code is monitored with the ignition on. Engine RPM greater than 1000 RPM. With no other charging system codes set. DTC P0563 is set when battery voltage is 1 volt greater than desired voltage. Battery voltage greater than 15.75 volts. One trip fault. Three good trips to turn off the MIL.

  1. Good trip equal to zero.
  2. Generator operation.
  3. (K20) gen field control circuit shorted to voltage.
  4. PCM.

Note. Ensure the battery is in good condition. Using the Midtronics Battery Tester, test the battery before continuing.

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

  1. Turn the ignition off. Ensure the generator drive belt is in good operating condition. Inspect the fuses in the IPM. If a fuse is open use the wire diagram/schematic as a guide, inspect the wiring and connectors for damage. Turn the ignition on, engine not running. With the DRBIII(R), read DTC's and record the related Freeze Frame data. If the good trip counter displays and is equal to zero, go to next step. If the counter does not display zero, see «INTERMITTENT CONDITION»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) .
  2. Turn the ignition off. Disconnect the generator field harness connector. Using a 12-volt test light, jump across the generator field harness connector. Turn ignition on, engine not running. With the DRBIII(R), actuate the generator field driver. If the test light illuminates brightly and flashes on and off, replace the generator. See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) . If the test light does not illuminate or flash on and off, go to next step.
  3. Turn the ignition off. Disconnect the PCM harness connectors. Turn ignition on, engine not running. Measure the voltage on the (K20) gen field control circuit at the generator field harness connector. If the voltage is above 1 volt, repair the short to voltage in the (K20) gen field control circuit. See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) . If the voltage is not above 1 volt, go to next step.
  4. Using the schematics 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/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) .

This code is monitored when the ignition is ON. DTC P0622 sets when the feedback signal does not match the commanded signal for the voltage regulator.

  1. Generator.
  2. Open driver circuit.
  3. Gen source shorted to battery negative.
  4. Field driver circuit shorted to voltage.
  5. Gen source open.
  6. ECM.
  1. Turn the ignition off. Disconnect the generator field harness connector. Check connectors. Clean or repair as necessary. Measure the resistance between the generator field terminals. If the resistance is between .5 and 15 ohms, go to next step. If the voltage is not as specified, replace the generator.
  2. Disconnect the ECM harness connector. Check connectors. Clean or repair as necessary. Measure the resistance of the generator driver wire between the generator harness connector and the ECM harness connector. If the resistance is less than 10 ohms, go to the next step. If the resistance is not less than 10 ohms, repair the open driver circuit.
  3. Measure the resistance of the generator source circuit between the generator harness connector an battery negative. If the resistance is less than 10 ohms, repair the gen source shorted to battery negative. If the resistance is not less than 10 ohms, go to next step.
  4. Measure the voltage between the generator field driver circuit in the generator harness connector and battery negative. If the voltage is greater than 1 volt, repair the generator field driver circuit shorted to voltage. If the voltage is not greater than 1 volt, go to next step.
  5. Measure voltage of the gen source circuit at the generator harness connector. If the voltage is within 1 volt of battery voltage, replace the ECM. If the voltage is not within 1 volt of battery voltage, repair the open or high resistance of gen source circuit.

This DTC is monitored with the ignition key ON and the engine running. DTC P0622 sets when the PCM tries to regulate the generator field with no result during monitoring.

  1. Generator field performance.
  2. (K125) gen field source circuit open.
  3. (K20) gen field control circuit open.
  4. (K20) gen field control circuit shorted to ground.
  5. Generator.
  6. PCM.
  1. Turn ignition on, engine not running. Record all DTC's and the related Freeze Frame data. Using a 12-volt test light connected to ground, backprobe the (K20) gen field control circuit at the back of the generator. With the DRBIII, actuate the generator field driver. If the test light blinks, see «INTERMITTENT CONDITION»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) . If the test light does not blink, go to next step.
  2. Turn ignition on, engine not running. Carefully inspect all connectors for corrosion or spread terminals before continuing. Backprobe the (K125) generator field source circuit at back of generator with a voltmeter. With the DRBIII(R), actuate the generator field driver. If the voltage is above 10 volts, go to next step. If the voltage is not above 10 volts, repair the open in the (K125) gen field source circuit. See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) .
  3. Turn the ignition off. Disconnect the PCM harness connector. Disconnect the generator field harness connector. Measure the resistance of the (K20) generator field control circuit from the generator field harness connector to the PCM 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) gen field control circuit. See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) .
  4. Measure to the resistance between ground and the (K20) generator field control circuit in the PCM harness connector. If the resistance is below 100 ohms, repair the short to ground in the (K20) gen field control circuit. See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) . If the resistance is not below 100 ohms, go to next step.
  5. Measure the resistance across the generator field terminals at the generator. If the resistance is between .5 ohms and 15 ohms, go to next step. If the resistance is not as specified, repair the generator as necessary. See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) .
  6. Using the schematics 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/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . Perform «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) .

This code is monitored with the ignition on and the engine running. DTC P0622 is set when the PCM tries to regulate the generator field with no result during monitoring. One trip fault. Three good trips to turn off the MIL.

  1. Good trip equal to zero.
  2. Generator operation.
  3. (K20) gen field control circuit shorted to voltage.
  4. (K20) gen field control circuit open.
  5. (K20) gen field control circuit shorted to ground.
  6. (Z346) ground circuit open.
  7. PCM.
  1. Turn ignition on, engine not running. With the DRBIII(R), read DTC's and record the related freeze frame data. If the good trip counter displayed and equal to zero, go to next step. If the good trip counter does not equal zero, see «INTERMITTENT CONDITION»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) .
  2. Turn the ignition off. Disconnect the generator field harness connector. Using a 12-volt test light, jump it across the generator field harness connector. Turn the ignition on, engine not running. With the DRBIII(R), actuate the generator field control circuit. If the test light illuminates and flashes on and off, replace the generator. See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) . If the test light does not illuminate or flash on and off, go to next step.
  3. Turn the ignition off. Disconnect the PCM harness connectors. Turn the ignition on, engine not running. Measure the voltage on the (K20) gen field control circuit in the generator field harness connector. If the voltage is above 1 volt, repair the short to voltage in the (K20) gen field control circuit. See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) . If the voltage is not above 1 volt, go to next step.
  4. Turn the ignition off. Measure the resistance of the (K20) gen field control circuit from the generator field harness connector to appropriate terminal of the Miller Special Tool (8815). If the resistance is below 5 ohms, go to next step. If the resistance is not below 5 ohms, repair the open in the (K20) gen field control circuit. See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) .
  5. Measure the resistance between ground and the (K20) gen field control circuit in the generator field harness connector. If the resistance is below 100 ohms, repair the short to ground in the (K20) gen field control circuit. See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) . If the resistance is below 100 ohms, go to next step.
  6. Using a 12-volt test light connected to battery voltage, probe the (Z346) ground circuit in the gen field harness connector. If the test light illuminates, go to next step. If the test light does not illuminate, repair the open in the (Z346) ground circuit. See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) .
  7. Using the schematics 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/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . Perform «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) .

The code is monitored with the ignition key on. DTC P1492 is set when the PCM senses the voltage from the battery temperature sensor above 4.9 volts for 3 seconds.

  1. Battery temp sensor voltage above 4.8 volts.
  2. Battery temperature sensor.
  3. (K118) batt temp signal circuit shorted to voltage.
  4. (K118) batt temp signal circuit open.
  5. (K4) sensor ground circuit open.
  6. PCM.
  1. Turn ignition on, engine not running. Record all DTC's and the related Freeze Frame data. With the DRBIII(R), monitor the battery temperature sensor voltage. If the voltage is above 4.8 volts, go to next step. If the voltage is not above 4.8 volts, see «INTERMITTENT CONDITION»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) .
  2. Turn the ignition off. Disconnect the battery temp sensor harness connector. Turn the ignition on, engine not running. With the DRBIII(R) in Sensors, read the battery temp signal circuit and the (K4) sensor ground circuit at the battery temp sensor connector. If the battery temp sensor voltage changes from greater than 4.5 volts to less than 1 volts, replace the battery temp sensor. See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) . If the voltage did not change from greater than 4.5 volts to less than 1 volt, go to next step.
  3. Turn the ignition off. Disconnect the PCM harness connectors. Turn ignition on, engine not running. Measure the voltage on the (K118) battery temp signal circuit at the sensor harness connector. If the voltage is above 5.2 volts, repair the short to voltage in the (K118) battery temp signal circuit. See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) . If the voltage is not above 5.2 volts, go to next step.
  4. Turn the ignition off. Measure the resistance of the (K118) battery temp signal circuit from the battery temp sensor harness connector to the PCM 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 (K118) batt temp signal circuit. See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) .
  5. Measure the resistance in the (K4) sensor ground circuit from the PCM harness connector to the sensor 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 (K4) sensor ground circuit. See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) .
  6. Using the schematics 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/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) .

This code is monitored with the ignition on. The Powertrain Control Module (PCM) senses voltage from ambient battery temperature sensor to be less than 0.5 volts for 3 seconds.

  1. Battery temp sensor volts below .5 volt.
  2. Battery temp sensor.
  3. (K118) batt temp signal circuit shorted to ground.
  4. (K118) batt temp signal circuit shorted to the (K4) sensor ground.
  5. PCM.
  1. Turn the ignition on, engine not running. Record all DTC's and the related Freeze Frame data. With the DRBIII(R), monitor the ambient/battery temperature sensor voltage. If the voltage is below .5 volt, go to next step. If the voltage is not below .5 volt, see «INTERMITTENT CONDITION»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) .
  2. Turn ignition on, engine not running. With the DRBIII(R) in sensors, read the battery temp sensor voltage. Disconnect the battery temp sensor harness connector. If the battery temperature sensor voltage changed from below 1 volt to above 4.5 volts, replace the battery temperature sensor. See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) . If the voltage did not change from below 1 volt to above 4.5 volts, go to next step.
  3. Turn the ignition off. Disconnect the PCM harness connectors. Measure the resistance between ground and the (K118) battery temp signal circuit at the battery temp sensor harness connector. If the resistance is below 100 ohms, repair the short to ground in the (K118) battery temp signal circuit. See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) . If the resistance is not below 100 ohms, go to next step.
  4. Measure the resistance between the (K118) battery temp signal circuit and the (K4) sensor ground circuit at the battery temp sensor harness connector. If the resistance is below 100 ohms, repair the short between the (K4) sensor ground circuit and the (K118) batt temp signal circuit. See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) . If the resistance is not below 100 ohms, go to next step.
  5. Using the schematics 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 «PCM»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__pcm-ngc-or-ecm-cummins) . See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) .

Monitored with the ignition key on and the engine speed greater than 0 RPM. When the PCM regulates the generator field and there are no detected field problems, but the voltage output does not decrease.

  1. Charging system operation.
  2. (K20) generator field control circuit shorted to ground.
  3. Generator field coil shorted to ground.
  4. Battery temperature sensor.
  5. PCM.
  1. Turn the ignition on, engine not running. With DRBIII(R), read DTC's and the related Freeze Frame data then clear the DTC's. With DRBIII(R), actuate the generator field driver. With a 12-volt test light connected to ground, backprobe the (K20) gen field control circuit in the back of the generator field harness connector. If the test light illuminates and flashes, go to next step. If the test light does not illuminate or flash, see «INTERMITTENT CONDITION»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) .
  2. Turn the ignition off. Disconnect the PCM harness connectors. Disconnect the generator field harness connector. Carefully inspect the related connectors for corrosion or spread terminals before continuing. Measure the resistance between ground and the (K20) generator field driver circuit at the generator field harness connector. If the resistance is below 100 ohms, repair the short to ground in the (K20) generator field control circuit. See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) . If the resistance is not below 100 ohms, go to next step.
  3. Measure the resistance between ground and the generator field terminals on the generator. If the resistance is below 100 ohms, replace or repair the generator field coil for a short to ground. See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) . If the resistance is not below 100 ohms, go to next step.
  4. Connect the PCM harness connectors and the generator harness connector. Turn ignition on, engine not running. With the DRBIII(R) in Inputs/Outputs, read the battery temp sensor value. Using a thermometer, measure under hood temperature near battery tray. If the temperature is within 10 degrees of battery temperature, go to next step. If the temperature is not within 10 degrees of battery temperature, replace the battery temperature sensor. See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) .
  5. Using the schematics as a guide, inspect the wire harness and connectors. Pay particular attention to the power and ground circuits. If there are no possible causes remaining, replace and program the PCM. See «PROGRAMMING»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) .

This code is monitored with the ignition key on and the engine running over 1500 RPM after 25 seconds. When the PCM regulates the generator field and there are no detected field problems, but the voltage output does not increase.

  1. Charging voltage below 15.1 volts.
  2. Battery temperature sensor.
  3. Resistance in the battery positive circuit.
  4. (K125) generator field source circuit open.
  5. Resistance in the generator ground.
  6. (K125) generator field source circuit shorted to ground.
  7. (K20) generator field control circuit open.
  8. Resistance in the generator field coil.
  9. PCM.
WARNINGWhen the engine is operating, DO NOT stand in a direct line with the fan. DO NOT put your hands near the pulleys, belts or fan. DO NOT wear loose clothing.
  1. Start engine. Record all DTC's and the related Freeze Frame data. With the DRBIII(R), read the target charging voltage. If the target charging voltage is above 15.1 volts, see «INTERMITTENT CONDITION»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) . If the target charging voltage is not above 15.1 volts, go to next step.
  2. Turn the ignition off. Generator belt tension and condition must be checked before continuing. Start the engine. Allow the engine to reach normal operating temperature. With the DRBIII(R) in sensors, read the battery temp sensor value. Using a thermometer, measure underhood temperature. If the temperature is within 10°F degrees of the battery temperature, go to next step. If the temperature is not within 10°Fdegrees of the battery temperature, replace the battery temperature sensor. See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) .
  3. Turn ignition on, engine not running. Measure the voltage between the generator B+ terminal and the battery positive post. Start the engine. If the voltage is above .4 volt, repair the excessive resistance in the battery positive circuit between the generator and battery. See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) . If the voltage is not above .4 volt, go to next step.
  4. Start the engine. Warm the engine to operating temperature. Measure the voltage between the generator case and battery negative post. If the voltage is above .1 volt, repair the excessive resistance in the generator ground circuit between the generator case and battery negative side. See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) . If the voltage is not above .1 volt, go to next step.
  5. Turn ignition on, engine not running. Carefully inspect all connectors for corrosion or spread terminals before continuing. With the DRBIII(R), actuate the generator field driver. While backprobing, measure the voltage on the (K125) generator field source circuit at back of generator. If the voltage is above 10 volts, go to next step. If the voltage is not above 10 volts, repair the open in the (K125) generator field source circuit. See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) .
  6. Turn the ignition off. Disconnect the PCM harness connectors. Disconnect the generator field harness connector. Measure the resistance between ground and the (K125) generator field source circuit in the PCM harness connector. If the resistance is below 100 ohms, repair the short to ground in the (K125) generator field source circuit and replace the PCM. If the resistance is not below 100 ohms, go to next step.
  7. Measure the resistance of the (K20) generator field driver circuit from the generator harness connector to the PCM 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 control circuit. See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) .
  8. Measure the resistance across the generator field terminals at the generator. If the resistance is above 15 ohms, replace or repair the generator as necessary. See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) . If the resistance is not above 15 ohms, go to next step.
  9. Using the schematics as a guide, inspect the wire harness and connectors. Pay particular attention to all power and ground circuits. If there are no more possible causes remaining, replace and program the PCM. See «PROGRAMMING»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . Perform «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) .

This code is monitored while the engine is running. DTC P2502 is set when the ECM cycles the voltage regulator in the generator while monitoring for a change in output voltage. If the voltage does not drop when the regulator is off, the fault is set.

  1. Dirty or loose connections.
  2. High resistance in the B+ circuit.
  3. High resistance in the B+ crossover cable.
  4. Generator.
  5. ECM.
  6. Intermittent condition.
  1. Visually inspect the positive and negative connections at the battery. Visually inspect the battery negative connections at the engine block. If the connections are free of corrosion and are tight, go to next step. If the connections are not free of corrosion or are loose, clean and/or tighten the connections. See «POWERTRAIN VERIFICATION TEST VER-4 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-4-diesel) .
  2. Measure the voltage between the B+ post of the generator and the B+ post of the battery while the engine is running. If the voltage is above .4 volts, repair the high resistance in the B+ circuit from battery to the generator. See «POWERTRAIN VERIFICATION TEST VER-4 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-4-diesel) . If the voltage is as specified, go to next step.
  3. Measure the voltage betwen the B+ post of the generator and the B+ post of the right side battery to the left side battery while the engine is running. If the voltage is above .4 volts, repair the high resistance in the B+ crossover cable from right side battery to left side battery. See «POWERTRAIN VERIFICATION TEST VER-4 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-4-diesel) . If the voltage is not above .4 volts, go to next step.
  4. Measure the voltage between the generator case and the B- post of the battery. If the voltage is above .1 volt, repair the high resistance in the ground circuit. See «POWERTRAIN VERIFICATION TEST VER-4 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-4-diesel) . If the voltage is not above .1 volt, go to next step.
  5. Disconnect the generator field harness connector. Check connectors, and clean and repair as necessary. Measure the resistance between the generator field terminals. If the resistance is between .5 and 15 ohms, go to next step. If the resistance is not as specified, replace the generator. See «POWERTRAIN VERIFICATION TEST VER-4 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-4-diesel) .
  6. Turn the ignition off. Reconnect the generator field harness connector. Disconnect the ECM harness connectors. Check the connectors, clean or repair as necessary. Turn the ignition on, engine not running. Measure the voltage between battery positive circuits of the ECM harness connector. Turn the ignition off. Reconnect the ECM harness connectors. Start the engine. Use the DRBIII(R) to measure and record battery voltage. Compare the voltage reading from the voltmeter with that of the DRBIII(R). If the readings are within 3 volts of each other, test is complete. If the readings are not within specifications, replace and program the ECM. See «PROGRAMMING»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . Perform «POWERTRAIN VERIFICATION TEST VER-4 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-4-diesel) .

This code is monitored while the engine is running. DTC P2503 sets when the battery voltage exceeds target voltage by more than a calibrated value.

  1. Other DTC's present.
  2. Generator.
  3. Field driver circuit shorted to ground.
  4. ECM.
  5. Intermittent condition.
  1. With the DRBIII(R), read DTC's. If DTC P2502 is set, repair other DTC's first. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) . If DTC P2502 is not set, go to next step.
  2. Disconnect the generator field harness connector. Check connectors, clean or repair as necessary. Measure the resistance between the generator terminals at the generator. If the resistance is between .5 and 15 ohms, go to next step. If the resistance is not as specified, replace the generator. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) .
  3. Disconnect the ECM harness connectors. Check connectors, clean or repair as necessary. Measure the resistance of the greator field driver circuit shorted to ground. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) .
  4. Measure and record the voltage between battery positive circuit of the ECM harness connector and the battery negative circuits of the ECM harness connector. Reconnect the ECM connectors. Use the DRBIII(R) to measure and record battery voltage. Compare the voltage reading from the voltmeter with that of the DRBIII(R). If the readings are within 3 volts of each other, see «INTERMITTENT CONDITION»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . Perform «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) . If the readings are not within specifications, replace and program the ECM. See «PROGRAMMING»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . Perform «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) .

This code is monitored with the engine running. The engine speed greater than 1157 RPM. DTC P2503 is set when the battery sensed 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. One trip fault. Three good trips to turn off the MIL.

  1. Good trip counter equal to zero.
  2. Excessive resistance in the battery positive circuit.
  3. Excessive resistance in the case ground.
  4. Generator operation.
  5. (K20) gen field control circuit shorted to voltage.
  6. (K20) gen field control circuit open.
  7. (K20) gen field control circuit shorted to ground.
  8. Gen ground circuit open.
  9. PCM.
WARNINGWhen the engine is operating, DO NOT stand in a direct line with the fan. DO NOT put your hands near the pulleys, belts or fan. DO NOT wear loose clothing.

Note. Ensure all wires are clear of the engine's moving parts.

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

Note. The battery must be fully charged.

Note. The generator belt tension and condition must be checked before continuing.

  1. Turn the ignition on, engine not running. With the DRBIII(R), read DTC's and record the related freeze frame data. With the DRBIII(R), erase DTC's. Start the engine. Allow the idle to stabilize. Turn the ignition on, engine not running. With the DRBIII(R), read DTC's. If the good trip counter is equal to zero, go to next step. If the good trip counter is not equal to zero, see «INTERMITTENT CONDITION»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) .
  2. Turn the ignition on, engine not running. Measure the voltage between the generator B+ output terminal and the battery + post. Start the engine. If the voltage is above .4 volt, repair the excessive resistance in the battery positive circuit between the generator and battery. See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) . If the voltage is not above .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 .1 volt, repair the excessive resistance in the generator case ground. See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-gas) . If the voltage is not above .1 volt, go to next step.
  4. Turn the ignition off. Disconnect the generator field harness connector. Using a 12-volt test light, jump it across the generator field harness connector. Turn ignition on, engine not running. With the DRBIII(R), actuate the generator field driver. If the test light illuminates brightly or flashes on and off, replace the generator. See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) . If the test light illuminates or flashes on and off, go to next step.
  5. Turn the ignition off. Disconnect the PCM harness connectors. Turn the ignition on, engine not running. Measure the voltage on the (K20) gen field control circuit at the generator field harness connector. If the voltage is above 1 volt, repair the short to voltage in the (K20) gen field control circuit. See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) . If the voltage is not above 1 volt, go to next step.
  6. Turn the ignition off. Measure the resistance of the (K20) gen field control circuit from the generator field harness connector to the appropriate terminal of Miller Special Tool (8815). If the resistance is below 5 ohms, go to next step. If the resistance is not below 5 ohms, repair the open in the (K20) gen field control circuit. See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) .
  7. Measure the resistance between the ground and the (K20) gen field control circuit in the generator field harness connector. If the resistance is below 100 ohms, repair the short to ground in the (K20) gen field control circuit. See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) . If the resistance is not below 100 ohms, go to next step.
  8. Using a 12-volt test light connected to battery voltage, probe the (Z13) ground circuit in the generator field harness connector. If the test light illuminates brightly, go to next step. If the test light does not illuminate, repair the open in the generator ground circuit. See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) .
  9. Using the schematics as a guide, inspect the wire harness and connectors. Pay particular attention to all power and ground circuits. If there are no more possible causes remaining, replace and program the PCM. See «PROGRAMMING»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-3-ngc) .

This code is monitored while the engine is running. DTC P2504 is set when battery voltage is less than 11.5 volts for more than 8 seconds. Battery voltage must exceed 12 volts for more than 5 seconds for fault to become inactive.

  1. Other DTC's present.
  2. Dirty or loose connections.
  3. Add-on or accessory wires at battery terminal.
  4. High resistance in the B+ circuit.
  5. High resistance in the B+ crossover cable.
  6. High resistance in the ground circuit.
  7. Generator.
  8. ECM.
  9. Intermittent condition.
  1. With the DRBIII(R), read DTC's. If DTC P2502 is set, repair other DTC's first. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) . If the DTC is not set, go to next step.
  2. Visually inspect the positive and negative connections at the battery. Visually inspect the battery negative connections at the engine block. If the connections are free of corrosion and are tight, go to next step. If the connections are not free of corrosion or tight, clean and or tighten the connections. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) .
  3. Check for add-on or accessory wiring at positive (+) terminal of the battery. If there are any damaged wires at the battery, remove defective or mis-wired add-on or accessory wiring from battery. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) . If there are no damaged wires at the battery, go to next step.
  4. Measure the voltage between the B+ post of the generator and the B+ post of the battery while the engine is running. If the voltage is above .4 volts, repair the high resistance in the B+ circuit from battery to the generator. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) . If the voltage is not above .4 volt, go to next step.
  5. Measure the voltage between the B+ post of the generator and the B+ post of the right side battery to the left side battery while the engine is running. If the voltage is above .4 volt, repair the high resistance in the B+ crossover cable from right side battery to left side battery. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) . If the voltage is not above .4 volt, go to next step.
  6. Measure the voltage between the generator case and the B- post of the battery. If the voltage is above .1 volt, repair the hight resistance in the ground circuit. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) . If the voltage is not above .1 volt, go to next step.
  7. Disconnect the generator field harness connector. Check connectors and clean or repair as necessary. Measure the resistance between the generator field terminals at the generator. If the resistance is between .5 and 15 ohms, go to next step. If the resistance is not as specified, replace the generator. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) .
  8. Measure and record the voltage between battery positive circuit of the ECM harness connector and the battery negative circuits of the ECM harness connector. Reconnect the ECM connectors. Use the DRBIII(R) to measure and record battery voltage. Compare the voltage reading from the voltmeter with that of the DRBIII(R). If the readings are within 3 volts of each other, see «INTERMITTENT CONDITION»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . Perform, «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) . If the readings are not within specifications, replace and program the ECM. See «PROGRAMMING»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) . See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-1-diesel) .

Diesel

WARNINGWhen the engine is operating, DO NOT stand in a direct line with the fan. DO NOT put your hands near the pulleys, belts or fan. DO NOT wear loose clothing.

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 DRBIII(R) 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 DRBIII(R) 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 an chafed, pierced, pinched, partially broken wires and broken, bent, pushed out, or corroded terminals.
  5. Inspect and clean all ECM, engine, and chassis grounds that related to the DTC set.
  6. If numerous trouble codes were set, use a wire schematic to help you find any common ground or supply circuits.
  7. For any related DTC's , actuate the relay with the DRBIII(R) and wiggle the related wire harness to try to interrupt the actuation.
  8. A data recording, and/or lab scope should be used to help diagnose intermittent conditions.
  9. Use the DRBIII(R) to perform a system test if one applies to failing component.
  10. If problems were found during the inspections, repair as necessary. See «POWERTRAIN VERIFICATION TEST VER-5 (DIESEL)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-diesel) . If no problems were found, test is complete.

Gas

WARNINGWhen the engine is operating, DO NOT stand in a direct line with the fan. DO NOT put your hands near the pulleys, belts or fan. DO NOT wear loose clothing.

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 DRBIII(R) 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 DRBIII(R) parameters related to the DTC while wiggling the wire harness. Look for parameter values to change and/or a DTC to set.
  4. Visually inpsect 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 that related to the DTC set.
  6. If numerous trouble codes were set, use the wire schematic to help find any common ground or supply circuits.
  7. For intermittent misfire DTC's check for restrictions in the intake and exhaust system, improper installation of sensors, vacuum leaks, and binding components driven by the accessory drive belt.
  8. A co-pilot, data recording, and/or lab scope should be used to help diagnose intermittent conditions.
  9. Use the DRBIII(R) to perform a system test if one applies to failing component.
  10. If any problems are found during the above inspections, repair as necessary. See «POWERTRAIN VERIFICATION TEST VER-5 (GAS)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-gas) . If no problems were found, test is complete.

NGC

WARNINGWhen the engine is operating, DO NOT stand in a direct line with the fan. DO NOT put your hands near the pulleys, belts or fan. DO NOT wear loose clothing.

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 DRBIII(R) 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 DRBIII(R) parameters related to the DTC while wiggling the wire harness. Look for parameter values to change and/or a DTC to set.
  4. Turn ignition off.
  5. Visually inspect the related wire harness. Disconnect all the related harness connectors. Look for any chafed, pierced, pinched, partially broken wires and broken, bent pushed out, or corroded terminals.
  6. Perform «VOLTAGE DROP TEST»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__voltage-drop-test) on the related circuits between the suspected faulty component and the PCM.
  7. Inspect and clean all PCM, engine, and chassis grounds that are related to the most current DTC.
  8. If numerous trouble codes were set, use a wire schematic and look for any common ground or supply circuits.
  9. For any relay DTC's, actuate the relay with the DRBIII(R) and wiggle the related wire harness to try to interrupt the actuation.
  10. For intermittent Misfire DTC's, check for restrictions in the intake and exhaust system, proper installation of sensors, vacuum leaks, and binding components that are run by the accessory drive belt.
  11. Use the DRBIII(R) to perform a system test if one applies to failing component.
  12. A co-pilot, data recorder, and/or lab scope should be used to help diagnose intermittent conditions.
  13. If any problems were found during the above inspections, repair as necessary. See «POWERTRAIN VERIFICATION TEST VER-5 (NGC)»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__powertrain-verification-test-ver-5-ngc) . If no problems were found, test is complete.

POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)

  1. Clear the DTC before continuing.
  2. Check if any of the following conditions exist.
  3. The ECM has been disconnected or replaced.
  4. The battery power has been disconnected.
  5. The APPS has been disconnected or replaced.
  6. If any of the conditions exist, perform the following steps, otherwise go to step 8 .
  7. APPS Programming Procedure Reassemble all components. Turn the ignition key to the ON or RUN position. Without starting the engine, slowly press the throttle pedal to the floor and then slowly release.
  8. This step must be done (only once) to ensure the accelerator pedal position sensor calibration has been programmed in the ECM.
  9. If the ECM has been replaced and the correct VIN and mileage have not been programmed, a DTC will be set in the ABS and Airbag Modules. If the ECM has not been replaced, go to step 11 .
  10. For ABS and Airbag Systems, enter correct VIN and Mileage in ECM. Erase ABS and Airbag Module codes.
  11. If the ECM has not been replaced, inspect the vehicles to ensure that all engine components are connected. Reassemble and reconnect components as necessary.
  12. Attempt to start the engine.
  13. If the engine is unable to start, look for any TSB's that may relate to this condition. Return to symptom list if necessary.
  14. If there are no DTC's present and all components are functional, the repair is complete. If any DTC's are present, repair is not complete, refer to appropriate symptom. If no DTC's are present, repair is complete.

POWERTRAIN VERIFICATION TEST VER-2 (NGC)

Note. If this vehicle is equipped with a 5.7L NGCII system and the APP sensors, PCM, or Throttle Body Assembly has been replaced, use the DRBIII(R) under the MISC. menu to perform the LEARN ETC. function.

Note. After completing this test, see TRANSMISSION (45RFE/545RFE) VERIFICATION TEST VER-1 (NGC) .

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

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

  1. Inspect the vehicle to ensure that all components related to the repair are properly installed and connected.
  2. With the DRBIII(R), clear DTC's and Reset Memory all engine values.
  3. Run the engine for one warm-up cycle to verify proper operation.
  4. Road test the vehicle. Use all accessories that may be related to this repair.
  5. With the DRBIII(R), confirm that no DTC's or secondary indicators are present and that all components are functioning properly.
  6. If this test is being performed after a NO TROUBLE CODE test, verify the symptom is no longer present.
  7. If any DTC's or symptoms are remaining, check for any related TSB's and/or refer to the appropriate symptom list. If no codes or symptoms are present, repair is complete.

POWERTRAIN VERIFICATION TEST VER-3 (GAS)

  1. Inspect the vehicle to ensure that all engine components are properly installed and connected. Reassemble and reconnect components as necessary.
  2. Connect the DRBIII(R) to the Data Link Connector and erase the DTC's.
  3. If the PCM was not replaced, skip steps 4 - 6 then continue the verification.
  4. If the PCM was replaced, the correct VIN and mileage must be programmed or a DTC will set in the ABS and Airbag Modules. In addition, if the vehicle is equipped with Sentry Key Immobilizer Module (SKIM), Secret Key data must be updated to enable start.
  5. For ABS and Airbag systems, enter correct VIN and Mileage in PCM. Erase codes in ABS and Airbag modules.
  6. For SKIM theft alarm, connect DRBIII(R) to data link connector. Go to Theft Alarm, SKIM, Misc. and place SKIM in secured access mode, by using the appropriate PIN code for this vehicle. Select UPDATE THE SECRET KEY DATA. Data will be transferred from SKIM to PCM.
  7. Perform the generator output test.
  8. Start the engine and set the engine speed to 2000 RPM for at least 30 seconds.
  9. Allow the engine to return to idle.
  10. Cycle the ignition key off then on.
  11. With the DRBIII(R), read DTC's.
  12. If any DTC's or symptoms are present, check for any related TSB's and/or see appropriate symptom list. If no DTC's or symptoms are present, repair is complete.

POWERTRAIN VERIFICATION TEST VER-3 (NGC)

Note. If this vehicle is equipped with a 5.7L NGCII system and the APP Sensors, PCM, or Throttle Body Assembly has been replaced use the DRBIII(R) under the MISC menu, to perform the LEARN ETC function.

Note. After completing this test, see TRANSMISSION (45RFE/545RFE) VERIFICATION TEST VER-1 (NGC) .

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

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

  1. Inspect the vehicle to ensure that all components related to the repair are properly installed and connected.
  2. With the DRBIII(R), clear DTC's.
  3. Perform generator output test.
  4. Start the engine and set engine speed to 2000 RPM for at least 30 seconds.
  5. Cycle the ignition key off and on.
  6. With the DRBIII(R), read the DTC's.
  7. If any DTC's are remaining, check for any TSB's and/or refer to the appropriate symptom list. If no DTC's are remaining, repair is complete.

POWERTRAIN VERIFICATION TEST VER-4 (DIESEL)

  1. Check if any of the following conditions exist.
  2. The ECM has been disconnected.
  3. The battery power has been disconnected.
  4. The APPS has been disconnected or replaced.
  5. If any of the conditions exist, perform the following steps, otherwise go to step 9 .
  6. APPS Programming Procedure Reassemble all components. Turn the ignition key to the ON or RUN position. Without starting the engine, slowly press the throttle pedal to the floor and then slowly release.
  7. This step must be done to ensure the accelerator pedal position sensor calibration has been programmed in the ECM.
  8. DO NOT attempt to adjust screws or disassemble the APPS sensor. These settings are set at the factory and are intended to be changed.
  9. Inspect the vehicle to ensure that all engine components are properly installed and connected. Reassemble and reconnect components as necessary.
  10. With the DRBIII(R), erase DTC's.
  11. If the PCM has been replaced, perform steps 12 and 13 , then continue with the verification.
  12. If the PCM has been changed and correct VIN and mileage have not been programmed, a DTC will be set in ABS and Airbag modules. In addition, if vehicle is equipped with a Sentry Key Immobilizer Module (SKIM), Secret Key data must be updated to enable start.
  13. For ABS and Airbag systems, enter correct VIN and Mileage in PCM. Erase codes in ABS and Airbag modules.
  14. For SKIM Theft Alarm, connect DRBIII(R) to data link connector. Go to THEFT ALARM, SKIM, MISC. and place SKIM in secured access mode, by using the appropriate PIN code for this vehicle. Select UPDATE THE SECRET KEY DATA. Data will be transferred from SKIM to PCM.
  15. Turn the speed control ON (if equipped, cruise light will be on).
  16. Depress and release the SET switch. If the speed control did not engage, the repair is not complete. Check for TSB's that pertain to speed control problem and then, if necessary, return to symptom list.
  17. Depress and hold the RESUME/ACCEL switch. If the vehicle speed did not increase by at least 2 MPH the repair is not complete. Check for TSB's that pertain to speed control problem and then, if necessary, return to symptom list.
  18. Press and hold the COAST switch. The vehicle speed should decrease. If it did not decrease, the repair is not complete. Check for TSB's that pertain to speed control problem and then, if necessary, return to symptom list.
  19. Using caution, depress and release the brake pedal. If the speed control did not disengage, the repair is not complete. Check for TSB's that pertain to speed control problem and then, if necessary, return to symptom list.
  20. Bring the vehicle speed back up to 35 MPH.
  21. Depress the RESUME/ACCEL switch. If the speed control did not resume the previously set speed, the repair is not complete. Check the TSB's that pertain to speed control problem and then, if necessary, return to symptom list.
  22. Hold down the SET switch. If the vehicle did not decelerate, the repair is not complete. Check for TSB's that pertain to speed control problem and then, if necessary, return to symptom list.
  23. Ensure vehicle speed is greater than 35 MPH and release the SET switch. If vehicle did not adjust and set a new vehicle speed, the repair is not complete. Check for TSB's that pertain to speed control problem and then, if necessary, return to symptom list.
  24. Depress and release the CANCEL switch. If the speed control did not disengage, the repair is not complete. Check for TSB's that pertain to speed control problem and then, if necessary, return the symptom list.
  25. Bring the vehicle speed back up above 35 MPH and engage speed control.
  26. Depress and release the OFF switch. If the speed control did not disengage, the repair is not complete. Check for TSB's that pertain to speed control problem and then, if necessary, return to symptom list.
  27. If the vehicle successfully passed all of the previous tests, the speed control system is now functioning as designed. The repair is now complete.
  28. OVERSHOOT/UNDERSHOOT following speed control set.
  29. If the vehicle operator repeatedly presses and releases the SET button with their foot off of the accelerator (referred to as "lift foot set"), the vehicle may accelerate and exceed the desired set speed by up to 5 MPH (8 KMH).
  30. It may also decelerate to less than the desired set speed, before finally achieving the desired set speed.
  31. The Speed Control System has an adaptive strategy that compensates for vehicle-to-vehicle variations in speed control cables lengths.
  32. When the speed control is set with the vehicles operators foot off of the accelerator pedal, the speed control thinks there is excessive speed control cable slack and adapts accordingly.
  33. If the "Lift Foot Sets", are continually used, a speed control overshoot/undershoot condition will develop.
  34. To "unlearn" the overshoot/undershoot condition, the vehicle operator has to press and release the set button while maintaining the desired set speed using the accelerator pedal (not decelerating or accelerating).
  35. Then turning the cruise control switch to the OFF position (or press the CANCEL button if equipped) after waiting 10 seconds.
  36. This procedure must be performed appropriately 10-15 times to completely unlearn the overshoot/undershoot condition.
  37. If the speed control passes the above test, repair is not complete, see appropriate symptom. If the speed control did not pass the above test, repair is complete.

POWERTRAIN VERIFICATION TEST VER-5 (DIESEL)

  1. Check if any of the following conditions exist.
  2. The ECM has been disconnected or replaced.
  3. The battery power has been disconnected.
  4. The APPS has been disconnected or replaced.
  5. If any of the conditions exist, perform the following steps, otherwise go to step 9 .
  6. For APPS Programming procedure, reassemble all components. Turn the ignition key to the ON or RUN position. Without starting the engine, slowly press the throttle pedal to the floor and then slowly release.
  7. This step must be done to ensure the accelerator pedal position sensor calibration has been programmed in the ECM.
  8. DO NOT attempt to adjust screws or disassemble the APPS sensor. These settings are set at the factory and are intended to be changed.
  9. Inspect the vehicle to ensure that all engine components are properly installed and connected. Reassemble and reconnect components as necessary.
  10. If any existing diagnostic trouble codes have not been repaired, go to symptom list and follow path specified.
  11. Connect the DRBIII(R) to the data link connector.
  12. Ensure the fuel tank has at least a quarter tank of fuel. Turn off all accessories.
  13. Perform steps 15 - 17 if the ECM has been replaced skip those steps and continue verification.
  14. If the PCM has been changed and correct VIN and mileage have not been programmed, a DTC will be set in ABS and Airbag modules. In addition, if vehicle is equipped with a Sentry Key Immobilizer Module (SKIM), Secret Key data must be updated to enable start.
  15. For ABS and Airbag systems, enter correct VIN and Mileage in ECM. Erase codes in ABS and Airbag modules.
  16. For SKIM theft alarm, connect DRBIII(R) to data link connector to Theft Alarm, SKIM, MISC. and place SKIM in secured access mode by using appropriate PIN code for this vehicle. Select UPDATE THE SECRET KEY data. Data will be transferred from SKIM to ECM.
  17. If a comprehensive component DTC was repaired, perform steps 10 - 13 . If a major OBDII monitor DTC was repaired, skip those steps and continue verification.
  18. After the ignition has been off for at least 10 seconds, restart the vehicle and run 2 minutes.
  19. If there are no new DTC's, the repair was successful and is now complete. Erase DTC's and disconnect the DRBIII(R).
  20. 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.
  21. If another DTC has set, return to the symptom list and follow the path specified for that DTC.
  22. 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).
  23. If the monitor ran, the repair was successful and is now complete. Erase DTC's and disconnect the DRBIII(R).
  24. 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.
  25. If another DTC has set, return to the symptom list and follow the path specified for that DTC. If any DTC's are present, repair is not complete, refer to appropriate symptom. If no DTC's are set, the repair is complete.

POWERTRAIN VERIFICATION TEST VER-5 (GAS)

  1. Inspect the vehicle to ensure that all engine components are properly installed and connected. Reassemble and reconnect as necessary.
  2. If any existing diagnostic trouble codes have not been repaired, go to the appropriate symptom list and follow the path specified.
  3. Connect the DRBIII(R) to the data link connector.
  4. Ensure the fuel tank has at least a quarter tank of fuel. Turn off all accessories.
  5. If the PCM was not replaced, skip steps 6 - 8 and continue the verification.
  6. If the PCM was replaced, the correct VIN and mileage must be programmed or a DTC will set in the ABS and Airbag modules. In addition, if the vehicle is equipped with Sentry Key Immobilizer Module (SKIM), Secret Key data must be updated to enable start.
  7. For ABS and Airbag systems, enter correct VIN and Mileage in PCM. Erase codes in ABS and Airbag modules.
  8. For SKIM theft alarm, connect the DRBIII(R) to data link connector Theft Alarm, SKIM, MISC. and place SKIM in secured access mode by using the appropriate PIN code for this vehicle. Select UPDATE THE SECRET KEY data. Data will be transferred from SKIM to PCM.
  9. If the catalyst was replaced, with the DRBIII(R) go to the MISC menu option "CATALYST REPLACED" and press enter.
  10. If a comprehensive component DTC was repaired, perform steps 11 - 13 . If a major OBDII Monitor DTC was repaired, skip step 11 and continue the verification.
  11. After the ignition has been off for at least 10 seconds, restart the vehicle and run 2 minutes.
  12. 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).
  13. If the conditions cannot be duplicated, erase all DTC's with the DRBIII(R).
  14. If another DTC has set, return to the symptom list and follow the path specified for that DTC.
  15. If the OBDII monitor ran successfully and the Good Trip Counter changed to one or more, repair is complete. If not, check for any related TSB's and/or refer to the appropriate symptoms list.

POWERTRAIN VERIFICATION TEST VER-5 (NGC)

Note. After completing this test see TRANSMISSION (45RFE/545RFE) VERIFICATION TEST VER-1 (NGC) .

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

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

Note. If this vehicle is equipped with a 5.7L NGCII system and the APP Sensors, PCM, or Throttle Body Assembly has been replaced, use the DRBIII(R) under the MISC menu to perform the LEARN ETC function.

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

  1. The NGC learns the characteristics of each O2 heater element and these old values should be cleared when installing a new O2 sensor. The customer may experience driveability issues if this is not performed.
  2. Inspect the vehicle to ensure that all engine components are properly installed and connected. Reassemble and reconnect components as necessary.
  3. Connect the DRBIII(R) to the data link connector.
  4. Ensure the fuel tank has at least a quarter tank of fuel. Turn off all accessories.
  5. If the catalyst was replaced, with the DRBIII(R) go to the MISC menu option "CATALYST REPLACED" and press enter.
  6. If a comprehensive component DTC was repaired, perform steps 6 - 9 . If a major OBDII monitor DTC was repaired skip those steps and continue verification.
  7. After the ignition has been off for at least 10 seconds, restart the vehicle and run 2 minutes.
  8. With the 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).
  9. If the repaired OBDII trouble code has reset or was seen in the monitor while on the road test, the repair is not complete. Check for any related TSB's or flash updates and return to symptom list.
  10. If the conditions cannot be duplicated, erase all DTC's with the DRBIII(R).
  11. If another DTC has set, return to the symptom list and follow the path specified for that DTC.
  12. If the OBDII monitor ran successfully and the Good Trip Counter changed to one or more, the repair is complete. If not, check for any related TSB's and/or see the appropriate symptom list.

TRANSMISSION (45RFE/545RFE) VERIFICATION TEST VER-1 (NGC)

  1. Connect the DRBIII(R) to the Data Link Connector (DLC).
  2. Reconnect any disconnected components.
  3. With the DRBIII(R), perform a BATTERY DISCONNECT, this will clear the EATX EVENT DATA.
  4. With the DRBIII(R), erase all Transmission and Engine DTC's.
  5. If the PCM has been replaced or if the transmission has been repaired or replaced it is necessary to perform the DRBIII(R) Quick Learn Procedure.
  6. With the DRBIII(R), display transmission temperature. Start and run the engine until the transmission temperature is HOT, above 100°F (43°C).
  7. Check the transmission fluid level and adjust if necessary.
  8. Road test the vehicle.
  9. Perform the following shifts from a standing start with a constant throttle opening of 20-25 degrees to the speeds of 60 MPH (97 KMH); make 15-20; 1-2, 2-3, 3-4 upshifts and for 545RFE, 4 to 4-prime.
  10. Perform the following shifts with speeds below 25 MPH (40 KMH); make 5-8 wide open throttle kickdowns to 1st gear. Allow at least 5 seconds each in 2nd and 3rd gear between each kickdown.
  11. Check for DTC's during the road test.
  12. If any DTC's were set during the road test, refer to symptom list for the appropriate diagnostic tests. If no DTC's were set, repair is complete.

Removal

The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray.

  1. Remove battery.
  2. Pry sensor straight up from battery tray mounting hole to gain access to electrical connector.
  3. Disconnect sensor from engine wire harness electrical connector.

Installation

  1. Pull electrical connector up through mounting hole in top of battery tray.
  2. Connect sensor.
  3. Snap sensor into battery tray.
  4. Install battery.
CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

Removal (3.7L & 4.7L)

WARNINGDisconnect negative cable from battery before removing battery output wire (B+ wire) from generator. Failure to do so can result in injury or damage to electrical system.
  1. Disconnect negative battery cable at battery.
  2. Remove generator drive belt.
  3. Unsnap plastic insulator cap from B+ output terminal. (Scheme 1)
  4. Remove B+ terminal mounting nut at rear of generator. Disconnect terminal from generator.
  5. Disconnect field wire connector at rear of generator by pushing on connector tab.
  6. Remove 1 rear vertical generator mounting bolt. (Scheme 2)
  7. Remove 2 front horizontal generator mounting bolts.
  8. Remove generator from vehicle.

Scheme 1

Scheme 1
Scheme 1

Scheme 2

Scheme 2
Scheme 2

Removal (5.7L)

WARNINGDisconnect negative cable from battery before removing battery output wire (B+ wire) from generator. Failure to do so can result in injury or damage to electrical system.
  1. Disconnect negative battery cable at battery.
  2. Remove generator drive belt.
  3. Unsnap plastic insulator cap from B+ output terminal.
  4. Remove B+ terminal mounting nut at rear of generator.
  5. Disconnect field wire connector at rear of generator by pushing on connector tab.
  6. Remove generator support bracket nuts and bolt and remove support bracket. (Scheme 3)
  7. Remove 2 generator mounting bolts. (Scheme 4)
  8. Remove generator from vehicle.

Scheme 3

Scheme 3
Scheme 3

Scheme 4

Scheme 4
Scheme 4

Removal (5.9L Diesel)

WARNINGDisconnect negative cable from battery before removing battery output wire (B+ wire) from generator. Failure to do so can result in injury or damage to electrical system.
  1. Disconnect both negative battery cables at both batteries.
  2. Remove generator drive belt.
  3. Unsnap plastic insulator cap from B+ output terminal.
  4. Remove B+ terminal mounting nut at rear of generator. Disconnect terminal from generator.
  5. Disconnect field wire connector at rear of generator by pushing on connector tab.
  6. Remove upper mounting bracket bolt. (Scheme 5)
  7. Remove lower mounting bracket bolt and nut.
  8. Remove generator from vehicle.

Scheme 5

Scheme 5
Scheme 5

Removal (8.3L SRT-10)

  1. Disconnect negative battery cable at battery.
  2. Remove air cleaner assembly.
  3. Remove the accessory drive belt.
  4. Disconnect the field connector. (Scheme 6)
  5. Disconnect the battery positive cable from the wiring harness side. (Scheme 7)
  6. Remove the upper mounting bolt. (Scheme 8)
  7. Remove the lower mounting bolt and nut.
  8. Remove the generator. (Scheme 9)

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9

Installation (3.7L & 4.7L)

  1. Position generator to engine and install 2 horizontal bolts and 1 vertical bolt.
  2. Tighten all 3 bolts. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__torque-specifications) .
  3. Snap field wire connector into rear of generator.
  4. Install B+ terminal eyelet to generator output stud. Tighten mounting nut. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__torque-specifications) .
  5. Install generator drive belt.
  6. Install negative battery cable to battery.

Installation (5.7L)

  1. Position generator to engine and install 2 mounting bolts.
  2. Tighten bolts. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__torque-specifications) .
  3. Position support bracket to front of generator and install bolt and nuts. Tighten bolts/nuts. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__torque-specifications) .
  4. Snap field wire connector into rear of generator.
  5. Install B+ terminal eyelet to generator output stud. Tighten mounting nut. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__torque-specifications) .
  6. Install generator drive belt. See «SPECIFICATIONS & DRIVE BELT ROUTING»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#cooling-system-specifications-drive-belt-routing) .
  7. Install negative battery cable to battery.

Installation (5.9L Diesel)

  1. Position generator to upper and lower mounting brackets and install upper bolt and lower bolt/nut. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__torque-specifications) .
  2. Tighten all bolts/nut. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__torque-specifications) .
  3. Snap field wire connector into rear of generator.
  4. Install B+ terminal eyelet to generator output stud. Tighten mounting nut.
  5. Install generator drive belt.
  6. Install both negative battery cables to both batteries.

Installation (8.3L)

  1. Install generator.
  2. Install the lower mounting bolt and nut.
  3. Install the upper mounting bolt.
  4. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__torque-specifications) .
  5. Connect the battery positive cable to the generator, and install the B+ stud cap.
  6. Connect the field connector.
  7. Install the accessory drive belt. See «SPECIFICATIONS & DRIVE BELT ROUTING»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#cooling-system-specifications-drive-belt-routing) article in ENGINE COOLING (MECHANICAL).
  8. Install air cleaner assembly.
  9. Connect the negative battery cable, tighten the nut to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators__torque-specifications) .

OVERHAUL

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

TORQUE SPECIFICATIONS

ApplicationFt. Lbs. (N.m)
Generator (Long) Horizontal Bolt (3.7L & 4.7L)40 (54)
Generator Mounting Bolts (5.7L)30 (41)
Generator (Short) Horizontal Bolt (3.7L & 4.7L)55 (74)
Generator Support Bracket Bolt/Nuts (5.7L)30 (41)
Generator Upper & Lower Mounting Bolt (8.3L)41 (55)
Generator Upper Mounting Bolt (5.9L Diesel)30 (41)
Generator Vertical Mounting Bolt (3.7L & 4.7L)40 (54)
INCH Lbs. (N.m)
B+ Output Cable Terminal Nut108 (12)

TORQUE SPECIFICATIONS

WIRING DIAGRAMS

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

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