Inspection and Verification
INSPECTION AND VERIFICATIONWARNING:
- Batteries contain sulfuric acid. Avoid contact with skin, eyes, or clothing. Also, shield your eyes when working near batteries to protect against possible splashing of the acid solution. In case of acid contact with skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If acid is swallowed, call a physician immediately. Failure to follow these instruction may result in personal injury.
- Batteries normally produce explosive gases. Therefore, do not allow flames, sparks or lighted substances to come near the battery. When charging or working near a battery, always shield your face and protect your eyes. Always provide ventilation. Failure to follow these instructions may result in personal injury.
- When lifting a battery, excessive pressure on the end walls could cause acid to spew through the vent caps, resulting in personal injury, damage to the vehicle or battery. Lift with a battery carrier or with your hands on opposite corners. Failure to follow these instructions may result in personal injury.
CAUTION:
- Do not make jumper connections except as directed. Incorrect connections may damage the voltage regulator test terminals, fuses, or fusible links.
- Do not allow any metal object to come in contact with the generator housing and internal diode cooling fins. A short circuit may result and burn out the diodes.
NOTE:
- While carrying out any pinpoint test, disregard the diagnostic trouble codes (DTCs) set while following a specific pinpoint test. After the completion of any test, be sure to clear all DTCs in the PCM.
- All voltage measurements are referenced to the negative (-) battery post unless otherwise specified.
1. Verify the customer concern.
Visual Inspection Chart:
2. Visually inspect for obvious signs of mechanical or electrical damage.
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
4. Verify the battery condition. Refer to Battery.
5. Check the operation of the charging system warning indicator (instrument cluster). Normal operation is as follows:
- With the key OFF, the charging system warning indicator should be off.
- With the key ON and the engine off, the charging system warning indicator should be on.
- With the engine running, the charging system warning indicator should be off.
6. Turn off the headlamps and the A/C system (if equipped). Turn the climate control blower to LOW/OFF. Check the battery voltage before and after starting the engine to determine if the battery voltage increases.
7. If the cause is not visually evident, connect the diagnostic tool to the data link connector (DLC) located under the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle:
- check that the diagnostic card is correctly installed.
- check the connections to the vehicle.
- check the ignition switch position.
8. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool operating manual.
9. Carry out the diagnostic tool data link test. If the diagnostic tool responds with:
- controller area network (CAN), standard corporate protocol (SCP), or International Standards Organization (ISO) circuit fault; all electronic control units no response/not equipped, refer to Information Bus (Module Communications Network).
- No response/not equipped for instrument cluster, refer to Instrument Panel, Gauges and Warning Indicators.
- No response/not equipped for PCM, refer to Computers and Control Systems.
- System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs, and carry out the self-test diagnostics for the PCM.
10. If the DTCs retrieved are related to the concern, go to the Powertrain Control Module (PCM) Diagnostic Trouble Code (DTC) Index. Powertrain Control Module (PCM) Diagnostic Trouble Code (DTC) Index
11. If no DTCs related to the charging system are retrieved, GO to Symptom Chart. Symptom Related Diagnostic Procedures
NOTE: DTC P0622 can be set by the loss of the communication lines between the generator and the PCM. The charging system warning indicator then illuminates until the engine is operated at greater than 4,500 rpm (approximately wide open throttle [WOT]) for a minimum of 3 seconds. At this time, the generator self-excites. The charging system warning indicator remains illuminated, and the generator operates in a default mode (approximately 13.5 volts) until the engine is turned off.