Chrysler Town, Dodge Caravan. Manual — part 664
Symptom:
P2503-CHARGING SYSTEM VOLTAGE LOW
When Monitored and Set Condition:
P2503-CHARGING SYSTEM VOLTAGE LOW
When Monitored:
The engine running. The engine speed greater than 1157 RPM.
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
CHARGING VOLTAGE BELOW 15.1 VOLTS
(A11) B+ CIRCUIT HIGH RESISTANCE
GENERATOR GROUND HIGH RESISTANCE
GENERATOR OPERATION
(Z1) GEN FIELD GROUND CIRCUIT OPEN
(K20) GEN FIELD CONTROL CIRCUIT SHORTED TO BATTERY VOLTAGE
(K20) GEN FIELD CONTROL CIRCUIT SHORTED TO GROUND
(K20) GEN FIELD CONTROL CIRCUIT OPEN
PCM
TEST
ACTION
APPLICABILITY
1
NOTE: 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 DRBIII
t, read the Target Charging Voltage.
Is the Target Charging Voltage above 15.1 volts?
All
Yes
→ Refer to the INTERMITTENT CONDITION symptom in the
Driveability category.
Perform POWERTRAIN VERIFICATION TEST VER - 3 - NGC.
No
→ Go To 2
464
DRIVEABILITY - NGC
TEST
ACTION
APPLICABILITY
2
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.
Ignition on, engine not running.
NOTE: Ensure all wires are clear of the engine’s moving parts.
Start the engine.
Measure the voltage between the (A11) Generator B+ Terminal and the Battery+
Post.
Is the voltage above 0.4 of a volt?
All
Yes
→ Repair the (A11) B+ circuit for high resistance between the
Generator and Battery.
Perform POWERTRAIN VERIFICATION TEST VER - 3 - NGC.
No
→ Go To 3
3
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.
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 of a volt?
All
Yes
→ Repair Generator Ground for high resistance, Generator Case to
Battery ground side.
Perform POWERTRAIN VERIFICATION TEST VER - 3 - NGC.
No
→ Go To 4
4
Turn the ignition off.
Disconnect the Generator Field harness connector.
Using a 12-volt test light, jumper it across the Generator Field harness connector.
Ignition on, engine not running.
With the DRBIII
t, actuate the Gen Field Control circuit.
Does the test light illuminate brightly and flash on and off?
All
Yes
→ Replace the Generator.
Perform POWERTRAIN VERIFICATION TEST VER - 3 - NGC.
No
→ Go To 5
5
Turn the ignition off.
Disconnect the Generator Field harness connector.
Using a 12-volt test connected to battery voltage, probe the (Z1) Gen Field Ground
circuit in the Generator Field harness connector.
Does the test light illuminate brightly?
All
Yes
→ Go To 6
No
→ Repair the open in the (Z1) Gen Field Ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 3 - NGC.
465
DRIVEABILITY - NGC
P2503-CHARGING SYSTEM VOLTAGE LOW —
Continued
TEST
ACTION
APPLICABILITY
6
Turn the ignition off.
Disconnect the Generator Field harness connector.
Disconnect the PCM harness connector.
Measure the voltage on the (K20) Gen Field Control circuit at the Generator Field
harness connector.
Is the voltage above 1.0 volt?
All
Yes
→ Repair the short to voltage in the (K20) Gen Field Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 3 - NGC.
No
→ Go To 7
7
Turn the ignition on.
Disconnect the Generator Field harness connector.
Disconnect the PCM harness connector.
Measure the resistance between ground and the (K20) Gen Field Control circuit in
the Generator Field harness connector.
Is the resistance below 100 ohms?
All
Yes
→ Repair the (K20) Gen Field Control circuit for a short to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 3 - NGC.
No
→ Go To 8
8
Turn the ignition off.
Disconnect the Generator Field harness connector.
Disconnect the PCM harness connector.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI-
NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K20) Gen Field Control circuit from the Generator
Field harness connector to the appropriate terminal of the special tool #8815.
Is the resistance below 5.0 ohms?
All
Yes
→ Go To 9
No
→ Repair the open in the (K20) Generator Field Control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 3 - NGC.
9
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 - NGC.
466
DRIVEABILITY - NGC
P2503-CHARGING SYSTEM VOLTAGE LOW —
Continued
Symptom:
*CHECKING PCM POWER AND GROUND CIRCUITS
POSSIBLE CAUSES
(A14) PCM FUSED B+ CIRCUIT
(A41) PCM FUSED IGNITION SWITCH OUTPUT CIRCUIT
(Z12) PCM GROUND CIRCUITS
TEST
ACTION
APPLICABILITY
1
NOTE: The battery must be fully charged before continuing.
Turn the ignition off.
Disconnect the PCM harness connector.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI-
NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Using a 12-volt test light connected to ground, probe the (A14) PCM Fused B+ circuit
in the Pinout Box.
Does the test light illuminate brightly?
All
Yes
→ Go To 2
No
→ Repair the (A14) Fused B+ circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 - NGC.
2
Turn the ignition off.
Disconnect the PCM harness connector.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI-
NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Turn the ignition on.
Using a 12-volt test light connected to ground, probe the (A41) PCM Fused Ignition
Switch Output circuit in the Pinout Box.
Does the test light illuminate brightly?
All
Yes
→ Go To 3
No
→ Repair the (A41) Ignition Switch Output circuit
Perform POWERTRAIN VERIFICATION TEST VER - 1 - NGC.
3
Turn the ignition off.
Disconnect the PCM harness connector.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI-
NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Using a 12-volt test light connected to battery voltage, probe the (Z12) PCM ground
circuits in the Pinout Box.
Does the test light illuminate brightly?
All
Yes
→ Test Complete.
No
→ Repair the (Z12) PCM ground circuits.
Perform POWERTRAIN VERIFICATION TEST VER - 1 - NGC.
467
DRIVEABILITY - NGC
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