Charging System - Generators & Regulators (Except Coupe): Diagnosis Dodge Stratus I

SELF-DIAGNOSTIC SYSTEM

If a problem is sensed in a monitored circuit, a Diagnostic Trouble Code (DTC) will be stored in PCM and Malfunction Indicator Light (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 .

ON-BOARD DIAGNOSTICS

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

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. Perform appropriate self-diagnostic test. See «SELF-DIAGNOSTIC TESTS»(ref-58773-S09505313552001011700000) . Once repairs are made, clear DTCs from PCM memory. See «CLEARING DTCS»(ref-58773-S35662843192001011700000) .

SELF-DIAGNOSTIC TESTS

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

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

DTC TEST - CHECKING SYSTEM FOR DIAGNOSTIC TROUBLE CODES

Note. Ensure battery is fully charged before proceeding with test.

1. Attempt to start engine. Crank engine for up to 10 seconds (if necessary). Read and record DTCs. See «RETRIEVING DTCS»(ref-58773-S01036432972001011700000) under SELF-DIAGNOSTIC SYSTEM. If scan tool displays NO RESPONSE, go to TEST NS-6A in the appropriate TESTS W/CODES article in the ENGINE PERFORMANCE section. See the «G - TESTS W/CODES ARTICLE MENU & LINKS»(ref-58773-S04025397982001011700000) table.
2. If scan tool will not power up, check for loose cable connections or bad cable. If cable connections and cable are okay, check voltage at terminal No. 16 (Pink wire) on DLC. Voltage should be at least 11 volts. If voltage is not as specified, check wiring circuit and necessary fuses. See «WIRING DIAGRAMS»(ref-58773-S06298674712001011700000) .
3. If scan tool displays an error message, (i.e., USER-REQUESTED COLD BOOT or USER-REQUESTED WARM BOOT), follow scan tool manufacturer's instructions. If scan tool displays a BUS failure (i.e., SHORT TO BATTERY), this indicates either a scan tool failure or BUS failure. To diagnose and correct BUS failures, see BODY CONTROL COMPUTER - VEHICLE COMMUNICATIONS article.
4. If DTCs are displayed, see SCAN TOOL DTC MESSAGES table and perform appropriate test(s). Only DTCs relating to charging system are listed. For all other DTCs, see appropriate TESTS W/CODES article. Refer to the «G - TESTS W/CODES ARTICLE MENU & LINKS»(ref-58773-S04025397982001011700000) table. If no DTCs are displayed, go to «TEST CH-1A»(ref-58773-S23175040052001011700000) .

SCAN TOOL DTC MESSAGES

Scheme 3

Scheme 4

1. Verify battery condition. Charge or replace battery as necessary. Inspect generator belt tension and condition. Replace generator belt as necessary. Start engine. Using scan tool, set engine speed to 1600 RPM for 30 seconds. Using scan tool, return engine to idle speed and read Diagnostic Trouble Codes (DTCs). If any charging system DTCs are set, see «SCAN TOOL DTC MESSAGES»(ref-58773-S15729168292001011700000) table and perform appropriate test. If no charging system DTCs are set, go to next step.
2. Turn ignition on with engine off. Using scan tool, actuate generator field. Using scan tool in voltmeter mode, backprobe generator field terminal located on back of generator. (Scheme 3)or (Scheme 4). Voltage should cycle from zero volts to battery voltage every 1.4 seconds at both terminals. While observing scan tool, wiggle field terminal wiring harness back to Powertrain Control Module (PCM). If any interruption of voltage cycling occurred, repair wiring harness where wiggling caused failure. Perform «TEST VER-3A»(ref-58773-S18019063262001011700000). If wiggling did not interrupt voltage cycling, go to next step. (Scheme 3): Identifying Generator Terminals (2.0L & 2.4L - Except Neon) (Scheme 4): Identifying Generator Terminals (2.5L & Neon)
3. Using scan tool, read DTCs. If any charging system DTCs are set, see «SCAN TOOL DTC MESSAGES»(ref-58773-S15729168292001011700000) table and perform appropriate test. If no charging system trouble codes are set, go to next step.
4. Using an external voltmeter, check voltage between generator B+ terminal located on rear of generator and battery positive terminal. (Scheme 3)or (Scheme 4). Ensure voltmeter wires are clear of moving engine parts. Start engine and observe voltmeter. If voltage is.4 volt or less, go to next step. If voltage is more than.4 volt, repair high resistance between generator B+ terminal and battery positive terminal. Perform «TEST VER-3A»(ref-58773-S18019063262001011700000).
5. Turn ignition off. Using an external voltmeter, check voltage between generator case and battery negative terminal. Using scan tool, read and record battery voltage. Using an external voltmeter, check and record battery voltage between battery terminals. If difference between voltage measurements is one volt or more, go to next step. If difference between voltage measurements is less than one volt, test is complete. Perform «TEST VER-3A»(ref-58773-S18019063262001011700000).
6. Turn ignition off. Disconnect the PCM connector. Turn ignition on. Using a scan tool set in voltmeter mode, check voltage of fused B+ circuit at the PCM connector terminal No. 46. Refer to the «PCM CONNECTOR WIRE IDENTIFICATION»(ref-58773-S11450021392001011700000) table. If voltage is within one volt of scan tool voltage, repair high resistance between PCM connector terminal No. 46 and battery positive terminal. Perform «TEST VER-3A»(ref-58773-S18019063262001011700000). If voltage is not within one volt of scan tool voltage, replace the PCM. Perform «TEST VER-3A»(ref-58773-S18019063262001011700000).

PCM CONNECTOR WIRE IDENTIFICATION

TEST TC-5A - CHARGING SYSTEM VOLTAGE TOO LOW

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

1. Using scan tool, read voltage goal. If voltage goal is 15.1 volts or less, go to next step. If voltage goal is more than 15.1 volts, go to step 3).
2. Using scan tool temperature probe, measure and record actual underhood temperature near Powertrain Control Module (PCM). Using scan tool, read Battery Temperature Sensor (BTS) temperature. If battery temperature is within 10°F (-12°C) of underhood temperature, go to next step. If battery temperature is not within 10°F (-12°C) of underhood temperature, replace BTS. On JA and JX bodies, BTS is located on left front of impact beam, below grille. On PL body, the BTS is located below battery tray next to the air inlet tube. Perform «TEST VER-3A»(ref-58773-S18019063262001011700000) .
3. Connect an external voltmeter between generator B+ terminal and battery positive terminal. Start engine. If voltage is less than .4 volt, go to next step. If voltage is .4 volt or more, repair B+ circuit for high resistance between generator and battery. Perform «TEST VER-3A»(ref-58773-S18019063262001011700000) .
4. Turn ignition off. Connect an external voltmeter between generator case and battery negative terminal. Start engine. If voltage is .1 volt or less, go to next step. If voltage is more than .1 volt, repair generator ground for high resistance between generator case and battery negative terminal. Perform «TEST VER-3A»(ref-58773-S18019063262001011700000) .
5. Manually set engine speed to 1600 RPM. Using scan tool, read and compare voltage and voltage goal. If difference between voltage and voltage goal is one volt or less, allow engine to idle. Turn ignition off. Clear DTCs. Perform «TEST CH-1A»(ref-58773-S23175040052001011700000) - CHARGING SYSTEM NO CODE TEST. If difference between voltage and voltage goal is more than one volt, perform «TEST TC-5B - CHARGING SYSTEM VOLTAGE TOO LOW»(ref-58773-S36555539282001011700000) .

TEST TC-5B - CHARGING SYSTEM VOLTAGE TOO LOW

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

Note. Perform TEST TC-5A before proceeding with this test.

1. Turn ignition off. Disconnect generator field connector and PCM. Using an external ohmmeter, measure resistance of Dark Green/Orange wire between generator field wiring harness connector and terminal No. 6 at PCM connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open circuit in wiring harness as necessary. Perform «TEST VER-2A»(ref-58773-S13022180142001011700000) .
2. Measure resistance of Dark Green wire between generator field wiring harness connector and terminal No. 4 at PCM connector. If resistance is less than 5 ohms, repair or replace generator as necessary. Perform «TEST VER-2A»(ref-58773-S13022180142001011700000) . If resistance is 5 ohms or more, repair open circuit in wiring harness as necessary. Perform «TEST VER-2A»(ref-58773-S13022180142001011700000) .

TEST TC-6A - CHARGING SYSTEM VOLTAGE TOO HIGH

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

1. Using scan tool, actuate generator field driver. Using scan tool in voltmeter mode, backprobing generator field connector, check voltage on Dark Green wire. If voltage shifts low to high go to «TEST TC-6B»(ref-58773-S12205803442001011700000) . If voltage does not shift low to high, go to next step.
2. Using scan tool, stop generator field actuation. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Disconnect generator field connector from back of generator. Using scan tool in ohmmeter mode, check resistance of PCM connector terminal No. 4 (Dark Green wire). If resistance is less than 5 ohms, repair or replace shorted generator as necessary. Perform «TEST VER-3A»(ref-58773-S18019063262001011700000) . If resistance is 5 ohms or more, replace PCM. Perform «TEST VER-3A»(ref-58773-S18019063262001011700000) .

TEST TC-6B - CHARGING SYSTEM VOLTAGE TOO HIGH

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

Note. Perform TEST TC-6A before proceeding with this test.

1. Using scan tool, stop generator field driver actuation. Using scan tool, read charging voltage goal. If voltage goal is more than 13 volts, go to step 3). If voltage goal is 13 volts or less, go to next step.
2. Using scan tool temperature probe, measure and record actual underhood temperature near Powertrain Control Module (PCM). Using scan tool, read Battery Temperature Sensor (BTS) temperature. If battery temperature is within 10°F (-12°C) of underhood temperature, go to next step. If battery temperature is not within 10°F (-12°C) of underhood temperature, replace BTS. On JA and JX bodies, BTS is located on left front of impact beam, below grille. On PL body, BTS is located below battery tray next to air inlet tube. Perform «TEST VER-3A»(ref-58773-S18019063262001011700000) .
3. Start engine. Manually set engine speed to 1600 RPM. Using scan tool, read and compare voltage and voltage goal. Observe voltage for up to 5 minutes (if necessary) for a one volt difference between voltage and voltage goal. If difference between voltage and voltage goal is more than one volt, replace Powertrain Control Module (PCM). Perform «TEST VER-3A»(ref-58773-S18019063262001011700000) .

TEST TC-11A - GENERATOR FIELD NOT SWITCHING PROPERLY

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

1. Using scan tool, actuate generator field driver circuit. Using a voltmeter, backprobe generator field connector ASD relay output circuit Dark Green/Orange wire. Generator field connector is located on back of generator. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open ASD relay output circuit. Perform «TEST VER-3A»(ref-58773-S18019063262001011700000) .
2. Using a voltmeter, backprobe generator field connector generator field driver circuit Dark Green wire. If voltage shifts from low to high, go to next step. If voltage does not shift from low to high, go to step 5).
3. Condition to set trouble code is not present at this time. GENERATOR FIELD NOT SWITCHING PROPERLY DTC sets when Powertrain Control Module (PCM) tries to regulate generator field with no result during monitoring. Possible causes are: field driver circuit open or shorted, generator internal open or short or PCM failure. Go to next step.
4. Wiggle wiring harness from generator to PCM. Using scan tool, read DTCs with actuator test still running. If generator field driver circuit failure returned, repair wiring harness as necessary where wiggling caused problem to appear. Perform «TEST VER-3A»(ref-58773-S18019063262001011700000) . If generator field driver circuit failure did not appear, no problem is found at this time. Test is complete. Perform «TEST VER-3A»(ref-58773-S18019063262001011700000) .
5. Using scan tool, stop generator field driver activation. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Disconnect generator field connector from back of generator. Using an external ohmmeter, check resistance of generator field driver circuit Dark Green wire between generator field driver connector and PCM connector No. 4. If resistance is 5 ohms or more, repair open generator field driver circuit. Perform «TEST VER-3A»(ref-58773-S18019063262001011700000) . If resistance is less than 5 ohms, go to next step.
6. Using an external ohmmeter, check resistance between generator field terminals on generator. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair generator as necessary. Perform «TEST VER-3A»(ref-58773-S18019063262001011700000) .
7. Using scan tool in ohmmeter mode, check resistance of generator field connector generator field driver circuit or Dark Green wire. If resistance is less than 5 ohms, repair short to ground on generator field driver circuit. Perform «TEST VER-3A»(ref-58773-S18019063262001011700000) . If resistance is 5 ohms or more, replace Powertrain Control Module (PCM). Perform «TEST VER-3A»(ref-58773-S18019063262001011700000) .

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

Note. For connector terminal identification, see CONNECTOR IDENTIFICATION in 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 BTS voltage is .4 volt or more, go to next step. If BTS voltage is less than .4 volt, go to step 5).
2. If BTS voltage is 4.9 volts or less, go to next step. If BTS voltage is less than 4.9 volts, go to «TEST TC-153B»(ref-58773-S33019426202001011700000) .
3. While observing scan tool BTS voltage, wiggle wiring harness for BTS sensor. If voltage changed, repair wiring harness as necessary where wiggling caused problem to appear. Perform «TEST VER-2A»(ref-58773-S13022180142001011700000) . If voltage did not change, go to next step.
4. Condition to set trouble code is not present at this time. BATTERY TEMPERATURE SENSOR VOLTAGE EITHER TOO HIGH OR TOO LOW DTC sets if BTS voltage is less than .5 volt or more than 4.9 volts for 3 seconds. Possible causes are: BTS failure, BTS signal circuit open, BTS signal circuit shorted or PCM failure. Go to next step.
5. Inspect all related wiring and connectors and repair as necessary. If wiring and connectors are okay, no problem is indicated at this time. Test is complete. Perform «TEST VER-2A»(ref-58773-S13022180142001011700000) . If related wiring and connectors were repaired, perform «TEST VER-2A»(ref-58773-S13022180142001011700000) .
6. Disconnect BTS connector. On JA and JX bodies, BTS is located on left front of impact beam, below grille. On PL body, BTS is located below battery tray next to air inlet tube. On all vehicles, use scan tool to read BTS voltage. If BTS voltage is 4 volts or less, go to next step. If BTS voltage is more than 4 volts, replace BTS. Perform «TEST VER-2A»(ref-58773-S13022180142001011700000) .
7. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using scan tool in ohmmeter mode, check resistance of BTS signal circuit at BTS connector Violet/Light Green wire. If resistance is less than 5 ohms, repair short to ground on Violet/Light Green wire. Perform «TEST VER-2A»(ref-58773-S13022180142001011700000) . If resistance is 5 ohms or more, replace PCM. Perform «TEST VER-2A»(ref-58773-S13022180142001011700000) .

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

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

Note. Perform TEST TC-153A before proceeding with this test.

1. Disconnect BTS connector. On JA and JX bodies, BTS is located on left front of impact beam, below grille. On PL body, BTS is located below battery tray next to air inlet tube. On all vehicles, turn ignition on. Using an external voltmeter, measure voltage between ground and Violet/Light Green wire at BTS connector. If voltage is 5 volts or less, go to next step. If voltage is more than 5 volts, repair short to voltage is Violet/Light Green wire. Perform «TEST VER-2A»(ref-58773-S13022180142001011700000) .
2. Connect a jumper wire between BTS connector terminals. Using scan tool, read BTS voltage. If voltage is one volt or more, go to next step. If voltage is less than one volt, replace BTS. Perform «TEST VER-2A»(ref-58773-S13022180142001011700000) .
3. Move jumper wire from BTS connector ground circuit Black/Light Blue wire to an engine ground. Using scan tool, read BTS voltage. If voltage is one volt or more, go to next step. If voltage is less than one volt, repair open BTS connector Black/Light Blue wire. Perform «TEST VER-2A»(ref-58773-S13022180142001011700000) .
4. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an external ohmmeter, check resistance of BTS signal circuit Violet/Light Green wire between BTS connector and PCM connector terminal No. 52. If resistance is less than 5 ohms, replace PCM. Perform «TEST VER-2A»(ref-58773-S13022180142001011700000) . If resistance is 5 ohms or more, repair open Violet/Light Green wire. Perform «TEST VER-2A»(ref-58773-S13022180142001011700000) .

TEST VER-2A - ROAD TEST VERIFICATION

1. Inspect vehicle to ensure all engine components are connected. Reassemble and reconnect components as necessary.
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.
3. If any DTCs have not been diagnosed, go to «DTC TEST»(ref-58773-S32231109902001011700000) 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. If this test is for an A/C relay control circuit DTC, ensure vehicle is road tested for at least 5 minutes with A/C on. For all DTCs, road test vehicle at a speed of at least 40 MPH. During road test, stop vehicle and turn engine off for at least 10 seconds or more. Restart engine and continue road test. Ensure transaxle shifts through all gears. After road test, turn engine off. Go to next step.
6. 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»(ref-58773-S32231109902001011700000) , 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, erase DTCs from PCM.
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. 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»(ref-58773-S32231109902001011700000) , 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

OUTPUT VOLTAGE TEST

Note. OUTPUT VOLTAGE TEST determines if generator is capable of delivering its rated current output.

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»(ref-58773-S33846622192001011700000) - 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»(ref-58773-S41394430772001011700000) - 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.

AMPERAGE OUTPUT TEST

Note. Ammeter with inductive pick-up clamp-type test lead is recommended. Perform test soon after starting engine, as charging amperage will drop quickly.

1. Disconnect negative battery cable. Disconnect generator output wire from generator terminal B+. (Scheme 3)or (Scheme 4). Connect ammeter in series between terminal B+ and disconnected output wire. Connect voltmeter between terminal B+ and ground. Reconnect negative battery cable.
2. Voltmeter should read battery voltage. If voltmeter reads zero volts, check for an open in wire between generator terminal B+ and positive battery terminal, a blown fusible link or a poor ground connection.
3. Turn on all electrical accessories. Start engine and accelerate to 2500 RPM. Read maximum amps output. If generator amps output is within specification, generator is functioning properly. See the «GENERATOR SPECIFICATIONS»(ref-58773-S34711487042001011700000) table.

VOLTAGE DROP TEST

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

1. Using external voltmeter, connect positive lead to generator B+ terminal stud (not the nut). (Scheme 3)or (Scheme 4). Connect voltmeter negative lead to positive battery cable. 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 0.8 volt.
3. If voltage drop is more than 0.8 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.