Step | Action | Value(s) | Yes | No |
|---|---|---|---|---|
DEFINITION: A malfunction exists. The Charge indicator may be stuck ON or OFF. The battery may be undercharged or overcharged. The vehicle may still start. | ||||
1 | Did you perform the Charging System Check? | -- | Go to Step 2 | Go to Charging System Check |
2 |
Is the voltage above 12 volts? | -- | Go to Step 5 | Go to Step 3 |
3 |
Is the Battery Load Test complete? | -- | Go to Step 4 | -- |
4 | Check for a major electrical drain with the ignition switch OFF. Is there an electrical drain? | -- | Go to Step 5 | Go to Step 5 |
5 | Place the ignition switch in the RUN position. Did the charge indicator come ON? | -- | Go to Step 6 | Go to Step 35 |
6 |
Did the charge indicator go OFF and stay OFF? | -- | Go to Step 9 | Go to Step 7 |
7 |
Did the voltmeter indicate battery voltage? | -- | Go to Step 21 | Go to Step 8 |
8 | Repair the open RED (2) wire between the starter solenoid and the generator. Are the repairs complete? | -- | Go to Charging System Check . | -- |
9 |
Did the voltmeter indicate more than 16 volts? | -- | Go to Step 10 | Go to Step 11 |
10 | Replace the generator. Are the repairs complete? | -- | Go to Charging System Check . | -- |
11 | Did the voltmeter indicate less than 13 volts? | -- | Go to Step 12 | Go to Step 15 |
12 |
Did the voltmeter indicate battery voltage? | -- | Go to Step 13 | Go to Step 14 |
13 | Replace the generator. Are the repairs complete? | -- | Go to Charging System Check . | -- |
14 | Repair the open RED (2) wire between the starter solenoid and the generator. Are the repairs complete? | -- | Go to Charging System Check . | -- |
15 |
Was the generator able to produce 73 amperes? | -- | Go to Step 17 | Go to Step 16 |
16 | Replace the generator. Are the repairs complete? | -- | Go to Charging System Check . | -- |
17 | Did the voltmeter indicate more than 13 volts? | -- | Go to Step 18 | Go to Step 22 |
18 | With the output at this level, connect a voltmeter between the generator RED (2) Output terminal BAT and the battery positive terminal. Did the voltmeter indicate more than 0.5 volt? | -- | Go to Step 19 | Go to Step 20 |
19 |
Are the repairs complete? | -- | Go to Charging System Check . | -- |
20 | With the output at this level, connect a voltmeter between the generator metal housing and the battery negative terminal. Did the voltmeter indicate more than 0.5 volt? | -- | Go to Step 21 | Charging System is OK. Go to Charging System Check . |
21 |
Are the repairs complete? | -- | Go to Charging System Check . | -- |
22 | With the output at this level, connect a voltmeter between the generator RED (2) output terminal BAT and the metal generator housing. Did the voltmeter indicate more than 13 volts? | -- | Go to Step 18 | Go to Step 23 |
23 | Replace the generator. Are the repairs complete? | -- | Go to Charging System Check . | -- |
24 |
Does the charge light come on? | -- | Go to Step 25 | Go to Step 28 |
25 | Connect an ohmmeter across the BLK (450) wire between the battery negative terminal and the engine block. Did the ohmmeter indicate more than 5 Ohms? | -- | Go to Step 26 | Go to Step 27 |
26 | Repair the open BLK (450) wire between the battery and the engine block. Are the repairs complete? | -- | Go to Charging System Check . | -- |
27 | Replace the generator. Are the repairs complete? | -- | Go to Charging System Check . | -- |
28 | Remove and inspect the charge indicator lamp. Is the lamp open? | -- | Go to Step 29 | Go to Step 30 |
29 | Replace the open lamp? Are the repairs complete? | -- | Go to Charging System Check . | -- |
30 |
Did the ohmmeter indicate continuity? | -- | Go to Step 32 | Go to Step 31 |
31 | Repair the open BRN (25) wire between the I/P cluster and the generator. Are the repairs complete? | -- | Go to Charging System Check . | -- |
32 | Connect a voltmeter between the PNK (39) wire cavity B17 of the cluster connector and ground. Did the voltmeter indicate battery voltage? | -- | Go to Step 33 | Go to Step 34 |
33 | Repair or Replace the instrument cluster as necessary. Are the repairs complete? | -- | Go to Charging System Check . | -- |
34 | Repair the open PNK (39) wire between the fuse block and the cluster. Are the repairs complete? | -- | Go to Charging System Check . | -- |
35 | With the ignition switch still in the RUN position. Disconnect the generator 4-way connector. Did the charge indicator go OFF? | -- | Go to Step 36 | Go to Step 37 |
36 | Replace the generator. Are the repairs complete? | -- | Go to Charging System Check . | -- |
37 | Repair the BRN (25) wire for a short to ground between the generator and the cluster. Are the repairs complete? | -- | Go to Charging System Check . | -- |
