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Charging System Test (w Generator/Battery Control Module)

Charging System Test (w Generator/Battery Control Module)

Step Action Value(s) Yes No
1 Did you perform the Diagnostic System Check - Vehicle? - Go to Step 2  Go to Diagnostic System Check - Vehicle
2 With ignition OFF, install the Midtronics Digital Battery Analyzer and verify the condition of the battery.
Is the battery sufficiently charged for testing?		 - Go to Step 3  Go to Battery Inspection/Test (Non-HP2)  or Battery Inspection/Test (HP2) 
3
  1. Disconnect the Midtronics Digital Battery Analyzer.
  2. Connect the Sun Vat 40 tester or equivalent to the battery.
  3. Turn the ignition to the OFF/LOCK position.
  4. Observe and record the battery voltage reading at the battery terminals on the Sun Vat 40 tester.
  5. Start the engine and observe the system voltage reading on the tester.
Does the voltage increase from the first specified (engine OFF) to the second (engine ON specified range)?		 Engine Off = B+
Engine On = 13.9-15.5 V		 Go to Step 4  Go to Step 6 
4
  1. Turn on the following accessories:
    • Headlights - HI beams
    • A/C on Max
    • Blower Fan - On high
    • Rear window defogger
    • Heated seats (If equipped)
  2. Maintain engine speed at 2500 RPM.
Is voltage still within the specified value?		 13.9-15.5 V Go to Step 5  Go to Step 6 
5
  1. Turn OFF all accessories.
  2. Turn OFF the ignition.
  3. Connect a carbon pile tester to the vehicle.
    4. IMPORTANT: When measuring generator output current, be sure the inductive probe encircles the generator output wire.
  4. Connect an inductive ammeter probe to the output circuit of the generator.
  5. Start the engine.
  6. Increase engine speed to 2,500 RPM.
  7. Adjust the carbon pile as necessary in order to obtain the maximum current output.
Is the generator output greater than or equal to the load test value as specified in Generator Usage  ?		 - System OK Go to Step 10 
6
  1. Turn the engine OFF.
  2. Disconnect the generator harness connector.
  3. Turn the ignition to the ON position.
  4. Using a DMM, measure the voltage on the L-terminal circuit.
Is the voltage greater than the specified value?		 0 V Go to Step 11  Go to Step 7 
7
  1. Turn the engine OFF.
  2. Start the engine and check the voltage on the L-terminal.
Is the voltage within the specified value?		 3 V or above Go to Step 8  Go to Step 12 
8
  1. Turn engine OFF.
  2. Turn ignition switch to ON position.
  3. Using the scan tool, observe the duty cycle in the F-terminal signal parameter.
Does the scan tool display near the indicated value?		 0% Go to Step 9  Go to Step 13 
9 Connect a test lamp to B+ and repeatedly touch the F-terminal at the generator harness connector while monitoring the GEN-F terminal signal parameter on the scan tool.
Does the scan tool indicate that the generator PWM is above the specified range?		 90% Go to Step 10  Go to Step 14 
10
  1. Turn the engine OFF.
  2. Inspect the generator B+ output terminal at the generator for an open or high resistance. Refer# to Circuit Testing and Wiring Repairs .
Did you find and correct the condition?		 - Go to Step 19  Go to Step 15 
11 Test the L-terminal circuit for a short to voltage. Refer# to Circuit Testing and Wiring Repairs .
Did you find and correct the condition?		 - Go to Step 19  Go to Step 16 
12 Test the L-terminal circuit for open or short to ground. Refer# to Circuit Testing and Wiring Repairs .
Did you find and correct the condition?		 - Go to Step 19  Go to Step 16 
13 Test the GEN-F terminal for a short to voltage. Refer# to Circuit Testing and Wiring Repairs .
Did you find and correct the condition?		 - Go to Step 19  Go to Step 16 
14 Test the GEN-F terminal circuit for an open or short to ground. Refer# to Circuit Testing and Wiring Repairs .
Did you find and correct the condition?		 - Go to Step 19  Go to Step 16 
15 Inspect for poor connections at the generator. Refer# to Circuit Testing and Wiring Repairs .
Did you find and correct the condition?		 - Go to Step 19  Go to Step 18 
16 Inspect for poor connections at the harness connector of the generator battery control module (GBCM). Refer# to Testing for Intermittent Conditions and Poor Connections and Connector Repairs .
Did you find and correct the condition?		 - Go to Step 19  Go to Step 17 
17 Replace the GBCM. Refer# to Control Module References for replacement, setup, and programming.
Did you complete the replacement?		 - Go to Step 19  -
18 Replace the generator. Refer# to Generator Replacement (4.8L, 5.3L, and 6.0L)  or Generator Replacement (6.6L)  or Generator Replacement (8.1L) .
Did you complete the replacement?		 - Go to Step 19  -
19 Operate the vehicle in order to verify the repair.
Did you correct the condition?		 - System OK Go to Step 2 
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