Charging System - Generators & Regulators: Diagnosis Dodge Pickup R2500

TROUBLE SHOOTING

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

ON-VEHICLE TESTING

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.

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

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

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

RETRIEVING DIAGNOSTIC TROUBLE CODES

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

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

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

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

SCAN TOOL DTC MESSAGES

CLEARING DIAGNOSTIC TROUBLE CODES

Powertrain Control Module (PCM) automatically clears DTCs from memory after 40 engine warm-up cycles if fault dos not reoccur. DTCs can also be cleared by using scan tool.

DIAGNOSTIC TESTS

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

Testing

1. Turn ignition on, engine not running. With 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»(ref-165616-S20632131972004083100000) . Perform «POWERTRAIN VERIFICATION TEST VER-5 (GAS)»(ref-165616-S23555402112004083100000) .
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)»(ref-165616-S23555402112004083100000) . 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)»(ref-165616-S23555402112004083100000) . 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)»(ref-165616-S23555402112004083100000) .
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)»(ref-165616-S23555402112004083100000) .
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»(ref-165616-S31530119022004083100000) . Perform «POWERTRAIN VERIFICATION TEST VER-5 (GAS)»(ref-165616-S23555402112004083100000) .

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»(ref-165616-S20632131972004083100000) . See «POWERTRAIN VERIFICATION TEST VER-4 (DIESEL)»(ref-165616-S13896201002004083100000) . If the temperature did not increase at least 5°F, replace the battery temperature sensor. See «POWERTRAIN VERIFICATION TEST VER-4 (DIESEL)»(ref-165616-S13896201002004083100000) .

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)»(ref-165616-S04884054712004083100000) .
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)»(ref-165616-S04884054712004083100000) .
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)»(ref-165616-S04884054712004083100000) .
4. Reconnect the ECM harness connectors. Turn the ignition on. Measure the voltage between the supply circuit and the return circuit in the sensor harness connector. If the voltage is between 4.5 and 5.5 volts, go to next step. If the voltage is not as specified, go to step 6 .
5. 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»(ref-165616-S20632131972004083100000) . Perform «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(ref-165616-S04884054712004083100000) . If DTC P0517 did not set, replace the ECM. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(ref-165616-S04884054712004083100000) .
6. Disconnect the ECM harness connectors. Measure the voltage of the supply circuit of the sensor harness connector. If the voltage is between 4.5 and 5.5 volts, repair the 5-volt supply shorted to voltage. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(ref-165616-S04884054712004083100000) . If the voltage is not as specified, replace the ECM. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(ref-165616-S04884054712004083100000) .

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»(ref-165616-S20632131972004083100000) . Perform «POWERTRAIN VERIFICATION TEST VER-2 (NGC)»(ref-165616-S11669884922004090100000) .
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)»(ref-165616-S11669884922004090100000) . 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)»(ref-165616-S11669884922004090100000) . 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»(ref-165616-S31530119022004083100000) . See «POWERTRAIN VERIFICATION TEST VER-2 (NGC)»(ref-165616-S11669884922004090100000) .

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»(ref-165616-S20632131972004083100000) . See «POWERTRAIN VERIFICATION TEST VER-2 (NGC)»(ref-165616-S11669884922004090100000) .
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 (K118) batt temp signal circuit and the (K4) 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)»(ref-165616-S11669884922004090100000) . 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. Measure the voltage on the (K118) batt temp signal circuit at the battery temp sensor harness connector. If the voltage is above 5.2 volts, repair the short to voltage in the (K118) batt temp signal circuit. See «POWERTRAIN VERIFICATION TEST VER-2 (NGC)»(ref-165616-S11669884922004090100000) . If the voltage is not above 5.2 volts, go to next step.
4. Turn the ignition off. Measure the resistance of the (K118) 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 (K4) sensor ground circuit. See «POWERTRAIN VERIFICATION TEST VER-2 (NGC)»(ref-165616-S11669884922004090100000) .
5. Measure the resistance in the (K4) 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 (K4) sensor ground circuit. See «POWERTRAIN VERIFICATION TEST VER-2 (NGC)»(ref-165616-S11669884922004090100000) .
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»(ref-165616-S31530119022004083100000) . See «POWERTRAIN VERIFICATION TEST VER-2 (NGC)»(ref-165616-S11669884922004090100000) .

1. Read the DTC's with DRBIII(R). If P0622 is set, repair first. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(ref-165616-S04884054712004083100000) . 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)»(ref-165616-S04884054712004083100000) . 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)»(ref-165616-S04884054712004083100000) . 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)»(ref-165616-S04884054712004083100000) .
5. Check for acc-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)»(ref-165616-S04884054712004083100000) . 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)»(ref-165616-S04884054712004083100000) .
7. Turn the ignition off. Disconnect the ECM harness connectors. 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)»(ref-165616-S04884054712004083100000) .
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»(ref-165616-S20632131972004083100000) . Perform «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(ref-165616-S04884054712004083100000) . If the readings are not within 3 volts or each other, replace the ECM. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(ref-165616-S04884054712004083100000) .

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 after market 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»(ref-165616-S20632131972004083100000) . See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(ref-165616-S17038193052004090100000) .
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)»(ref-165616-S17038193052004090100000) . 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 side. 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)»(ref-165616-S17038193052004090100000) . 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)»(ref-165616-S17038193052004090100000) .
6. Measure the resistance between ground and the (K20) gen 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)»(ref-165616-S17038193052004090100000) . 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)»(ref-165616-S17038193052004090100000) .
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»(ref-165616-S31530119022004083100000) . See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(ref-165616-S17038193052004090100000) .

1. With the DRBIII(R), read DTC's. If P0622 is set, repair first. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(ref-165616-S04884054712004083100000) . 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)»(ref-165616-S04884054712004083100000) . 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)»(ref-165616-S04884054712004083100000) . If P2504 did not set, go to next step.
4. Disconnect the ECM harness connectors. Measure the battery voltage between the positive circuits and ground 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)»(ref-165616-S04884054712004083100000) .
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»(ref-165616-S20632131972004083100000) . Perform «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(ref-165616-S04884054712004083100000) . If the readings are not within 3 volts, replace the ECM. See «POWERTRAIN VERIFICATION TEST VER-1 (DIESEL)»(ref-165616-S04884054712004083100000) .

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

Note. Inspect the vehicle for after market 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»(ref-165616-S20632131972004083100000) . See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(ref-165616-S17038193052004090100000) .
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)»(ref-165616-S17038193052004090100000) . 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)»(ref-165616-S17038193052004090100000) . 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»(ref-165616-S31530119022004083100000) . See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(ref-165616-S17038193052004090100000) .

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»(ref-165616-S20632131972004083100000) . See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(ref-165616-S36034568212004090100000) . 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)»(ref-165616-S36034568212004090100000) .
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)»(ref-165616-S36034568212004090100000) .
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)»(ref-165616-S36034568212004090100000) . 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)»(ref-165616-S36034568212004090100000) .
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»(ref-165616-S31530119022004083100000) . Perform «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(ref-165616-S36034568212004090100000) .

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»(ref-165616-S20632131972004083100000) . See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(ref-165616-S17038193052004090100000) .
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)»(ref-165616-S17038193052004090100000) . 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)»(ref-165616-S17038193052004090100000) . 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)»(ref-165616-S17038193052004090100000) .
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)»(ref-165616-S17038193052004090100000) . 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)»(ref-165616-S17038193052004090100000) .
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»(ref-165616-S31530119022004083100000) . Perform «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(ref-165616-S17038193052004090100000) .

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 and 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.

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»(ref-165616-S20632131972004083100000) . See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(ref-165616-S36034568212004090100000) .
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 volt, replace the battery temp sensor. See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(ref-165616-S36034568212004090100000) . 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)»(ref-165616-S36034568212004090100000) . 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)»(ref-165616-S36034568212004090100000) .
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)»(ref-165616-S36034568212004090100000) .
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»(ref-165616-S31530119022004083100000) . See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(ref-165616-S36034568212004090100000) .

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»(ref-165616-S20632131972004083100000) . See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(ref-165616-S36034568212004090100000) .
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)»(ref-165616-S36034568212004090100000) . 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) batter 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)»(ref-165616-S36034568212004090100000) . 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)»(ref-165616-S36034568212004090100000) . 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»(ref-165616-S19248462122004083100000) . See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(ref-165616-S36034568212004090100000) .

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»(ref-165616-S20632131972004083100000) . See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(ref-165616-S36034568212004090100000) .
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)»(ref-165616-S36034568212004090100000) . 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)»(ref-165616-S36034568212004090100000) . 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 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)»(ref-165616-S36034568212004090100000) .
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»(ref-165616-S31530119022004083100000) . See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(ref-165616-S36034568212004090100000) .

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»(ref-165616-S20632131972004083100000) . See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(ref-165616-S36034568212004090100000) . 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 of the battery temperature, go to next step. If the temperature is not within 10°F of the battery temperature, replace the battery temperature sensor. See «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(ref-165616-S36034568212004090100000) .
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)»(ref-165616-S36034568212004090100000) . 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)»(ref-165616-S36034568212004090100000) . 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)»(ref-165616-S36034568212004090100000) .
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)»(ref-165616-S36034568212004090100000) .
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)»(ref-165616-S36034568212004090100000) . 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»(ref-165616-S31530119022004083100000) . Perform «POWERTRAIN VERIFICATION TEST VER-3 (GAS)»(ref-165616-S36034568212004090100000) .

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»(ref-165616-S20632131972004083100000) . See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(ref-165616-S17038193052004090100000) .
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)»(ref-165616-S17038193052004090100000) . 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)»(ref-165616-S36034568212004090100000) . 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)»(ref-165616-S17038193052004090100000) . 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)»(ref-165616-S17038193052004090100000) . 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)»(ref-165616-S17038193052004090100000) .
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)»(ref-165616-S17038193052004090100000) . 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 (Z346) gen ground circuit. See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(ref-165616-S17038193052004090100000) .
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»(ref-165616-S31530119022004083100000) . See «POWERTRAIN VERIFICATION TEST VER-3 (NGC)»(ref-165616-S17038193052004090100000) .

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 PCM has been replaced, do the following: If the PCM 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 PCM has not been replaced, go to step 11 .
10. For ABS and Airbag Systems: Action: Enter correct VIN and Mileage in PCM. Erase ABS and Airbag Module codes.
11. If the PCM has not been replaced, do the following: 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 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 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 did not pass the above test, repair is complete. If the speed control passes the above test, repair is not complete, see appropriate symptom.

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. 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 PCM 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 PCM. 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 PCM.
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 net, 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 - 9 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.

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.
3. Ensure the fuel tank has at least a quarter tank of fuel. Turn off all accessories.
4. If the catalyst was replaced, with the DRBIII(R) go to the MISC menu option "CATALYST REPLACED" and press enter.
5. If a comprehensive component DTC was repaired, perform steps 5 - 8 . If a major OBDII monitor DTC was repaired, skip those steps and continue verification.
6. After the ignition has been off for at least 10 seconds, restart the vehicle and run 2 minutes.
7. 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).
8. 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.
9. If the conditions cannot be duplicated, erase all DTC's with the DRBIII(R).
10. If another DTC has set, return to the symptom list and follow the path specified for that DTC.
11. 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.