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 | Turn the ignition switch and all other electrical loads OFF. Connect a voltmeter between the Battery's positive and negative terminals. Is the voltage above 12 volts? | -- | ||
2 |
Is the Battery Load Test complete? | -- | -- | |
3 | Check for a major electrical drain with the ignition switch Off. Is there an electrical drain? | -- | ||
4 |
Did the Charge indicator come On? | -- | ||
5 |
Did the charge indicator go Off and stay Off? | -- | ||
6 |
Did the voltmeter indicate battery voltage? | -- | ||
7 |
Are the repairs complete? | -- | -- | |
8 |
Did the voltmeter indicate more than 16 volts? | -- | ||
9 |
Are the repairs complete? | -- | -- | |
10 | Did the voltmeter indicate less than 13 volts? | -- | ||
11 |
Did the voltmeter indicate battery voltage? | -- | ||
12 |
Are the repairs complete? | -- | -- | |
13 |
Are the repairs complete? | -- | -- | |
14 | Stop the engine. Install a carbon pile load tester across the battery terminals. attach an inductive ammeter to the Generator output lead. Start the engine and let it idle briefly. Increase the engine speed to 2500 RPM. Turn the carbon pile load On and adjust until Generator output reading on the inductive ammeter is 73 amperes. With the output at this level, connect a voltmeter between the Battery's positive terminal and negative terminal. Was the Generator able to produce 73 amperes? | -- | ||
15 |
Are the repairs complete? | -- | -- | |
16 | Did the voltmeter indicate more than 13 volts? | -- | ||
17 | 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? | -- | ||
18 | Turn Off the carbon pile load and stop the engine. Clean and tighten all connections in the affected circuit. also Repair any wires that may be damaged. Are the repairs complete? | -- | -- | |
19 | 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? | -- | Charging System is OK. Go to Starter and Charging System Check . | |
20 | Turn Off the carbon pile load and stop the engine. Clean and tighten all connections in the affected circuit. also Repair any wires that may be damaged. Are the repairs complete? | -- | -- | |
21 | 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? | -- | ||
22 |
Are the repairs complete? | -- | -- | |
23 | Disconnect the 4-way Generator connector. Turn the ignition switch to the Run position. Connect a fused jumper wire from BRN (25) wire cavity B of the Generator connector to ground. Does the Charge light come on? | -- | ||
24 | 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? | -- | ||
25 | Repair the open BLK (450) wire between the battery and the engine block. Are the repairs complete? | -- | -- | |
26 |
Are the repairs complete? | -- | -- | |
27 | Remove and inspect the Charge indicator lamp. Is the lamp open? | -- | ||
28 | Replace the open lamp? Are the repairs complete? | -- | -- | |
29 | Return the Charge indicator lamp to the cluster. Disconnect the cluster connector. Connect an ohmmeter across the BRN (25) wire between the cluster connector cavity B16 and the Generator 4-way connector. Did the ohmmeter indicate continuity? | -- | ||
30 | Repair the open BRN (25) wire between the I/P cluster and the Generator. Are the repairs complete? | -- | -- | |
31 | Connect a voltmeter between the PNK (39) wire cavity B17 of the cluster connector and ground. Did the voltmeter indicate battery voltage? | -- | ||
32 | Repair or Replace the Instrument Cluster as necessary. Are the repairs complete? | -- | -- | |
33 | Repair the open PNK (39) wire between the fuse block and the cluster. Are the repairs complete? | -- | -- | |
34 | With the ignition switch still in the Run position. Disconnect the Generator 4-way connector. Did the Charge indicator go Off? | -- | ||
35 |
Are the repairs complete? | -- | -- | |
36 | Repair the BRN (25) wire for a short to ground between the Generator and the cluster. Are the repairs complete? | -- | -- | |
