Generator & Regulator Dodge Ram Wagon B3500

DESCRIPTION

Chrysler Corp. light trucks use either a Bosch or 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.

GENERATOR APPLICATION

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, fault code will be stored in PCM memory and Malfunction Indicator Light (MIL) will come on, provided specific criteria have been met. Fault codes can be read using MIL or Chrysler's Diagnostic Readout Box (DRB).

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

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

BELT TENSION

BELT TENSION

TROUBLE SHOOTING

Note. See TROUBLE SHOOTING - BASIC PROCEDURES article in GENERAL TROUBLE SHOOTING section.

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, defective generator, 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

Self-diagnostic system, if properly used, can simplify testing. PCM monitors several different engine control system circuits.

If a problem is sensed in a monitored circuit, fault code 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 fault code results from a particular system failure. Fault code 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 fault code after 50 ignition on-off cycles . Fault codes can also be cleared using DRB. See the ERASING FAULT CODES procedure under ON-BOARD DIAGNOSTICS .

HARD FAILURES

Hard failures will cause MIL to illuminate and remain on until malfunction is repaired. If MIL comes on and remains on (or light flashes) during vehicle operation, cause of malfunction must be determined using diagnostic tests.

If a sensor fails, PCM will use a substitute value in its calculations, allowing engine operation in limp-in mode. In this condition, vehicle will run but driveability will be poor.

INTERMITTENT FAILURES

Intermittent failures may cause MIL to flicker or stay on until intermittent failure goes away. However, corresponding fault code will be retained in PCM memory. If failure does not reoccur within a certain time frame (50 ignition on-off cycles), corresponding fault code will be erased from PCM memory.

Intermittent failures can be caused by faulty sensor, bad connection, or wiring related problems. See INTERMITTENTS section in appropriate TESTS W/O CODES article in ENGINE PERFORMANCE section. See the following list.

1. «TESTS W/O CODES - GASOLINE»(/dodge/ram-wagon-b3500/1991-2000/remont/testing-diagnostics/#engine-controls-tests-wo-codes-gasoline)
2. «TESTS W/O CODES - CNG»(/dodge/ram-wagon-b3500/1991-2000/remont/testing-diagnostics/#engine-controls-tests-wo-codes-cng)
3. «TESTS W/O CODES - DIESEL»(ref-11139)

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.
3. DO NOT cause short circuits when performing electrical tests. This will set additional fault codes, 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 fault code number (MIL) or first fault displayed (DRB).
6. Always perform verification test after repairs are made.
7. Always disconnect DRB after use.
8. Always disconnect DRB before charging battery.

ON-BOARD DIAGNOSTICS

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

Faults may be retrieved using Malfunction Indicator Light (MIL) on instrument panel or DRB. See MIL DIAGNOSTIC MODE and DRB DIAGNOSTIC MODE procedures. DRB provides a more complete diagnosis. Following is a brief description of fault codes and conditions

1. Code 12 Battery feed to PCM has been interrupted within last 50-100 engine starts. PCM monitors this circuit whenever ignition is on.
2. Code 41 Generator field control fails to switch properly. PCM monitors this circuit whenever ignition is on.
3. Code 44 Battery temperature sensor voltage is out of range. PCM monitors this circuit whenever ignition is on.
4. 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.
5. 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.

Note. MIL cannot be used to perform actuator test mode, sensor test modes or engine running test.

MIL Diagnostic Mode

1. Start engine (if possible). On A/T models, move transmission shift lever through all positions, ending in Park. On all models, turn A/C switch on and then off (if equipped).
2. Turn engine off. Without starting engine again, turn ignition on, off, on, off and on. MIL will come on for 2 seconds as a bulb check, followed by fault codes. Record 2-digit fault codes displayed by MIL.
3. For example, Code 23 is displayed as flash, flash, pause, then flash, flash, flash. Fault codes are displayed in numerical order and are separated by 4-second pause.
4. Once MIL begins flashing fault codes, cycle cannot be stopped. To enter diagnostic mode again, repeat step 1). Code 55 indicates end of fault code display. For more information on self-diagnostics, see appropriate G - TESTS W/ CODES article in ENGINE PERFORMANCE section. Refer to the following list. «TESTS W/CODES - 3.9L»(/dodge/ram-wagon-b3500/1991-2000/remont/testing-diagnostics/#engine-controls-tests-wcodes-39l) «TESTS W/CODES - 5.2L CNG»(/dodge/ram-wagon-b3500/1991-2000/remont/testing-diagnostics/#engine-controls-tests-wcodes-52l-cng) «TESTS W/CODES - 5.2L GASOLINE»(/dodge/ram-wagon-b3500/1991-2000/remont/testing-diagnostics/#engine-controls-tests-wcodes-52l-gasoline) «TESTS W/CODES - 5.9L DIESEL»(ref-11112) «TESTS W/CODES - 5.9L GASOLINE»(/dodge/ram-wagon-b3500/1991-2000/remont/testing-diagnostics/#engine-controls-tests-wcodes-59l-gasoline) «TESTS W/CODES - 8.0L»(ref-11101)
5. After retrieving fault codes, refer to CHARGING SYSTEM FAULT CODES table to identify problem circuit (same description is displayed on DRB). Test appropriate circuit, and repair or replace components as necessary. See appropriate test procedure under «TESTING - ON-VEHICLE»(/dodge/ram-wagon-b3500/1991-2000/remont/charging-system/#generator-regulator__testing-on-vehicle) . CHARGING SYSTEM TROUBLE CODES Fault Code Circuit Description MIL On 12 Battery Feed To PCM No 41 (1) Generator Field Control Yes 44 (1) Battery Temp. Sensor Yes 46 (1) High Battery Voltage Yes 47 (1) Low Battery Voltage Yes 55 End Of Diagnostic Mode No (1) This code will cause limp-in mode. NOTE: Only charging system-related codes are listed. For engine-related codes, see appropriate G - TESTS W/ CODES article in ENGINE PERFORMANCE section: Refer to the following list. «TESTS W/CODES - 3.9L»(/dodge/ram-wagon-b3500/1991-2000/remont/testing-diagnostics/#engine-controls-tests-wcodes-39l) «TESTS W/CODES - 5.2L CNG»(/dodge/ram-wagon-b3500/1991-2000/remont/testing-diagnostics/#engine-controls-tests-wcodes-52l-cng) «TESTS W/CODES - 5.2L GASOLINE»(/dodge/ram-wagon-b3500/1991-2000/remont/testing-diagnostics/#engine-controls-tests-wcodes-52l-gasoline) «TESTS W/CODES - 5.9L DIESEL»(ref-11112) «TESTS W/CODES - 5.9L GASOLINE»(/dodge/ram-wagon-b3500/1991-2000/remont/testing-diagnostics/#engine-controls-tests-wcodes-59l-gasoline) «TESTS W/CODES - 8.0L»(ref-11101)

DRB Diagnostic Mode

1. Turn ignition off. Attach DRB to Data Link Connector (DLC). DLC is located in engine compartment, near PCM.
2. Start engine (if possible). On A/T models, shift transmission lever through all positions, ending in Park. On all models, turn A/C switch on and then off (if equipped).
3. Turn engine off. Without starting engine again, turn ignition on. Enter CHARGING MENU. See DRB TEST FUNCTIONS. At CHARGING MENU, press "2" (READ FAULTS) key. Press ENTER key. Read fault messages and perform appropriate test. See SELF-DIAGNOSTIC TESTS.

Erasing Fault Codes

1. DRB is required to erase fault codes. To erase codes, press ATM key. At DRB display, press "2" (ERASE) key. DRB will display: ERASE FAULTS ARE YOU SURE? (ENTER TO ERASE). Press ENTER key.
2. When DRB is finished erasing fault codes, it will display FAULTS ERASED. This display will remain until ATM key is pressed. After ATM key is pressed, display will return to CHARGING MENU screen.

DRB TEST FUNCTIONS

Note. DO NOT touch DRB keypad during DRB power-up sequence, or an ERROR message will result.

1. To access trouble code descriptions, and perform diagnostic tests using DRB, DRB must be in the CHARGING MENU display. To reach CHARGING MENU, turn ignition off. Connect DRB to Data Link Connector (DLC). DLC is located under center of dash, right of steering column.
2. Turn ignition switch to RUN position. All DRB character positions will illuminate and copyright information will appear on screen for several seconds. If DRB screen is blank or any error messages appear, refer to DRB PROBLEMS & ERROR MESSAGES under SELF-DIAGNOSTIC SYSTEM.
3. After several seconds DRB menu will appear. At DRB menu, press "4" (SELECT SYSTEM) key. Press ENTER key. At SELECT SYSTEM menu, press "1" (ENGINE) key. Press ENTER key. DRB menu will appear, indicating engine year and size, type of transmission and PCM part number.
4. After several seconds AIR COND menu will appear. Press "1" (WITH A/C) or press "2" (WITHOUT A/C). DRB display will change to ENGINE SYSTEMS menu. At ENGINE SYSTEMS menu, press "2" (CHARGING) key. Press ENTER key.
5. Display will change to CHARGING MENU. At CHARGING MENU of engine diagnostic program, specific test functions programmed into DRB can be performed. The following DRB modes can be accessed: READ TROUBLE CODES, STATE DISPLAYS, ACTUATOR TEST and ADJUSTMENTS.

SYSTEM TEST Mode

This function is not available in engine diagnostics program.

READ TROUBLE CODES Mode

This function allows the user to read and erase trouble codes. A trouble code counter will appear along with trouble code displayed on DRB. For example, DRB will display 1 OF 4 TROUBLE CODES. PCM will store up to 8 trouble codes. Trouble codes are numbered in reverse order of their setting. The most recent trouble code to occur will be number one. Vehicles without A/C will always have A/C CLUTCH RELAY CKT (circuit) stored in memory. This trouble code will always be number one if vehicle is not equipped with A/C. If no trouble codes are stored, DRB will display NO TROUBLE CODES DETECTED and start counter will show 0 STARTS SINCE ERS.

A start counter will appear below DRB trouble code counter display. Start counter counts number of times vehicle has started since trouble code(s) was set, erased or battery was disconnected. This helps determine if failure is intermittent. Memory space limits start counter to first 3 trouble codes. Start counter of zero equals a hard trouble code. Start counter number more than one indicates an intermittent trouble code. Start counter will count up to 255 starts. If no trouble codes are stored, DRB will display NO TROUBLE CODES DETECTED and start counter will show 0 STARTS SINCE ERS.

STATE DISPLAYS Mode

This function allows user to read states or values of a variety of sensors, inputs/outputs and components. PCM can only recognize high and low states on switch circuits. PCM cannot differentiate between an open or short circuit or a defective switch. If DRB displays a change between INPUT HIGH and INPUT LOW, assume the entire switch circuit to PCM is functioning.

ACTUATOR TEST Mode

This function allows user to check for proper operation of output circuits or devices, which PCM cannot internally recognize. DRB allows PCM to activate these outputs or devices, allowing an observer to verify proper operation.

Most tests available in this mode provide an audible or visual indication of device operation (click of relay contacts, spray fuel, etc.). With exception of an intermittent condition, if a device functions properly during its test, it can be assumed that device, wiring and its driver circuit are functioning properly.

ADJUSTMENTS Mode

This function allows user to erase trouble codes. Function also allows user to reset Service Reminder Indicator (SRI) light.

Note. Because DRB is grounded through DLC, only one volt/ohmmeter test lead is required when using volt/ohmmeter option. DRB volt/ohmmeter should only be used when diagnostic procedures require it.

DRB Volt/Ohmmeter Mode

1. To access DRB volt/ohmmeter mode, connect Red volt/ohmmeter test lead to Red port, located on right-top side of DRB.
2. To place DRB in voltmeter mode, press VOLT/OHM key once. Touch test probe to connector or wire to be measured. Read voltage on DRB display. When voltage testing is complete, press VOLT/OHM key 3 times to exit voltmeter mode.
3. To place DRB in ohmmeter mode, press VOLT/OHM key twice. Touch test probe to connector or wire to be measured. Read resistance to circuit ground on DRB display. When resistance testing is complete, press VOLT/OHM key twice to exit ohmmeter mode.

DRB Continuity Meter Mode

Press VOLT/OHM key 3 times. Display will read NO CONTINUITY. Touch test probe to connector or wire to be measured. Read continuity on DRB display. When continuity testing is complete, press VOLT/OHM key once to exit continuity meter mode.

VEHICLES TESTED Mode

1. This mode is used to show which vehicles are covered by DRB cartridge. To access vehicles tested mode, turn ignition off. Attach DRB to Data Link Connector. DLC is located under center of dash, right of steering column.
2. Turn ignition switch to RUN position. All DRB character positions will illuminate and copyright information will appear on screen for several seconds. After several seconds DRB menu will appear.
3. At DRB menu, press "1" (VEHICLES TESTED) key. Press ENTER key. DRB will display vehicles covered by cartridge. Screen will display for 5 seconds and return to DRB menu.

HOW TO USE Mode

Enter DRB menu display. Refer to steps 1) and 2) under VEHICLES TESTED MODE. At DRB menu, press "2" (HOW TO USE) key. Press ENTER key. A series of screens will display explaining keys used to perform engine diagnostic program.

CONFIGURE Mode

1. Configure option allows user to customize DRB display. Example; if metric system is more useful to use, simply select METRIC from appropriate menu.
2. All selections made under CONFIGURE option remain active until user changes selection. To enter configure mode, enter DRB menu display. Refer to steps 1) and 2) under VEHICLES TESTED MODE. At DRB menu, press "3" (CONFIGURE) key. Press ENTER key. DRB will display CONFIGURE menu.

Blank Message Screen

See appropriate G - TESTS W/ CODES article in ENGINE PERFORMANCE section: Refer to the following list.

1. «TESTS W/CODES - 3.9L»(/dodge/ram-wagon-b3500/1991-2000/remont/testing-diagnostics/#engine-controls-tests-wcodes-39l)
2. «TESTS W/CODES - 5.2L CNG»(/dodge/ram-wagon-b3500/1991-2000/remont/testing-diagnostics/#engine-controls-tests-wcodes-52l-cng)
3. «TESTS W/CODES - 5.2L GASOLINE»(/dodge/ram-wagon-b3500/1991-2000/remont/testing-diagnostics/#engine-controls-tests-wcodes-52l-gasoline)
4. «TESTS W/CODES - 5.9L DIESEL»(ref-11112)
5. «TESTS W/CODES - 5.9L GASOLINE»(/dodge/ram-wagon-b3500/1991-2000/remont/testing-diagnostics/#engine-controls-tests-wcodes-59l-gasoline)
6. «TESTS W/CODES - 8.0L»(ref-11101)

NO RESPONSE Message

See TEST NS-6A in appropriate G - TESTS W/ CODES article (see list above) in ENGINE PERFORMANCE section.

RAM TEST FAILURE Message

Replace DRB.

CARTRIDGE ERROR Message

Replace DRB cartridge.

KEY PAD TEST FAILURE Message

Power up DRB again with fingers off keypad. If error message returns, replace DRB.

HIGH BATTERY Or LOW BATTERY Message

Correct vehicle battery condition and reconnect DRB.

Note. For more information on DRB and PCM diagnostics, see appropriate G - TESTS W/ CODES article in ENGINE PERFORMANCE section: Refer to the following list.

1. «TESTS W/CODES - 3.9L»(/dodge/ram-wagon-b3500/1991-2000/remont/testing-diagnostics/#engine-controls-tests-wcodes-39l)
2. «TESTS W/CODES - 5.2L CNG»(/dodge/ram-wagon-b3500/1991-2000/remont/testing-diagnostics/#engine-controls-tests-wcodes-52l-cng)
3. «TESTS W/CODES - 5.2L GASOLINE»(/dodge/ram-wagon-b3500/1991-2000/remont/testing-diagnostics/#engine-controls-tests-wcodes-52l-gasoline)
4. «TESTS W/CODES - 5.9L DIESEL»(ref-11112)
5. «TESTS W/CODES - 5.9L GASOLINE»(/dodge/ram-wagon-b3500/1991-2000/remont/testing-diagnostics/#engine-controls-tests-wcodes-59l-gasoline)
6. «TESTS W/CODES - 8.0L»(ref-11101)

TESTING - ON-VEHICLE

GENERATOR OUTPUT WIRE RESISTANCE TEST

Note. Resistance test will show amount of voltage drop across generator output wire between generator B+ terminal and positive battery post.

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. CAUTION: Generator 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.
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.5 volt or less.
6. If voltage drop exceeds.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 2

CURRENT OUTPUT TEST

Note. Output test determines if generator is capable of delivering its rated current output.

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. CAUTION: Generator 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.
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-b3500/1991-2000/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

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.

TEST TC-1A - CHECKING FOR FAULT CODES

Note. For connector terminal identification, see appropriate G - TESTS W/ CODES article in ENGINE PERFORMANCE section: Refer to the following list.

1. «TESTS W/CODES - 3.9L»(/dodge/ram-wagon-b3500/1991-2000/remont/testing-diagnostics/#engine-controls-tests-wcodes-39l)
2. «TESTS W/CODES - 5.2L CNG»(/dodge/ram-wagon-b3500/1991-2000/remont/testing-diagnostics/#engine-controls-tests-wcodes-52l-cng)
3. «TESTS W/CODES - 5.2L GASOLINE»(/dodge/ram-wagon-b3500/1991-2000/remont/testing-diagnostics/#engine-controls-tests-wcodes-52l-gasoline)
4. «TESTS W/CODES - 5.9L DIESEL»(ref-11112)
5. «TESTS W/CODES - 5.9L GASOLINE»(/dodge/ram-wagon-b3500/1991-2000/remont/testing-diagnostics/#engine-controls-tests-wcodes-59l-gasoline)
6. «TESTS W/CODES - 8.0L»(ref-11101) NOTE: Battery must be fully charged before proceeding.

1. Attempt to start engine. If necessary, crank engine for up to 10 seconds. Connect DRB to Data Link Connector (DLC). Record DRB trouble codes. If DRB screen shows no response, go to TEST NS-6A in appropriate G - TESTS W/ CODES article (see above) in ENGINE PERFORMANCE section. If DRB has an error message or blank screen, go to «DRB PROBLEMS & ERROR MESSAGES»(/dodge/ram-wagon-b3500/1991-2000/remont/charging-system/#generator-regulator) under SELF-DIAGNOSTIC SYSTEM.
2. If fault codes are displayed, see «DRB FAULT MESSAGES»(/dodge/ram-wagon-b3500/1991-2000/remont/charging-system/#generator-regulator) table. Only fault codes relating to charging system are listed. For all other fault codes, See TEST TC-1A in appropriate G - TESTS W/ CODES article (see above) in ENGINE PERFORMANCE section. If no fault codes are displayed, go to TEST CH-1A.

DRB FAULT MESSAGES

TEST TC-2A - GENERATOR FIELD NOT SWITCHING PROPERLY

Note. Perform TEST TC-1A before proceeding. Perform TEST CH-VER after repairs are made.

1. Using DRB, actuate ASD fuel system. Backprobe ASD relay output circuit (Dark Blue or Dark Green/Orange wire) at back of generator. If voltage is 10 volts or less, repair open ASD relay output circuit. If voltage is greater than 10 volts, backprobe field driver circuit (Dark Green or Dark Green/White wire) at back of generator. If voltage is greater than 10 volts, go to step 5). If voltage is 10 volts or less, go to next step.
2. Using DRB, stop ASD fuel system actuation test. Turn ignition off. Disconnect PCM connector. Clean and repair connector as necessary. Disconnect generator harness quick disconnect (if equipped), or disconnect positive battery cable and connect DRB power clip to positive battery terminal.
3. Disconnect harness from back of generator. Clean and repair connector as necessary. Using external ohmmeter, check resistance between generator field terminals. (Scheme 1) If resistance is 5 ohms (10 ohms on 5.2L CNG) or more, replace generator. If resistance is less than 5 ohms (10 ohms on CNG), go to next step.
4. Put DRB in ohmmeter mode. Probe generator harness connector field driver circuit (Dark Green or Dark Green/White wire). If resistance is less than 5 ohms, repair field driver circuit for short to ground. If resistance is 5 ohms or more, replace PCM module.
5. Using DRB, stop ASD fuel system actuation test. Turn ignition off. Disconnect PCM connector. Clean and repair connector as necessary. Disconnect generator harness quick disconnect (if equipped), or disconnect positive battery cable. Disconnect harness from back of generator. Clean and repair connector as necessary.
6. Using external ohmmeter, check resistance between harness connector field driver terminal (Dark Green or Dark Green/White wire) and PCM terminal No. 20. (Scheme 4) If resistance is 5 ohms or more, repair open field driver circuit (Dark Green wire). If resistance is less than 5 ohms, replace PCM.

Scheme 4

TEST TC-3A - CHARGING SYSTEM VOLTAGE LOW

Note. Perform TEST TC-1A before proceeding. Perform TEST CH-VER after repairs are made.

1. Using DRB, read voltage goal. If voltage goal is greater than 15.1 volts, replace PCM. If voltage goal is 15.1 volts or less, connect positive lead of external voltmeter to generator B+ terminal, and negative lead to positive battery terminal. Ensure test leads are clear of engine's moving parts.
2. Start engine. If voltage is greater than 0.4 volt, repair high resistance condition in power circuit between generator B+ terminal and battery. If voltage is 0.4 volt or less, turn ignition off. Connect positive lead of external voltmeter to generator case and negative lead to negative battery terminal. Ensure test leads are clear of engine's moving parts.
3. Start engine. If voltage is greater than 0.1 volt, repair high resistance condition in ground circuit between generator and battery. If voltage is 0.1 volt or less, manually set engine speed to 1600 RPM. Note voltage and voltage goal on DRB. If difference between these 2 values is greater than one volt, replace generator. If difference is one volt or less, allow engine speed to return to idle. Turn engine off, but leave ignition on. Go to TEST CH-1A.

TEST TC-4A - CHARGING SYSTEM VOLTAGE HIGH

Note. Perform TEST TC-1A before proceeding. Perform TEST CH-VER after repairs are made.

1. Using DRB, actuate ASD fuel system. Put DRB in voltmeter mode. Backprobe field driver circuit (Dark Green or Dark Green/White wire) at back of generator. If voltage is greater than 10.0 volts, go to step 4). If voltage is 10.0 volts or less, stop fuel system actuation test using DRB. Turn ignition off. Disconnect PCM connector. Clean and repair connector as necessary.
2. Disconnect generator harness quick disconnect (if equipped), or disconnect positive battery cable and connect DRB power clip to positive battery terminal. Disconnect harness from back of generator. Using DRB in ohmmeter mode, check resistance at PCM terminal No. 20 (Dark Green or Dark Green/White wire). (Scheme 4)
3. If resistance is less than 5 ohms, repair generator field driver circuit for short to ground. If resistance is 5 ohms or more, check resistance at either generator field terminal. (Scheme 1) If resistance is less than 5 ohms, replace generator. If resistance is 5 ohms or more, replace PCM module.
4. Using DRB, stop ASD fuel system actuation test. Read voltage goal using DRB. If voltage goal is 13.0 volts or less, replace PCM. If voltage goal is greater than 13.0 volts, start engine. Manually set engine speed at 1600 RPM.
5. Observe voltage and voltage goal on DRB (up to 5 minutes if necessary). If voltage difference is at least one volt, replace PCM. If voltage difference is less than one volt, allow engine speed to return to idle. Turn off engine, but leave ignition on. Go to TEST CH-1A.

TEST TC-5A - BATTERY TEMPERATURE SENSOR VOLTAGE OUT OF LIMIT

Note. Perform TEST TC-1A before proceeding. Perform TEST CH-VER after repairs are made.

Using DRB, erase fault codes. Turn ignition off and wait 10 seconds. Read fault codes using DRB. If BATTERY TEMP SENSOR VOLTAGE message is displayed on DRB, replace PCM. If message is not displayed, problem does not exist at present moment. Test is complete.

TEST CH-1A - CHARGING SYSTEM NO CODE

Note. Perform TEST TC-1A before proceeding. Perform TEST CH-VER after repairs are made.

1. Verify battery is in good condition. Inspect generator belt tension and condition. Replace belt if necessary.
2. Start engine. Using DRB, set engine speed at 2000 RPM for 30 seconds. Return engine speed to idle, and read fault codes. If fault codes exist, go to appropriate test. See «DRB FAULT MESSAGES»(/dodge/ram-wagon-b3500/1991-2000/remont/charging-system/#generator-regulator) table under TEST TC-1A. If there are no fault codes, turn engine off, but leave ignition on. Using DRB, actuate generator field.
3. With DRB in voltmeter mode, backprobe field driver terminal (Dark Green or Dark Green/White wire) on back of generator. (Scheme 1) Ensure voltage cycles from zero to battery voltage every 1.4 seconds.
4. Observe DRB display, and wiggle wiring harness from generator field terminals to PCM and ASD relay. If normal cycling of voltage is interrupted, repair appropriate wire. If voltage cycling is not interrupted, go to next step.
5. Check for fault codes using DRB. If fault codes exist, perform appropriate test. See «DRB FAULT MESSAGES»(/dodge/ram-wagon-b3500/1991-2000/remont/charging-system/#generator-regulator) table under TEST TC-1A. If there are no fault codes, connect positive lead of external voltmeter to generator B+ terminal, and negative lead to positive battery terminal. (Scheme 1) Ensure all wires are clear of engine's moving parts.
6. Start engine and note voltmeter reading. If voltage is 0.4 volt or less, go to next step. If voltage is greater than 0.4 volt, repair high resistance condition in power circuit between generator B+ terminal and battery.
7. Turn ignition off. Connect positive lead of external voltmeter to generator case, and negative lead to negative battery terminal. Ensure all wires are clear of engine's moving part. Start engine and note reading on voltmeter. If voltage is 0.1 volt or less, go to next step. If voltage is greater than 0.1 volt, repair high resistance condition in ground circuit between generator and battery.
8. Using DRB, read battery voltage. Measure voltage across battery terminals using external voltmeter. Compare the 2 voltage readings. If voltage difference is greater than one volt, go to next step. If voltage difference is less than one volt, test is complete.
9. Disconnect PCM. Clean and repair connector as necessary. With DRB in voltmeter mode, probe PCM connector terminal No. 3. (Scheme 4) If voltage is within one volt of DRB voltage reading obtained in step 8), repair high resistance condition in circuit between PCM connector terminal No. 3 and battery. If voltage is not within one volt of previous DRB voltage reading, replace PCM.

TEST CH-VER - CHARGING VERIFICATION

Note. Ensure all engine components are connected. Reassemble and reconnect components as necessary.

1. If PCM has been replaced and vehicle is equipped with a factory theft alarm, start vehicle at least 20 times so alarm can be activated when desired. Connect DRB to PCM data link connector, and erase faults.
2. Start engine. Raise engine speed to 2000 RPM for at least 30 seconds. Allow engine to idle. Turn engine off. Turn ignition on. Using DRB, check for fault messages. If any fault is present, repair is incomplete. Check all pertinent Technical Service Bulletins (TSBs) and return to TEST TC-1A, if necessary. If there are no other faults, repair is complete.

TESTING - BENCH TESTS

Note. Generators are non-serviceable and must be replaced as complete units.

REMOVAL (EXCEPT DIESEL & RWD VAN)

1. Drive belt is equipped with spring-loaded automatic belt tensioner. Disconnect negative battery cable. Place socket wrench on automatic tensioner pulley bolt. On Pickup 5.9L HD and 8.0L, rotate tensioner COUNTERCLOCKWISE to relieve tension from belt. On all other models, rotate tensioner CLOCKWISE to relieve tension from belt. Note correct belt routing for installation reference. Remove belt from idler pulley. Remove belt from vehicle.
2. Remove generator lower mounting bolt and nut. Remove generator upper mounting bolt. Remove generator. Remove B+ terminal nut and field terminal nuts. Remove ground and harness hold-down nuts. Remove wire connectors.

Note. When installing serpentine accessory drive belt, ensure it is routed correctly to prevent engine overheat.

Installation (Except Diesel & RWD Van)

1. Install harness to generator. Tighten nuts to specification in following sequence: ground terminal nut, B+ terminal nut, wire harness hold-down nuts and field terminal nuts. Refer to the «TORQUE SPECIFICATIONS»(/dodge/ram-wagon-b3500/1991-2000/remont/charging-system/#generator-regulator) table. Install generator, and tighten bolts to specification. NOTE: When installing serpentine accessory drive belt, ensure it is routed correctly to prevent engine overheat.
2. On Pickup 5.9L HD and 8.0L, position drive belt over all pulleys except water pump pulley. On all others, position drive belt over all pulleys except idler pulley, located between generator and A/C compressor. Place socket wrench on automatic tensioner pulley bolt.
3. On Pickup 5.9L HD and 8.0L, rotate tensioner COUNTERCLOCKWISE. On all others, rotate tensioner CLOCKWISE. Route belt over water pump pulley (Pickup 5.9L HD and 8.0L) or idler pulley (all others). Allow tensioner to rotate back into place. Remove wrench. Ensure belt is properly seated on all pulleys. Reconnect negative battery cable.
4. On all models except Pickup 5.9L HD and 8.0L, check belt indexing marks. Tensioner and tensioner housing have an indexing arrow and an index mark, respectively. If a new belt is used, arrow must be within 1/8 inch (3 mm) of index mark. Belt is considered new if it has been in used less than 15 minutes.

Removal & Installation (Pickup Diesel)

1. Disconnect negative battery cable. Remove generator drive belt. Remove B+ terminal nut, field terminal nuts and ground/wire harness hold-down nuts. Remove wire connectors.
2. Remove generator upper mounting bolt and nut. Remove generator lower mounting bolt. Remove generator from vehicle. To install, reverse removal procedure. Tighten lower mounting bolt first, then tighten upper mounting bolts. See «TORQUE SPECIFICATIONS»(/dodge/ram-wagon-b3500/1991-2000/remont/charging-system/#generator-regulator) table.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Charging System Wiring Diagram (Pickup - Diesel). Scheme 5

Charging System Wiring Diagram (Pickup - Gasoline). Scheme 6

Charging System Wiring Diagram (Van). Scheme 7

See also:
• TROUBLE SHOOTING - BASIC PROCEDURES
• TESTS W/O CODES - GASOLINE
• TESTS W/O CODES - CNG
• TESTS W/CODES - 3.9L
• TESTS W/CODES - 5.2L CNG
• TESTS W/CODES - 5.2L GASOLINE
• TESTS W/CODES - 5.9L GASOLINE
• COMPUTER RELEARN PROCEDURES
• ON-BOARD DIAGNOSTICS
• INITIAL CHECKS
• TESTING - ON-VEHICLE
• GENERATOR APPLICATION
• TEST TC-5A
• TEST TC-2A
• TEST TC-3A
• TEST TC-4A