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Generator & Regulator Dodge Ram Wagon B1500

Charging System 4 illustrations ~5069 words

DEFINITION & APPLICATION

Chrysler Corp. light trucks use a Denso generator. The generator consists of a rotor, stator, rectifiers, front and rear covers and drive pulley. Voltage regulation is controlled by the Powertrain Control Module (PCM) on all models except diesel. On diesel models, voltage regulation is controlled by a transistorized voltage regulator.

Application(1) Case NumberPulley Grooves
Gasoline (3.9L, 5.2L, 5.9L & 8.0L)
75-Amp530086467
90-Amp530086477
120-Amp530086517
Diesel (5.9L, 120-Amp)560272218
(1) Located on tag on bottom of generator case.
(1)Located on tag on bottom of generator case.

GENERATOR APPLICATION

IDENTIFICATION

Note. The terms alternator and generator are interchangeable. Either may be found within illustrations.

Vehicle body codes are used throughout self-diagnostic tests. See BODY CODE DESIGNATION table for model identification.

Model NameBody Type
Ram Van/WagonAB

BODY CODE DESIGNATION

OPERATION

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

Application(1) New: In. (mm)(1) Used: In. (mm)
Ram Van/Wagon(2)(2) *
(1) Any belt operated for 15 minutes. (2) Dynamic tensioner is used; no adjustment is required.
(1)Any belt operated for 15 minutes.
(2)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.

NOISY 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 and charging system is functional.
  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 not be capable of performing all necessary test functions. Malfunction Indicator Light (MIL), also known as CHECK ENGINE light (located on instrument panel), may also be used for system diagnostics, but has 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, and on within 5 seconds. Record 2-digit DTCs displayed by MIL flashing on and off, and proceed to «SELF-DIAGNOSTIC TESTS»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__self-diagnostic-tests) . Once repairs are made, ensure DTCs are cleared from PCM memory. See «CLEARING DTCS»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__clearing-dtcs) . Following is a brief description of DTCs and conditions: Code 12 - Battery feed to PCM has been interrupted within last 50-100 engine starts. PCM monitors this circuit whenever ignition is on. Code 41 - Generator field control fails to switch properly. PCM monitors this circuit whenever ignition is on. Code 44 - Battery temperature sensor voltage is out of range. PCM monitors this circuit whenever ignition is on. Code 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. Code 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.

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 go to «SELF-DIAGNOSTIC TESTS»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__self-diagnostic-tests) . Once repairs are made, ensure DTCs are cleared from PCM memory. See «CLEARING DTCS»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__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. See appropriate articles

  1. For Ram Van 3.9L see «TESTS W/CODES - 3.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-39l) article
  2. For Ram Van 5.2L see «TESTS W/CODES - 5.2L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-52l)
  3. For Ram Van 5.2L see «TESTS W/CODES - 5.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-59l) article.

NO RESPONSE Message

See TEST NS-6A in articles

  1. For Ram Van 3.9L see «TESTS W/CODES - 3.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-39l) article
  2. For Ram Van 5.2L see «TESTS W/CODES - 5.2L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-52l)
  3. For Ram Van 5.2L see «TESTS W/CODES - 5.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-59l) article.

Error Message

If scan tool displays RAM TEST FAILURE, CARTRIDGE ERROR, KEY PAD TEST FAILURE, or LOW OR HIGH BATTERY.

SELF-DIAGNOSTIC TESTS

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 articles

  1. For Ram Van 3.9L see «TESTS W/CODES - 3.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-39l) article
  2. For Ram Van 5.2L see «TESTS W/CODES - 5.2L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-52l)
  3. For Ram Van 5.2L see «TESTS W/CODES - 5.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-59l) article.
  1. Attempt to start engine. If necessary, crank engine for up to 10 seconds. Read and record DTCs. Refer to «RETRIEVING DTCS»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__retrieving-dtcs) under SELF-DIAGNOSTIC SYSTEM. If scan tool screen is blank, displays NO RESPONSE, or an error message, see SCAN TOOL PROBLEMS & ERROR MESSAGES under SELF-DIAGNOSTIC SYSTEM.
  2. If DTCs are displayed, see «SCAN TOOL DTC MESSAGES»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator) table. Only DTCs relating to charging system are listed. For all other DTCs, see DTC TEST, CHECKING SYSTEM FOR DIAGNOSTIC TROUBLE CODES in appropriate articles
  1. For Ram Van 3.9L see «TESTS W/CODES - 3.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-39l) article
  2. For Ram Van 5.2L see «TESTS W/CODES - 5.2L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-52l)
  3. For Ram Van 5.2L see «TESTS W/CODES - 5.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-59l) article.

If no DTCs display, go to TEST CH-1A, CHARGING SYSTEM NO CODE TEST .

Scan Tool DisplayGo To Test
BATTERY TEMP SENSOR VOLTAGE TOO LOW/HIGHTEST TC-153A
CHARGING SYSTEM VOLTAGE HIGHTEST TC-6A
CHARGING SYSTEM VOLTAGE LOWTEST TC-5A
GENERATOR FIELD NOT SWITCHING PROPERLYTEST 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 on.
CAUTIONEnsure all wires are clear of any moving engine parts.

Note. For connector terminal identification, see appropriate articles

  1. For Ram Van 3.9L see «TESTS W/CODES - 3.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-39l) article
  2. For Ram Van 5.2L see «TESTS W/CODES - 5.2L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-52l)
  3. For Ram Van 5.2L see «TESTS W/CODES - 5.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-59l) article.
  1. 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 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 battery temperature sensor connector. Inspect connector and terminals for damage. Repair connector and terminals as necessary and perform «TEST VER-2A»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__test-ver-2a-road-test-verification) . If connector and terminals are okay, go to next step.
  4. Connect a jumper wire across battery temperature sensor terminals. Using scan tool, read battery temperature sensor voltage. If voltage is zero, replace battery temperature sensor and perform «TEST VER-2A»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__test-ver-2a-road-test-verification) . If any voltage exists, replace powertrain control module and perform «TEST VER-2A»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__test-ver-2a-road-test-verification) .
  5. Using an external voltmeter, connect one voltmeter lead to B+ (battery) terminal on rear of generator. 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/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__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/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__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/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__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 DTC TEST.

TEST TC-6A, CHARGING SYSTEM VOLTAGE TOO HIGH

Note. For connector terminal identification, see appropriate articles

  1. For Ram Van 3.9L see «TESTS W/CODES - 3.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-39l) article
  2. For Ram Van 5.2L see «TESTS W/CODES - 5.2L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-52l)
  3. For Ram Van 5.2L see «TESTS W/CODES - 5.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-59l) article.
  1. Turn ignition on. Using scan tool, actuate generator field driver. Using an external voltmeter, backprobe field driver circuit (Dark Green/White wire on AB body; Dark Green wire on all other bodies) in 2-wire connector on rear of generator. If voltage cycles from low voltage to high voltage, perform «TEST TC-6B»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__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 connectors and terminals as necessary and perform «TEST VER-2A»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__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 of PCM White connector, field driver circuit (Dark Green/White wire on AB body; Dark Green wire on all other bodies) to ground. If resistance is less than 5 ohms, repair short to ground in field driver circuit and perform «TEST VER-2A»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__test-ver-2a-road-test-verification) . If resistance is 5 ohms or more, go to next step.
  4. Check resistance of field driver terminal in generator (Dark Green/White wire on AB body; Dark Green wire on all other bodies). If resistance is less than 5 ohms, repair or replace generator and perform «TEST VER-2A»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__test-ver-2a-road-test-verification) . If resistance is 5 ohms or more, replace PCM and perform «TEST VER-2A»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__test-ver-2a-road-test-verification) .

TEST TC-6B, CHARGING SYSTEM VOLTAGE TOO HIGH

Note. Perform TEST TC-6A before proceeding.

Note. For connector terminal identification, see appropriate articles

  1. For Ram Van 3.9L see «TESTS W/CODES - 3.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-39l) article
  2. For Ram Van 5.2L see «TESTS W/CODES - 5.2L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-52l)
  3. For Ram Van 5.2L see «TESTS W/CODES - 5.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-59l) article.
  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 temperature. Using a thermometer, read underhood temperature. If temperatures are within 10 percent of each other, perform TEST TC-153A. 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 charging voltage. Compare readings for 5 minutes. If difference between readings is more than one volt, replace powertrain control module and perform «TEST VER-2A»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__test-ver-2a-road-test-verification) . If difference between readings is one volt or less, go to next step.
  4. Allow engine to idle. Turn ignition off. Perform «DTC TEST»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__dtc-test-checking-system-for-diagnostic) .

TEST TC-11A, GENERATOR FIELD NOT SWITCHING PROPERLY

Note. For connector terminal identification, see appropriate article

  1. For Ram Van 3.9L see «TESTS W/CODES - 3.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-39l) article
  2. For Ram Van 5.2L see «TESTS W/CODES - 5.2L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-52l)
  3. For Ram Van 5.2L see «TESTS W/CODES - 5.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-59l) article.
  1. Using scan tool, actuate generator field driver circuit. Using scan tool in voltmeter mode, backprobe Auto Shutdown (ASD) relay output circuit (Dark Green/Orange wire) in 2-wire connector on rear of generator. If voltage is 10 volts or less, repair open ASD relay output circuit from generator to splice and perform «TEST VER-3A»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__test-ver-3a-charging-verification) . If voltage is more than 10 volts, go to next step.
  2. Backprobe generator field driver circuit (Dark Green/White wire on AB body; Dark Green wire on all other bodies) in 2-wire connector on rear of generator. If voltage does not cycle from low voltage to high voltage, go to step 6). If voltage cycles from low voltage to high voltage, go to next step.
  3. 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.
  4. Inspect all related wiring and connectors. Repair wiring and connections as necessary and perform «TEST VER-3A»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__test-ver-3a-charging-verification) . If wiring and connections are okay, go to next step.
  5. 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/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__test-ver-3a-charging-verification) . If DTC does not reset, see INACTIVE DTC CONDITION in appropriate articles; For Ram Van 3.9L see «TESTS W/CODES - 3.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-39l) article, For Ram Van 5.2L see «TESTS W/CODES - 5.2L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-52l) , For Ram Van 5.2L see «TESTS W/CODES - 5.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-59l) article.
  6. Using scan tool, stop generator field driver actuation. Turn ignition off. Disconnect Powertrain Control Module (PCM) connectors. Inspect connectors and terminals for damage. Repair connectors and terminals as necessary and perform «TEST VER-3A»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__test-ver-3a-charging-verification) . If connectors and terminals are okay, go to next step.
  7. Disconnect 2-wire connector on rear of generator. Inspect connector and terminals for damage. Repair connector and terminals as necessary and perform «TEST VER-3A»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__test-ver-3a-charging-verification) . If connector and terminals are okay, go to next step.
  8. Using an external ohmmeter mode, check resistance of generator field driver circuit (Dark Green/White wire on AB body; Dark Green wire on all other bodies) between PCM White connector 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/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__test-ver-3a-charging-verification) . If resistance is less than 5 ohms, go to next step.
  9. Ensure 2-wire connector on rear of generator is disconnected. Using external ohmmeter, check resistance across terminals that 2-wire connector fits on at rear of generator. If resistance is 5 ohms or more, repair or replace generator as necessary and perform «TEST VER-3A»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__test-ver-3a-charging-verification) . If resistance is less than 5 ohms, go to next step.
  10. Using scan tool in ohmmeter mode, check resistance of generator field driver circuit (Dark Green/White wire on AB body; Dark Green wire on all other bodies) in generator 2-wire connector to ground. If resistance is less than 5 ohms, repair short to ground in field driver circuit and perform «TEST VER-3A»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__test-ver-3a-charging-verification) . If resistance is 5 ohms or more, replace PCM and perform «TEST VER-3A»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__test-ver-3a-charging-verification) .

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

Note. For connector terminal identification, see appropriate articles

  1. For Ram Van 3.9L see «TESTS W/CODES - 3.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-39l) article
  2. For Ram Van 5.2L see «TESTS W/CODES - 5.2L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-52l)
  3. For Ram Van 5.2L see «TESTS W/CODES - 5.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-59l) article.
  1. Using scan tool, read Battery Temperature (BT) sensor 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/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__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 BT sensor 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/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__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 TEMP SENSOR VOLTAGE TOO HIGH or TOO LOW DTC sets if PCM senses voltage from BT sensor 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 BT sensor 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/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__test-ver-2a-road-test-verification) . If wiring and connectors are okay, see INACTIVE DTC CONDITION in appropriate articles; For Ram Van 3.9L see «TESTS W/CODES - 3.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-39l) article, For Ram Van 5.2L see «TESTS W/CODES - 5.2L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-52l) , For Ram Van 5.2L see «TESTS W/CODES - 5.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-59l) article.
  5. Disconnect BT sensor connector. Using scan tool, read BT sensor voltage. If voltage is more than 4 volts, replace BT sensor and perform «TEST VER-2A»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__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 connectors and terminals as necessary and Perform «TEST VER-2A»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__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 of BT sensor connector, BT sensor signal circuit (Pink/Yellow wire). If resistance is less than 5 ohms, repair short to ground in BT sensor signal circuit and perform «TEST VER-2A»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__test-ver-2a-road-test-verification) . If resistance is 5 ohms or more, go to next step.
  8. Using an external ohmmeter, check resistance of BT sensor signal circuit (Pink/Yellow wire) between BT sensor connector and PCM Gray connector. If resistance is 5 ohms or more, replace PCM and perform TEST VER-2A. If resistance is less than 5 ohms, repair short to ground in sensor signal circuit and perform «TEST VER-2A»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__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 appropriate article

  1. For Ram Van 3.9L see «TESTS W/CODES - 3.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-39l) article
  2. For Ram Van 5.2L see «TESTS W/CODES - 5.2L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-52l)
  3. For Ram Van 5.2L see «TESTS W/CODES - 5.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-59l) article.
  1. Disconnect Battery Temperature (BT) sensor connector. Connect a jumper wire between BT sensor connector, BT sensor signal circuit (Pink/Yellow wire) and ground circuit (Black/Light Blue wire). Go to next step.
  2. Using scan tool, read BT sensor voltage. If voltage is less than one volt, replace BT sensor and perform «TEST VER-2A»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__test-ver-2a-road-test-verification) . If voltage is one volt or more, go to next step.
  3. Move jumper wire from BT sensor connector, ground circuit (Black/Light Blue wire) to engine ground. Read BT sensor voltage. If voltage is less than one volt, repair open ground circuit and perform TEST VER-2A. 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 connectors and terminals as necessary and Perform TEST VER-2A. If connectors and terminals are okay, go to next step.
  5. Using an external ohmmeter, check resistance of BT sensor signal circuit (Pink/Yellow wire) between BT sensor connector and PCM Gray connector. If resistance is less than 5 ohms, replace PCM and perform TEST VER-2A. If resistance is 5 ohms or more, repair open BT sensor signal circuit and perform TEST VER-2A.

TEST CH-1A, CHARGING SYSTEM NO CODE TEST

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

  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.
  2. Start engine. Using scan tool, set engine speed at 1600 RPM for 30 seconds. Using scan tool, return engine speed to idle and read Diagnostic Trouble Codes (DTCs). If any DTCs pertaining to charging system exist, go to appropriate test. See SCAN TOOL DTC MESSAGES table in «DTC TEST»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__dtc-test-checking-system-for-diagnostic) . If other DTC messages exist, see DTC TEST, CHECKING SYSTEM FOR DIAGNOSTIC TROUBLE CODES in appropriate article; For Ram Van 3.9L see «TESTS W/CODES - 3.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-39l) article, For Ram Van 5.2L see «TESTS W/CODES - 5.2L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-52l) , For Ram Van 5.2L see «TESTS W/CODES - 5.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-59l) article.
  3. Turn ignition off. Turn ignition on with engine off. Using scan tool, actuate generator field. Using scan tool in voltmeter mode, backprobe terminal No. 2 (Dark Green wire) in round 2-wire connector on rear of generator. Voltage should cycle from zero volts to battery voltage every 1.4 seconds.
  4. While monitoring voltage display on scan tool, wiggle wiring from round 2-pin connector on rear of generator to Powertrain Control Module (PCM) and Auto Shutdown (ASD) relay. PCM is located between driver's side front fender and power distribution center, near battery. ASD relay is located at rear of power distribution center at driver's side front corner of engine compartment, near battery.
  5. If no interruption of normal voltage cycle exists when wiggling wiring, go to next step. If interruption of normal voltage cycle exists when wiggling wiring, repair wiring as necessary. Perform TEST VER-3A.
  6. Using scan tool, read DTCs. If any DTCs exists pertaining to charging system, go to appropriate test. See «SCAN TOOL DTC MESSAGES»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator) table in DTC TEST. If other DTC messages exist, see DTC TEST, CHECKING SYSTEM FOR DIAGNOSTIC TROUBLE CODES in appropriate articles; For Ram Van 3.9L see «TESTS W/CODES - 3.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-39l) article, For Ram Van 5.2L see «TESTS W/CODES - 5.2L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-52l) , For Ram Van 5.2L see «TESTS W/CODES - 5.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-59l) 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/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__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/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__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/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__test-ver-3a-charging-verification) . If difference between both voltage readings is one volt or more, go to next step.
  13. Ensure ignition is off. Disconnect PCM connectors. Using external voltmeter, check voltage at PCM Black connector terminal No. 22 (Red/White wire). 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. If this voltage reading is within one volt of voltage reading obtained using scan tool in step 11), repair high resistance on Red/White wire between PCM Black connector terminal No. 22 and battery. Perform «TEST VER-3A»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator__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 if necessary.
  3. If any DTCs have not been diagnosed, go to DTC TEST 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, erase 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, 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 for at least 20 minutes so vehicle theft security system can be activated when desired. Using scan tool, erase 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, 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 battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

GENERATOR OUTPUT WIRE RESISTANCE TEST

CAUTIONGenerator has 2 field terminals: generator field driver (Dark Green or Dark Green/White wire) and ASD relay output (Dark Green/Orange or Dark Blue wire). DO NOT connect generator ASD relay output terminal to ground.
  1. Ensure battery is fully charged. Turn ignition off. Disconnect negative battery cable. Disconnect generator output wire from generator B+ terminal. (Scheme 1)
  2. Using a DC ammeter (0-150 amps), connect positive lead to generator B+ terminal. Connect negative lead to generator output wire. (Scheme 2) Using a voltmeter (0-18 volts minimum), connect positive lead to generator output wire. Connect negative lead to positive battery cable.
  3. Connect jumper wire between ground and generator field driver terminal (Dark Green or Dark Green/White wire) on back of generator.
  4. Connect engine tachometer, and reconnect negative battery cable. Connect carbon pile rheostat between battery terminals. Ensure carbon pile is in OFF position before connecting leads.
  5. Start engine, and immediately reduce engine speed to idle. Adjust engine speed and carbon pile to maintain 20-amp current flow in circuit. Note voltmeter reading. Voltage drop should be 0.5 volt or less.
  6. If voltage drop exceeds 0.5 volt, inspect, clean and tighten all connections between generator B+ terminal and positive battery post. Perform voltage drop test at each connection to locate connection with excessive resistance. If resistance is okay, reduce engine speed, and turn off carbon pile and ignition.
  7. Disconnect negative battery cable. Remove test ammeter, voltmeter, carbon pile and tachometer. Remove jumper wire between generator field driver terminal and ground. Connect generator output wire to generator B+ terminal. Reconnect negative battery cable. Connect hose between PCM and air cleaner, if removed.

Scheme 1

Scheme 1
Scheme 1

Scheme 2

Scheme 2
Scheme 2

CURRENT OUTPUT TEST

CAUTIONGenerator has 2 field terminals: generator field driver (Dark Green or Dark Green/White wire) and ASD relay output (Dark Green/Orange or Dark Blue wire). DO NOT connect generator ASD relay output terminal to ground.
  1. Ensure battery is fully charged. Disconnect negative battery cable. Disconnect generator output wire at generator B+ terminal. (Scheme 1)
  2. Using a DC ammeter (0-150 amps), connect positive lead to generator B+ terminal. Connect negative lead to generator output wire. (Scheme 3) Using a voltmeter (0-18 volts minimum), connect positive voltmeter lead to generator B+ terminal. Connect negative lead to good ground.
  3. Connect engine tachometer, and reconnect negative battery cable. Connect carbon pile rheostat between battery terminals. Ensure carbon pile is in OFF position before connecting leads.
  4. Connect jumper wire between ground and generator field driver terminal (Dark Green or Dark Green/White wire) on back of generator.
  5. 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 ammeter. Ensure generator output current is within its rating range. See «GENERATOR APPLICATION»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator) table at beginning of article. If generator output current is less than specified and generator output wire resistance is not excessive, replace generator.
  7. After output test is completed, reduce engine speed, and turn off carbon pile and ignition. Disconnect negative battery cable. Remove test ammeter, voltmeter, tachometer and carbon pile. Remove jumper wire between generator field driver terminal and ground. Reconnect generator output wire to generator B+ terminal. Connect negative battery cable. Connect air hose between PCM and air cleaner, if removed.

Scheme 3

Scheme 3
Scheme 3

REMOVAL & INSTALLATION

CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.
  1. Disconnect negative battery cable. Remove generator drive belt and generator mounting bolts. Remove pivot bolt, and position generator aside to access wire connectors. NOTE: When installing serpentine accessory drive belt, ensure it is routed correctly to prevent engine overheat.
  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»(/dodge/ram-wagon-b1500/1996-1997/remont/charging-system/#generator-regulator) .

TORQUE SPECIFICATIONS

ApplicationFt. Lbs. (N.m)
Mounting Bolts30 (41)
INCH Lbs. (N.m)
Battery Hold-Down Bolt/Nut20 (2)
Field Terminal Nuts25 (3)
Ground & B+ Terminal Nuts75 (8)

TORQUE SPECIFICATIONS

Charging System Wiring Diagram. Scheme 4

Scheme 4: Charging System Wiring Diagram
Scheme 4: Charging System Wiring Diagram