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 instructions may result in personal injury.
- Batteries normally produce explosive gases which can cause personal injury. 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 plastic-cased 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 to the battery. Lift with a battery carrier or with your hands on opposite corners. Failure to follow these instructions may result in personal injury.
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. Measure the open circuit battery voltage. If the battery voltage is less than 12.0 volts, test and recharge the battery before continuing with diagnosis. 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 A/C. Turn the blower to LOW/OFF. Check the battery voltage before and after starting the engine to determine if the battery voltage increases. Refer to Component Tests, Generator On-Vehicle Tests. Generator On-Vehicle Tests
7. If the concern remains after the inspection, 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 vehicle selection cannot be entered:
- check that the diagnostic card is correctly installed.
- check the connections to the vehicle.
- check the ignition switch position. If the diagnostic tool still does not allow the vehicle selection to be entered, refer to the diagnostic tool manual.
8. If any PCM DTCs are retrieved, go to the Powertrain Control Module (PCM) Diagnostic Trouble Code (DTC) Index to check if the codes retrieved are related to the charging system and to continue the diagnosis. Diagnostic Trouble Code Tests and Associated Procedures
9. If no DTCs related to the concern are retrieved, GO to Symptom Chart. Symptom Related Diagnostic Procedures
NOTE: DTC P0622 can be set by the loss of the communication lines, GEN COM circuit 1816 (YE/LB), and/or GEN MON circuit 1817 (YE). 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 which 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.