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Test A: Charging System Test

WARNING: This page is about a different car, the 2003 GMC Savana Special, 2003 GMC Savana Camper Special, 2003 GMC Savana, and 2003 Chevrolet Chevy Express. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Ensure battery is in good condition before proceeding with charging system tests. See BATTERY TESTING & INSPECTION  under ON-VEHICLE TESTING.
  1. If engine electrical diagnostic system check was performed, go to next step. If engine electrical diagnostic system check was not performed, go to ENGINE ELECTRICAL DIAGNOSTIC SYSTEM CHECK  under SELF-DIAGNOSTIC SYSTEM.
  2. Start engine and observe charge indicator on Instrument Panel Cluster (IPC) or message in Driver Information Center (DIC). If charge indicator illuminates or DIC displays a charging system message, go to next step. If charge indicator light does not illuminate or DIC does not display a charging system message, go to TEST C: CHARGE INDICATOR LIGHT INOPERATIVE .
    3. NOTE: Green POWER lamp of tester should remain illuminated while tester is being used.
  3. Turn ignition switch to OFF position. Using CS Electronic Generator Tester (J-41450-B), connect Red lead to generator output terminal (BAT) and Black lead to metal generator housing. If Green POWER light does not illuminate, go to next step. If Green POWER light illuminates, go to step  6.
  4. Using DVOM, measure voltage between generator output terminal (BAT) and metal generator housing. If battery voltage does not measure equal to 12.0 volts, go to next step. If battery voltage measures equal to 12.0 volts, go to step  14.
  5. Using DVOM, measure voltage between generator output terminal (BAT) and battery negative terminal. If battery voltage measures equal to 12.0 volts, go to step  12. If battery voltage does not measure equal to 12.0 volts, go to step  11.
    6. CAUTION: Make sure load is completely turned off before connecting or disconnecting carbon pile load tester to battery.
  6. Connect carbon pile tester to battery. Connect inductive ammeter to output circuit of generator. Disconnect generator harness connector. Locate matching harness connector on CS electronic generator tester and connect it to generator. If Red DIAGNOSTIC light illuminates, go to next step. If Red DIAGNOSTIC light does not illuminate, go to step  13.
  7. Increase engine speed to 2500 RPM. If Red DIAGNOSTIC light does not illuminate, go to next step. If Red DIAGNOSTIC light illuminates, go to step  15.
  8. Maintain engine speed at 2500 RPM. Turn on load of carbon pile tester and increase load until load is equal to test value of generator. See GENERATOR SPECIFICATIONS . If Red DIAGNOSTIC light does not illuminate, go to next step. If Red DIAGNOSTIC light illuminates, go to step  15.
  9. Maintain engine speed at 2500 RPM and continue to operate generator at load test value. See GENERATOR SPECIFICATIONS . Using a DVOM, measure voltage drop between generator output terminal and positive battery terminal. If voltage drop is less than 0.5 volt, go to next step. If voltage drop is 0.5 volt or more, go to step  11.
  10. Maintain engine speed at 2500 RPM and continue to operate generator at load test value. See GENERATOR SPECIFICATIONS . Using a DVOM, measure voltage drop between generator metal housing and negative battery terminal. If voltage drop is less than 0.5 volt, go to step  16. If voltage drop is 0.5 volt or more, go to step  12.
  11. Repair open or high resistance in generator output circuit (Red wire). See WIRING DIAGRAMS . After repairs are made, go to step  16.
  12. Repair open or high resistance in generator ground circuit. After repairs are made, go to step  16.
  13. Disconnect CS electronic generator tester harness connector, but leave alligator clips connected so Green POWER light remains illuminated. Connect a jumper with a 100 ohm in-line resistor between ground and generator connector terminal "B" (Red wire). See Fig 1. If Red DIAGNOSTIC light does not illuminate, go to next step. If Red DIAGNOSTIC light illuminates, go to step  15.
  14. There is a problem with the CS electronic generator tester. Refer to manufacturer's instructions to test the CS electronic generator tester for proper operation. Repair or replace tester, then go to step  3.
  15. Replace generator. See GENERATOR  under REMOVAL & INSTALLATION. After repairs are made, go to next step.
  16. Retest system to verify repair. If condition was found and corrected, system is okay. If condition was not found, go to step  3.
Fig 1: Identifying Generator 4-Pin Connector Terminals
G00050227Courtesy of GENERAL MOTORS CORP.
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