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Generator Dodge Pickup R2500

Charging System 2 illustrations ~5051 words

DESCRIPTION

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

ApplicationCase No. (1)Minimum Amps
Gasoline
117-Amp5206791290
136-Amp52067913120
Diesel (136-Amp)56027221120
(1) Located on tag on bottom of generator case.
(1)Located on tag on bottom of generator case.

GENERATOR APPLICATION

OPERATION

The amount of amperage produced by the generator is controlled by Electronic Voltage Regulator (EVR) circuitry within the PCM. EVR circuitry is connected in series with the generator field driver terminal and ground. A Battery Temperature Sensor (BTS), located in battery tray, is used to sense battery temperature. Sensed battery temperature and data from monitored line voltage is used by PCM to adjust battery charging rate. This is accomplished by cycling the ground path to control the strength of generator rotor magnetic field. PCM then compensates and regulates generator amperage output accordingly.

The PCM monitors critical input to control fuel injection, ignition, emission and other engine management functions. The PCM is also programmed to monitor charging system related circuits

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

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

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

Certain DTCs cause MIL to illuminate and PCM to enter limp-in mode. In limp-in mode, PCM attempts to compensate for particular component failure by substituting information from other sources. This allows vehicle operation until proper repairs are made.

BELT TENSION

ApplicationNew: Lbs. (kg)Used: Lbs. (kg)
Ram Pickup(1)(1)
(1) Dynamic tensioner is used. No adjustment is required.
(1)Dynamic tensioner is used. No adjustment is required.

BELT TENSION

INITIAL CHECKS

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

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

UNSTEADY OR LOW CHARGING

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

OVERCHARGING

Check for grounded generator field wiring or faulty generator.

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

SELF-DIAGNOSTIC SYSTEM

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

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

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

PRECAUTIONS

Before proceeding with diagnosis, observe following precautions.

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

ON-BOARD DIAGNOSTICS

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

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

RETRIEVING DTCS

Note. Self-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.

Using MIL

  1. Ensure battery is fully charged. Turn ignition on and note operation of MIL. When ignition is first turned on, MIL should come on and remain on for 3 seconds to verify bulb and circuit operation, and then go off.
  2. Turn ignition on-off-on-off-on within 5 seconds. Record 2-digit DTCs displayed by MIL flashing on and off. Following is a brief description of DTCs and conditions: DTC 12 - Battery feed to PCM has been interrupted within last 50-100 engine starts. PCM monitors this circuit whenever ignition is on. DTC 41 - Generator field control fails to switch properly. PCM monitors this circuit whenever ignition is on. DTC 44 - Battery temperature sensor voltage is out of range. PCM monitors this circuit whenever ignition is on. DTC 46 - Charging system voltage is more than one volt above desired control voltage for more than 20 seconds. PCM monitors this signal whenever engine is running. DTC 47 - Charging system voltage is at least one volt less than desired control voltage for more than 20 seconds. No significant change in voltage is detected during active test of generator. PCM monitors this signal whenever engine speed is more than 1500 RPM. DTC 55 - After all DTCs have been displayed, DTC 55 will flash indicating DTC retrieval is complete.

Using Scan Tool

  1. Ensure battery is fully charged. Connect scan tool to Data Link Connector (DLC). DLC is located below instrument panel, near steering column.
  2. Using scan tool manufacturer's instructions, retrieve and record DTCs displayed on scan tool and proceed to «SELF-DIAGNOSTIC TESTS»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__self-diagnostic-tests) . Once repairs are made, clear DTCs from PCM memory. See «CLEARING DTCS»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__clearing-dtcs) .

CLEARING DTCS

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

Blank Message Screen

Check for loose cable connections or bad cable. If cable connections and cable are okay, check voltage at 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

See TEST NS-6A in appropriate TESTS W/CODES article. Refer to the G - TESTS W/CODES ARTICLE MENU & LINKS table.

G - TESTS W/CODES ARTICLE MENU & LINKS

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

SELF-DIAGNOSTIC TESTS

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

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

DTC TEST - CHECKING SYSTEM FOR DIAGNOSTIC TROUBLE CODES

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

  1. Attempt to start engine. If necessary, crank engine for up to 10 seconds. Read and record DTCs. See «RETRIEVING DTCS»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__retrieving-dtcs) under SELF-DIAGNOSTIC SYSTEM. If scan tool screen is blank or displays NO RESPONSE, see «SCAN TOOL PROBLEMS & ERROR MESSAGES»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator) under SELF-DIAGNOSTIC SYSTEM.
  2. If DTCs are displayed, see SCAN TOOL DTC MESSAGES table. Only DTCs relating to charging system are listed. For all other DTCs, see TESTS W/CODES article. If no DTCs are displayed, go to «TEST CH-1A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ch-1a-charging-system-no) - CHARGING SYSTEM NO CODE TEST.
Scan Tool DisplayDTCPerform Test
BATTERY TEMP SENSOR VOLTS TOO HIGHP1492TEST TC-153A
BATTERY TEMP SENSOR VOLTS TOO LOWP1493TEST TC-153A
CHARGING SYSTEM VOLTAGE HIGHN/ATEST TC-6A
CHARGING SYSTEM VOLTAGE LOWN/ATEST TC-5A
GEN. FIELD NOT SWITCHING PROPERLYN/ATEST TC-11A

SCAN TOOL DTC MESSAGES

TEST TC-5A, CHARGING SYSTEM VOLTAGE TOO LOW

CAUTIONIf vehicle is a diesel, DO NOT perform any charging system tests with intake heaters installed.

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

  1. Ensure battery is fully charged. Start engine. Using scan tool, read TARGET CHARGING VOLTAGE. If voltage is 15.1 volts or less, go to step 5). If voltage is more than 15.1 volts, go to next step.
  2. Using scan tool, read Battery Temperature Sensor (BTS) temperature. Using a thermometer, read underhood temperature. If scan tool reading and thermometer reading are within 10 percent of each other, go to step 5). If temperatures are not within 10 percent of each other, go to next step.
  3. Disconnect BTS connector. BTS is located in battery tray. Inspect connector and terminals for damage. Repair as necessary and perform «TEST VER-2A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-2a-road-test-verification). If connector and terminals are okay, go to next step.
  4. Connect a jumper wire between BTS connector terminals. Using scan tool, read BTS voltage. If voltage is zero, replace BTS and perform «TEST VER-2A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-2a-road-test-verification). If any voltage exists, replace Powertrain Control Module (PCM) and perform «TEST VER-2A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-2a-road-test-verification). CAUTION: On 5.9L diesel engines, DO NOT perform charging system test with intake headers installed.
  5. If vehicle is equipped with a 5.9L diesel engine and engine will not run, see TEST TC-40A - NO CRANK REFERENCE SIGNAL AT PCM in TESTS W/CODES article. On all other models, using an external voltmeter, connect one voltmeter lead to B+ (battery) terminal on rear of generator. see scheme 1 Connect other voltmeter lead to positive battery terminal. Go to next step.
  6. Start engine and note voltage reading on voltmeter. If voltage is more than 0.4 volt, repair B+ circuit between battery and generator for high resistance and perform «TEST VER-2A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-2a-road-test-verification). If voltage is 0.4 volt or less, go to next step.
  7. Turn ignition off. Using external voltmeter, connect one voltmeter lead to generator case. Connect other voltmeter lead to negative battery terminal. Go to next step.
  8. Start engine and allow to reach operating temperature. Note voltage reading on voltmeter. If voltage is more than 0.1 volt, repair generator ground circuit between battery and generator for high resistance and perform «TEST VER-2A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-2a-road-test-verification). If voltage is 0.1 volt or less, go to next step.
  9. Maintain engine speed at 1600 RPM. Using scan tool, read target charging voltage and charging voltage. Compare readings. If difference between readings is more than one volt, repair or replace generator as necessary and perform «TEST VER-2A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-2a-road-test-verification). If difference between readings is one volt or less, go to next step.
  10. Allow engine to idle. Turn ignition off. Perform «TEST CH-1A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ch-1a-charging-system-no) - CHARGING SYSTEM NO CODE TEST.
Fig. 1: Identifying Generator Terminals (Typical)
Scheme 1: Identifying Generator Terminals (Typical)

TEST TC-6A - CHARGING SYSTEM VOLTAGE TOO HIGH

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

  1. Turn ignition on. Using scan tool, actuate generator field driver. Using an external voltmeter, backprobe field driver circuit (Dark Green wire) in 2-wire connector on rear of generator. If voltage cycles from low voltage to high voltage, perform «TEST TC-6B»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-tc-6b-charging-system-voltage-too) . If voltage does not cycle from low voltage to high voltage, go to next step.
  2. Using scan tool, stop generator field driver actuation. Turn ignition off. Disconnect Powertrain Control Module (PCM) connectors. Inspect connectors and terminals for damage. Repair as necessary and perform «TEST VER-2A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-2a-road-test-verification) . If connectors and terminals are okay, go to next step.
  3. Disconnect 2-wire connector on rear of generator. Using an external ohmmeter, check resistance between ground and terminal No. 10 (Dark Green wire) at PCM White connector. If resistance is less than 5 ohms, repair short to ground in field driver circuit and perform «TEST VER-2A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-2a-road-test-verification) . If resistance is 5 ohms or more, go to next step.
  4. Check resistance between ground and generator field driver circuit terminal (Dark Green wire). If resistance is less than 5 ohms, repair or replace shorted generator and perform «TEST VER-2A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-2a-road-test-verification) . If resistance is 5 ohms or more, replace PCM and perform «TEST VER-2A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-2a-road-test-verification) .

TEST TC-6B, CHARGING SYSTEM VOLTAGE TOO HIGH

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

  1. Using scan tool, stop generator field driver actuation. Note target charging voltage. If voltage is more than 13 volts, go to step 3). If voltage is 13 volts or less, go to next step.
  2. Using scan tool, read Battery Temperature Sensor (BTS) temperature. Using a thermometer, read underhood temperature. If temperatures are within 10 percent of each other, replace PCM. If temperatures are not within 10 percent of each other, go to next step.
  3. Start and maintain engine speed at 1600 RPM. Using scan tool, read target charging voltage and battery voltage. Compare readings for 5 minutes. If difference between readings is more than one volt, replace Powertrain Control Module (PCM) and perform «TEST VER-2A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-2a-road-test-verification) . If difference between readings is one volt or less, no problem is indicated at this time. Perform «TEST CH-1A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ch-1a-charging-system-no) - CHARGING SYSTEM NO CODE TEST.

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

  1. Record all DTC's and clear codes. Check all charging system related connectors for loose, corroded or damaged terminals. Repair as necessary. If connectors are okay, go to next step.
  2. Turn ignition on. Using scan tool, actuate generator field driver. Using an external voltmeter, measure voltage between ground and generator field source terminal (White/Dark Blue wire). If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open in generator field source circuit between generator and PCM.
  3. Backprobe field driver circuit (Dark Green wire) in 2-wire connector on rear of generator. If voltage does not cycle from low voltage to high voltage, go to step 7). If voltage cycles from low voltage to high voltage, go to next step.
  4. Condition required to set DTC is not present at this time. GENERATOR FIELD NOT SWITCHING PROPERLY DTC sets if Powertrain Control Module (PCM) tries to regulate generator field with no result. Possible causes are: open or shorted wiring, defective connectors, defective generator or PCM. Go to next step.
  5. Inspect all related wiring and connectors. Repair wiring and connections as necessary and perform «TEST VER-3A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-3a-charging-verification). If wiring and connections are okay, go to next step.
  6. Ensure actuator test is still running. Using scan tool, check for DTCs. Wiggle wiring harness from generator to PCM and note if GENERATOR FIELD NOT SWITCHING PROPERLY DTC resets. If DTC resets, repair wiring harness as necessary and perform «TEST VER-3A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-3a-charging-verification). If DTC does not reset, see no problem is indicated at this time. Test is complete. Perform «TEST VER-3A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-3a-charging-verification).
  7. Using scan tool, stop generator field driver actuation. Turn ignition off. Disconnect Powertrain Control Module (PCM) connectors. Inspect connectors and terminals for damage. Repair as necessary and perform «TEST VER-3A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-3a-charging-verification). If connectors and terminals are okay, go to next step.
  8. Disconnect 2-wire connector on rear of generator. Inspect connector and terminals for damage. Repair as necessary and perform «TEST VER-3A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-3a-charging-verification). If connector and terminals are okay, go to next step.
  9. Using an external ohmmeter, check resistance of generator field driver circuit (Dark Green wire) between PCM White connector terminal No. 10 and generator 2-wire connector. If resistance is 5 ohms or more, repair open generator field driver circuit between PCM and generator and perform «TEST VER-3A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-3a-charging-verification). If resistance is less than 5 ohms, go to next step.
  10. Ensure 2-wire connector on rear of generator is disconnected. Using external ohmmeter, check resistance between generator field terminals. see scheme 1 If resistance is 5 ohms or more, repair or replace generator as necessary and perform «TEST VER-3A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-3a-charging-verification). If resistance is less than 5 ohms, go to next step.
  11. Using scan tool in ohmmeter mode, check resistance of generator field driver circuit (Dark Green wire) between ground and generator 2-wire connector. If resistance is less than 5 ohms, repair short to ground in field driver circuit and perform «TEST VER-3A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-3a-charging-verification). If resistance is 5 ohms or more, replace PCM and perform «TEST VER-3A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-3a-charging-verification).

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

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

  1. Using scan tool, read Battery Temperature Sensor (BTS) voltage. If voltage is less than 0.4 volt, go to step 5). If voltage is more than 4.9 volts, perform «TEST TC-153B»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-tc-153b-battery-temp-sensor-voltage) . If voltage is 0.4-4.9 volts, go to next step.
  2. Wiggle connectors and harness from BTS to Powertrain Control Module (PCM) while observing scan tool display. If voltage changes while wiggling connectors and harness, repair connector or harness that caused voltage change and perform «TEST VER-2A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-2a-road-test-verification) . If voltage does not change, go to next step.
  3. Condition required to set DTC is not present at this time. BATTERY TEMPERATURE SENSOR VOLTAGE TOO HIGH or TOO LOW DTC sets if PCM senses voltage from BTS to be either less than 0.5 volt or more than 4.9 volts for 3 seconds with ignition on. Possible causes are: defective PCM, defective connector terminals, defective BTS or connector wires. Go to next step.
  4. Inspect all related wiring and connectors. Repair wiring and connectors as necessary and perform «TEST VER-2A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-2a-road-test-verification) . If wiring and connectors are okay, no problem is indicated at this time. Test is complete. Perform «TEST VER-2A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-2a-road-test-verification) .
  5. Disconnect BTS connector. Using scan tool, read BTS voltage. If voltage is more than 4 volts, replace BTS and perform «TEST VER-2A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-2a-road-test-verification) . If voltage is 4 volts or less, go to next step.
  6. Turn ignition off. Disconnect Powertrain Control Module (PCM) connectors. Inspect connectors and terminals for damage. Repair as necessary and Perform «TEST VER-2A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-2a-road-test-verification) . If connectors and terminals are okay, go to next step.
  7. Using scan tool in ohmmeter mode, check resistance between ground and Pink/Yellow wire at BTS connector. If resistance is less than 5 ohms, repair short to ground in BTS signal circuit. Perform «TEST VER-2A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-2a-road-test-verification) . If resistance is 5 ohms or more, go to next step.
  8. Using an external ohmmeter, check resistance BTS wiring harness connector terminals. If resistance is 5 ohms or more, replace PCM and perform «TEST VER-2A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-2a-road-test-verification) . If resistance is less than 5 ohms, sensor signal circuit is shorted to sensor ground. Repair as necessary. Perform «TEST VER-2A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-2a-road-test-verification) .

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

Note. Perform TEST TC-153A before proceeding. For connector terminal identification, see CONNECTOR IDENTIFICATION in appropriate TESTS W/CODES article. Refer to the G - TESTS W/CODES ARTICLE MENU & LINKS table.

  1. Disconnect Battery Temperature (BTS) connector. Turn ignition on. Measure voltage between ground and Pink/Yellow wire at BTS connector. If voltage is 6 volts or less, go to next step. If voltage is more than 6 volts, repair short to voltage in Pink/Yellow wire. Perform «TEST VER-2A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-2a-road-test-verification) .
  2. Connect a jumper wire between BTS connector terminals. Using scan tool, read BTS voltage. If voltage is less than one volt, replace BTS and perform «TEST VER-2A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-2a-road-test-verification) . If voltage is one volt or more, go to next step.
  3. Remove jumper wire. Connect jumper wire between ground and Pink/Yellow wire at BTS connector. Read BTS voltage. If voltage is less than one volt, repair open ground circuit. Perform «TEST VER-2A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-2a-road-test-verification) . If voltage is one volt or more, go to next step.
  4. Turn ignition off. Disconnect Powertrain Control Module (PCM) connectors. Inspect connectors and terminals for damage. Repair as necessary and perform «TEST VER-2A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-2a-road-test-verification) . If connectors and terminals are okay, go to next step.
  5. Using an external ohmmeter, check resistance of Pink/Yellow wire between BTS connector and PCM Gray connector. If resistance is less than 5 ohms, replace PCM and perform «TEST VER-2A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-2a-road-test-verification) . If resistance is 5 ohms or more, repair open circuit in Pink/Yellow wire. Perform «TEST VER-2A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-2a-road-test-verification) .

TEST CH-1A - CHARGING SYSTEM NO CODE TEST

Note. Perform DTC TEST , TEST TC-5A or TEST TC-6A before proceeding. Ensure battery is fully charged before proceeding.

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

  1. Inspect generator belt for proper tension and good condition. If generator belt is okay, go to next step. If generator belt tension is incorrect or belt is damaged, repair as necessary. Perform «TEST VER-3A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-3a-charging-verification) .
  2. Start engine. Using scan tool, set engine speed at 2000 RPM for 30 seconds. Using scan tool, return engine speed to idle and read Diagnostic Trouble Codes (DTCs). If any DTCs pertaining to charging system exist, go to appropriate test. See «SCAN TOOL DTC MESSAGES»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator) table in DTC TEST - CHECKING SYSTEM FOR DIAGNOSTIC TROUBLE CODES. If other non-charging system DTC messages exist, see DTC TEST - CHECKING SYSTEM FOR DIAGNOSTIC TROUBLE CODES in TESTS W/CODES article. If no DTCs exist, go to next step.
  3. Turn ignition off. Turn ignition on with engine off. Using scan tool, actuate generator field. Using scan tool in voltmeter mode, backprobe Dark Green wire at 2-wire connector on rear of generator. Voltage should cycle from zero volts to battery voltage every 1.4 seconds.
  4. While monitoring voltage display on scan tool, wiggle wiring from 2-pin connector on rear of generator to Powertrain Control Module (PCM). PCM is located between driver's side front fender and power distribution center, near battery.
  5. If no interruption of normal voltage cycle exists when wiggling wiring, go to next step. If interruption of normal voltage cycle exists when wiggling wiring, repair wiring as necessary. Perform «TEST VER-3A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-3a-charging-verification) .
  6. Using scan tool, read DTCs. If any DTCs exist pertaining to charging system, go to appropriate test. See «SCAN TOOL DTC MESSAGES»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator) table in DTC TEST - CHECKING SYSTEM FOR DIAGNOSTIC TROUBLE CODES. If other non-charging system DTC messages exist, see DTC TEST - CHECKING SYSTEM FOR DIAGNOSTIC TROUBLE CODES in TESTS W/CODES article. If no DTCs exist, go to next step.
  7. Using external voltmeter, connect voltmeter positive lead on B+ (battery) terminal on rear of generator. Connect voltmeter negative lead to positive battery terminal.
  8. Start engine and note voltage reading on voltmeter. If voltage is 0.4 volt or less, go to next step. If voltage is more than 0.4 volt, repair B+ circuit between battery and generator for high resistance. Perform «TEST VER-3A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-3a-charging-verification) .
  9. Turn ignition off. Using external voltmeter, connect voltmeter positive lead on generator case. Connect voltmeter negative lead to negative battery terminal.
  10. Start engine and note voltage reading on voltmeter. If voltage is 0.1 volt or less, go to next step. If voltage is more than 0.1 volt, repair generator ground circuit from generator case to negative battery terminal for high resistance. Perform «TEST VER-3A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-3a-charging-verification) .
  11. Remove external voltmeter. Using scan tool, read and record battery voltage reading. Using external voltmeter, read and record battery voltage between positive and negative battery terminals.
  12. Compare both voltage readings obtained in step 11). If difference between both voltage readings is less than one volt, test is complete. Perform «TEST VER-3A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-3a-charging-verification) . If difference between both voltage readings is one volt or more, go to next step.
  13. Turn ignition off. Disconnect PCM connectors. Using external voltmeter, check voltage between ground and terminal No. 22 (Red/Black wire) at PCM Black connector. Compare voltage reading to voltage reading obtained using scan tool in step 11).
  14. If voltage reading is not within one volt of voltage reading obtained using scan tool in step 11), replace PCM. Perform «TEST VER-3A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-3a-charging-verification) . If voltage reading is within one volt of voltage reading obtained using scan tool in step 11), repair high resistance on Red/White wire between PCM Black connector terminal No. 22 and battery. Perform «TEST VER-3A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-ver-3a-charging-verification) .

TEST VER-2A - ROAD TEST VERIFICATION

  1. Inspect vehicle to ensure all engine components are connected. Reassemble and reconnect components as necessary. Go to next step.
  2. Check if initial symptom still exists. If initial or another symptom exists, repair is not complete. Check for Technical Service Bulletins (TSBs) that apply to the symptom and return to «DTC TEST»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__dtc-test-checking-system-for) if necessary.
  3. If any DTCs have not been diagnosed, go to «DTC TEST»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__dtc-test-checking-system-for) and finish diagnosing remaining DTCs as necessary. If all DTCs have been diagnosed, go to next step.
  4. If Powertrain Control Module (PCM) has not been changed, using scan tool, clear DTCs from PCM. Using scan tool, reset all values in adaptive memory. Disconnect scan tool. To ensure no other DTCs remain, go to next step.
  5. Using scan tool, check for stored DTCs. If repaired DTC has reset, repair is not complete. Check for related Technical Service Bulletins (TSBs) and return to «DTC TEST»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__dtc-test-checking-system-for) if necessary. If another DTC exists, return to DTC TEST and follow path specified by other DTC. If no other DTCs exist, repair is now complete.

TEST VER-3A - CHARGING VERIFICATION

  1. Inspect vehicle to ensure all engine components are connected. Reassemble and reconnect components as necessary. If Powertrain Control Module (PCM) has been changed, go to next step. If PCM has not been changed, go to step 3).
  2. If vehicle is equipped with factory vehicle theft security system, start vehicle at least 20 times so vehicle theft security system can be activated when desired. Using scan tool, clear DTCs from PCM. Go to next step.
  3. To ensure no charging system problem exists, start engine. Increase engine speed to 2000 RPM for at least 30 seconds. Allow engine to idle. Turn engine off.
  4. Turn ignition on with engine off. Using scan tool, check for stored DTCs. If repaired DTC has reset, repair is not complete. Check for related Technical Service Bulletins (TSBs) and return to «DTC TEST»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__dtc-test-checking-system-for) if necessary. If another DTC exists, return to DTC TEST and follow specified procedure specified by other DTC. If no other DTCs exist, repair is now complete.

ON-VEHICLE TESTING

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

VOLTAGE DROP TEST

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

  1. Ensure battery is in condition and is fully charged. Clean battery terminals (if necessary). Using external voltmeter, connect positive lead to generator B+ terminal stud (not the nut). Connect voltmeter negative lead to positive battery post. Connect tachometer to engine. Fully engage parking brake, and place gear selector in Neutral position. Start engine and run for 2 minutes to allow for warm-up.
  2. Turn A/C system on, A/C-heater blower motor to high speed and headlights on high beam. Increase engine speed to 2400 RPM. Voltmeter reading should not be more than 0.6 volt.
  3. If voltage drop is more than 0.6 volt, inspect, clean and tighten all connections between generator B+ terminal and positive battery post. Voltage drop test may be performed at each connection to locate connection with excessive resistance. If resistance tests are satisfactory, reduce engine speed, turn off all electrical loads and ignition switch.

CURRENT OUTPUT TEST

CAUTIONGenerator has 2 field terminals: generator field driver (Dark Green wire) and generator field source (White/Dark Blue wire). DO NOT connect generator field source terminal to ground.

Note. Perform VOLTAGE DROP TEST before continuing with this test. Perform test soon after starting engine, as charging amperage will drop quickly. A volt/amp tester equipped with both a battery load control (carbon pile rheostat) and an inductive type pick-up clamp is required to perform the following test.

  1. Ensure battery is in good condition and is fully charged. Clean battery terminals (if necessary). Connect volt/amp tester leads to battery. Ensure carbon pile is in OFF position before connecting leads. Connect inductive pick-up clamp.
  2. Connect tachometer to engine. Start engine and raise engine speed to 2500 RPM. Slowly adjust rheostat control (load) on volt/amp tester until highest amperage reading is obtained. DO NOT allow voltage to drop less than 12 volts. NOTE: Depending on volt/amp tester manufacturer, load may be applied automatically. Refer to volt/amp tester manufacturers instructions.
  3. Note reading on ammeter. Generator amperage reading should be more than the minimum amperage rating specification. See «GENERATOR APPLICATION»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator) table under DESCRIPTION. If amperage reading is less than minimum specification, go to step 5). If amperage reading is more than minimum specification, go to next step.
  4. Rotate load control knob to OFF position. Continue to hold engine speed at 2500 RPM. Output amperage should change to less than 20-amps, indicating EVR circuitry is okay and charging system is functioning properly. It may take several minutes for amperage to change. If output amperage does not change to less than 20-amps, perform «TEST TC-11A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator) - GENERATOR FIELD NOT SWITCHING PROPERLY under SELF-DIAGNOSTIC TESTS.
  5. Connect a jumper wire between ground and generator field driver terminal (Dark Green wire) on back of generator. Start engine, and immediately reduce engine speed to idle. Adjust carbon pile and engine speed in increments until engine speed is 1250 RPM and voltmeter reads 15 volts. DO NOT allow voltage to exceed 16 volts.
  6. Note reading on volt/amp tester. Generator amperage reading should be more than the minimum amperage rating specification. See «GENERATOR APPLICATION»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator) table under DESCRIPTION. If amperage reading is less than minimum specification, replace generator. If amperage reading is more than minimum specification, a fault exists in EVR circuitry. Perform «TEST TC-11A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator) - GENERATOR FIELD NOT SWITCHING PROPERLY under SELF-DIAGNOSTIC TESTS.

OUTPUT VOLTAGE TEST

  1. Before performing this test, ensure battery is fully charged. Connect voltmeter leads across battery terminals. Record voltage with ignition switch and all electrical loads off. Fully engage parking brake, and place gear selector in Park position.
  2. Start engine and operate at normal operating temperature. Record voltage with engine speed at 1500 RPM and no electrical loads. Voltage should not be greater than voltage recorded in step 1) by more than 2.5 volts. If voltage is not as specified, go to «TEST TC-6A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-tc-6a-charging-system-voltage) - CHARGING SYSTEM VOLTAGE TOO HIGH under SELF-DIAGNOSTIC TESTS.
  3. Record voltage with engine speed at 2000 RPM, blower motor on high and headlights on high beam. Voltage should be more than 0.5 volt above battery voltage previously recorded in step 1). If voltage is less than 0.5 volt above previously recorded battery voltage, go to «TEST TC-5A»(/dodge/pickup-r2500/1997-1998/remont/charging-system/#generator__test-tc-5a-charging-system-voltage-too) - CHARGING SYSTEM VOLTAGE TOO LOW under SELF-DIAGNOSTIC TESTS. If voltage tests are satisfactory, reduce engine speed, and turn off blower motor, headlights and ignition switch.

REMOVAL & INSTALLATION

CAUTIONWhen vehicle battery is disconnected, vehicle computer systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION article.
  1. Disconnect negative battery cable. Remove generator drive belt and generator mounting bolts. Remove pivot bolt, and position generator aside to access wire connectors.
  2. Remove B+ terminal nut, field terminal nuts and ground/wire harness hold-down nuts. Remove wire connectors. Remove generator from vehicle. To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS.

TORQUE SPECIFICATIONS

ApplicationFt. Lbs. (N.m)
Mounting Bolts30 (41)
INCH Lbs. (N.m)
Field Terminal Nuts25 (3)
Ground & B+ Terminal Nuts75 (8)

TORQUE SPECIFICATIONS

Charging System Wiring Diagram (Ram Pickup). Scheme 1

Scheme 1: Charging System Wiring Diagram (Ram Pickup)
Scheme 1: Charging System Wiring Diagram (Ram Pickup)