Did you review the charging system operation and perform the necessary inspections?

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Go to Step 2

Go to Symptoms

Verify that the battery is undercharged or overcharged.

Is the battery undercharged or overcharged?

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Go to Testing for Intermittent Conditions and Poor Connections in Wiring Systems

Go to Step 3

Is the generator OK?

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Go to Step 4

Go to Step 15

1. Turn OFF all accessories. Connect the generator 4-way connector (if disconnected).
2. Start the engine and run at 2500 RPM.
3. Check the voltage across the battery terminals.

Is the voltage within the specified range?

13-16 V

Go to Step 5

Go to Step 7

1. Stop the engine.
2. Perform the Battery Electrical Drain/Parasitic Load Test .

Is the parasitic load below the specified value?

22 ma

Go to Step 18

Go to Step 6

Determine the source of the excessive parasitic drain and repair as necessary.

Is the repair complete?

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Go to Step 18

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Was the voltage across the battery terminals with the engine running at 2500 RPM too low?

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Go to Step 8

Go to Step 11

1. Disconnect the generator 4-way connector. Turn the ignition switch to RUN.
2. Use a DMM to measure the CKT 225 voltage in cavity B of the generator connector.

Is the voltage above the specified value?

12 V

Go to Step 9

Go to Step 12

Check CKT 225 between the generator and the PCM/VCM for an intermittent shorted/grounded condition or a poor connection Refer to Circuit Testing and Wiring Repairs in Wiring Systems.

Is CKT 225 OK?

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Go to Step 16

Go to Step 10

Repair CKT 225 as necessary Refer to Circuit Testing and Wiring Repairs in Wiring Systems.

Is CKT 225 repair complete?

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Go to Step 17

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Check the Generator 4-way connector for a mis-wired condition in cavity D. This cavity should be empty in this vehicle.

Has the mis-wired condition been repaired?

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Go to Step 17

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1. Disconnect or backprobe the CKT 225 connector at the PCM/VCM
2. Turn the ignition switch to RUN.
3. Use a DMM to check the voltage output of the PCM/VCM to CKT 225.

Is the voltage above the specified value?

12 V

Go to Step 13

Go to Step 14

Repair CKT 225 for a shorted, grounded, or open condition Refer to Circuit Testing and Wiring Repairs in Wiring Systems.

Is the CKT 225 repair complete?

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Go to Step 17

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Repair or replace the PCM/VCM. Refer to Powertrain Control Module Replacement in Engine Controls - 2.2L or VCM Replacement/Programming in Engine Controls - 4.3L Replacement.

Is the PCM/VCM repair complete?

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Go to Step 17

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Replace the generator. Refer to Generator Replacement .

Is the repair complete?

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Go to Step 17

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1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Disconnect and clean all connections between the battery positive terminal and the generator output terminal.
3. Check all cables for an intermittent open condition.
4. Disconnect and clean all connections in the ground circuit between the battery negative terminal and the generator housing.
5. Check all cables for an intermittent open condition.
6. Connect the battery negative cable.

Is the repair complete?

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Go to Step 17

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1. Turn OFF all accessories.
2. Connect the generator 4-way connector (if disconnected).
3. Start the engine and run at 2500 RPM.
4. Check the voltage across the battery terminals.

Is the voltage within the specified range?

13-16 V

Go to Step 18

Go to Step 7

Operate the system in order to verify the repair.

Did you correct the condition?

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System OK

Go to Step 3