Page 3809 of 4284
7.0
DIAGNOSTIC INFORMATION AND
PROCEDURES
15
Page 3810 of 4284

Symptom:
P0622-GENERATOR FIELD NOT SWITCHING PROPERLY
When Monitored and Set Condition:
P0622-GENERATOR FIELD NOT SWITCHING PROPERLY
When Monitored: With the ignition on. Engine running.
Set Condition: When the PCM tries to regulate the generator field with no result during
monitoring.
POSSIBLE CAUSES
WIRING HARNESS INTERMITTENT
INSPECT WIRING HARNESS
ASD RELAY OUTPUT CIRCUIT OPEN
GENERATOR FIELD DRIVER CIRCUIT SHORTED TO GROUND
GENERATOR FIELD DRIVER CIRCUIT OPEN
GENERATOR
POWERTRAIN CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, actuate the Generator Field Driver circuit.
Using a 12-volt test light connected to ground, backprobe the Generator Field Driver
circuit in the back of the Generator.
Does the test light illuminate brightly and flash?All
Ye s®Go To 2
No®Go To 4
2 Turn the ignition on.
With the DRBIIItactuate the Generator Field Driver circuit.
Wiggle the wiring harness from the Generator to PCM.
With the DRBIIIt, read DTC's.
Did the DTC reset?All
Ye s®Repair as necessary .
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No®Go To 3
3 Turn the ignition off.
Using the schematic as a guide, inspect the Wiring and Connectors.
Were any problems found?All
Ye s®Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No®Test Complete.
16
CHARGING
Page 3811 of 4284

TEST ACTION APPLICABILITY
4NOTE: Carefully inspect all Connectors for corrosion or spread Terminals
before continuing.
Disconnect the Generator Field harness connector.
Turn the ignition on.
With the DRBIIItactuate the Generator Field Driver circuit.
Using a 12-volt test light connected to ground, probe the ASD Relay Output circuit.
Does the test light illuminate brightly?All
Ye s®Go To 5
No®Repair the ASD Relay Output circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
5 Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the Generator Field harness connector.
Measure the resistance of the Generator Field Driver circuit from PCM harness
connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Generator Field Driver circuit for a shorted to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No®Go To 6
6 Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the Generator Field harness connector.
Measure the resistance of the Generator Field Driver circuit from the PCM harness
connector to the Generator Field harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 7
No®Repair the Generator Field Driver circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
7 Turn the ignition off.
Disconnect the Generator Field harness connector.
Measure the resistance across the Generator Field Terminals at the Generator.
Is the resistance below 5.0 ohms?All
Ye s®Repair or replace the Generator as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No®Go To 8
8 If there is no more possible causes remaining, view repair. All
Repair
Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
17
CHARGING
P0622-GENERATOR FIELD NOT SWITCHING PROPERLY ÐContinued
Page 3812 of 4284

Symptom:
P1594-CHARGING SYSTEM VOLTAGE TOO HIGH
When Monitored and Set Condition:
P1594-CHARGING SYSTEM VOLTAGE TOO HIGH
When Monitored: The engine running. The engine speed greater than 380 RPM.
Set Condition: Battery voltage is 1 volt greater than desired system voltage.
POSSIBLE CAUSES
TARGET VOLTAGE DIFFERS FROM BATTERY VOLTAGE
INTERMITTENT CONDITION
GENERATOR FIELD DRIVER CIRCUIT SHORTED TO GROUND
GENERATOR FIELD
POWERTRAIN CONTROL MODULE
TEST ACTION APPLICABILITY
1Note: Battery must be fully charged.
Note: Generator Belt tension and condition must be checked before con-
tinuing.
Turn the ignition on.
With DRBIIIt, actuate the Generator Field Driver.
With a 12-volt test light connected to ground, backprobe the Generator Field Driver
circuit in the back of Generator Field harness connector.
Does the test light illuminate brightly and flash?All
Ye s®Go To 2
No®Go To 5
2 With DRBIIIt, stop all actuation.
Turn the ignition on.
With DRBIIIt, read the Target Charging voltage.
Is the Target Charging voltage above 13 volts?All
Ye s®Go To 3
No®Go To 4
3 Start the engine.
With the DRBIIIt, manually set the engine speed to 1600 RPM.
With DRBIIIt, read both the Battery voltage and the Target Charging voltage.
Compare the Target Charging Voltage to the Battery Voltage reading.
Monitor voltage for 5 minutes, if necessary. Look for a 1.0 volt difference or more.
Was there more than a 1.0 volt difference?All
Ye s®Replace the Powertrain Control Module in accordance with the
Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No®Go To 4
18
CHARGING
Page 3813 of 4284

TEST ACTION APPLICABILITY
4WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
NOTE: The conditions that set the DTC are not present at this time. The
following list may help in identifying the intermittent condition.
With the engine running at normal operating temperature, monitor the DRB
parameters related to the DTC while wiggling the wiring harness. Look for param-
eter values to change and/or a DTC to set.
Review the DRB Freeze Frame information. If possible, try to duplicate the
conditions under which the DTC was set.
Refer to any Technical Service Bulletins (TSB) that may apply.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wiring harness connectors. Look for broken, bent, pushed
out, or corroded terminals.
Were any of the above conditions present?All
Ye s®Repair as necessary
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No®Test Complete.
5 Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the Generator Field harness connector.
Measure the resistance of the Generator Field Driver circuit from the PCM harness
connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Generator Field Driver circuit shorted to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No®Go To 6
6 Turn the ignition off.
Disconnect the Generator Field harness connector.
Measure resistance of the Generator Field Driver terminal to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair or replace the shorted Generator as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No®Go To 7
7 If there are no possible causes remaining, view repair. All
Repair
Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
19
CHARGING
P1594-CHARGING SYSTEM VOLTAGE TOO HIGH ÐContinued
Page 3814 of 4284

Symptom:
P1682-CHARGING SYSTEM VOLTAGE TOO LOW
When Monitored and Set Condition:
P1682-CHARGING SYSTEM VOLTAGE TOO LOW
When Monitored: With the ignition on. Engine RPM greater than 1152 RPM. With no
other charging system codes set.
Set Condition: The battery sensed voltage is 1 volt below the charging goal for 13.47
seconds. The PCM senses the battery voltage turns off the field driver and senses the
battery voltage again. If the voltages are the same, the code is set.
POSSIBLE CAUSES
BATTERY TEMPERATURE
B+ CIRCUIT HIGH RESISTANCE
GENERATOR GROUND HIGH RESISTANCE
INTERMITTENT CONDITION
GENERATOR FIELD DRIVER CIRCUIT OPEN
ASD RELAY OUTPUT CIRCUIT OPEN
GENERATOR
TEST ACTION APPLICABILITY
1NOTE: Inspect the vehicle for aftermarket accessories that may exceed the
Generator System output.
Turn the ignition off.
NOTE: The battery must be fully charged.
NOTE: The Generator belt tension and condition must be checked before
continuing.
Start the engine.
Allow the idle to stabilize.
With the DRBIIIt, read the Target Charging Voltage.
Is the Target Charging Voltage above 15.1 volts?All
Ye s®Go To 2
No®Go To 3
20
CHARGING
Page 3815 of 4284

TEST ACTION APPLICABILITY
2WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Turn the ignition on.
NOTE: Ensure all wires are clear of the engine's moving parts.
Measure the voltage between the Generator B+ Terminal and the Battery+ Post.
Start the engine.
Is the voltage above 0.4 volt?All
Ye s®Repair the B+ circuit for high resistance between the Generator
and Battery.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No®Go To 3
3WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Start the engine.
Warm the engine to operating temperature.
NOTE: Ensure all wires are clear of the engine's moving parts.
Measure the voltage between the Generator case and Battery ground post.
Is the voltage above 0.1 volt?All
Ye s®Repair Generator Ground for high resistance, Generator Case to
Battery ground side.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No®Go To 4
4 Start the engine.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Turn on all accessories, manually set engine speed to 1600 RPM.
With DRBIIIt, read Target Charging and Charging voltage.
Compare the two readings.
Is there more than a 1.0 volt difference?All
Ye s®Go To 5
No®Go To 8
5 Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the Generator Field harness connector.
Measure the resistance of the Generator Field Driver circuit from the PCM harness
connector to Generator harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 6
No®Repair the Generator Field Driver circuit an open.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
21
CHARGING
P1682-CHARGING SYSTEM VOLTAGE TOO LOW ÐContinued
Page 3816 of 4284

TEST ACTION APPLICABILITY
6 Disconnect the Generator Field harness connector.
Turn the ignition on.
With the DRBIIItactuate the Generator Field Driver.
Using a 12-volt test light connected to ground, probe the ASD Relay Output circuit.
Does the test light illuminate brightly?All
Ye s®Go To 7
No®Repair the ASD Relay Output circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 3.
7 If there is no possible causes remaining, view repair. All
Ye s®Repair or replace the Generator as necessary..
Perform POWERTRAIN VERIFICATION TEST VER - 3.
8WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
NOTE: The conditions that set the DTC are not present at this time. The
following list may help in identifying the intermittent condition.
With the engine running at normal operating temperature, monitor the DRB
parameters related to the DTC while wiggling the wiring harness. Look for param-
eter values to change and/or a DTC to set.
Review the DRB Freeze Frame information. If possible, try to duplicate the
conditions under which the DTC was set.
Refer to any Technical Service Bulletins (TSB) that may apply.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wiring harness connectors. Look for broken, bent, pushed
out, or corroded terminals.
Were any of the above conditions present?All
Ye s®Repair as necessary
Perform POWERTRAIN VERIFICATION TEST VER - 3.
No®Test Complete.
22
CHARGING
P1682-CHARGING SYSTEM VOLTAGE TOO LOW ÐContinued