2002 Chevrolet Malibu

Electrical Systems & Components / Electrical Systems / Charging Systems / CHARGING

SYSTEM

WARNING: Vehicles are equipped with air bag supplemental restraint system. Before attempting any repairs involving steering
column, instrument panel or related components, see DISABLING & ACTIVATING AIR BAG SYSTEM in AIR BAG
RESTRAINT SYSTEMS article in RESTRAINTS.

CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may
exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in
GENERAL INFORMATION before disconnecting battery.

DESCRIPTION & OPERATION

The CS 130D generator has high amperage output. See GENERATOR SPECIFICATIONS . Generator includes a delta stator, rectifier
bridge, and rotor with slip rings and brushes. A built-in regulator incorporates fault detection circuitry. A conventional pulley with (external)
fan is used to cool slip ring and frame. The "D" indicates dual internal fans designed to cool rectifier bridge and regulator.
Generator provides voltage to operate vehicle's electrical system and to charge its battery. A magnetic field is created when current flows
through rotor. This field rotates as rotor is driven by engine, creating an AC voltage in stator windings. AC voltage is converted to DC by
rectifier bridge and is supplied to electrical system at battery terminal.
When engine is running, generator turn-on signal is sent to generator from PCM, turning on regulator. Generator's voltage regulator
controls current to rotor, thereby controlling output voltage. Rotor current is proportional to electrical pulse width supplied by regulator.
When engine is started, regulator senses generator rotation by detecting AC voltage at stator through an internal wire. Once engine is
running, regulator varies field current by controlling pulse width. This regulates generator output voltage for proper battery charging and
electrical system operation. Generator F terminal is connected internally to voltage regulator and externally to PCM. When voltage
regulator detects a charging system problem, it grounds this circuit to signal PCM that a problem exists. PCM monitors generator field duty
cycle signal circuit. System voltage sense circuit receives battery positive voltage that is hot at all times through a fuse link that is
connected to starter motor. This voltage is used by regulator as reference for system.
Regulated voltage varies with temperature. System limits voltage by controlling rotor field current while field current is on. Regulator
switches rotor field current on and off at a fixed frequency of 400 cycles per second to help control radio noise. By varying overall on-off
time, correct average field current for proper system voltage control is obtained. At high speeds, with lower electrical loads, on-time may be
10 percent. At low speeds, with higher electrical loads, on-time may be as much as 90 percent.

COMPONENT LOCATIONS
For component locations, see ELECTRICAL COMPONENT LOCATOR .

ADJUSTMENTS

BELT TENSION

NOTE: Drive belt tension is controlled by a belt tensioner. No adjustment is required.

TROUBLESHOOTING

NOTE: See CHARGING SYSTEM - GENERAL TROUBLE SHOOTING article in GENERAL INFORMATION.

PRELIMINARY INSPECTION
Verify customer complaint by operating suspected system. Visually inspect for obvious signs of mechanical and electrical damage. Ensure
battery is fully charged and passes load test. See BATTERY TESTING & INSPECTION under ON-VEHICLE TESTING. Inspect for blown
fuses. See COMPONENT LOCATIONS . Inspect for loose or corroded connections, damaged wiring harnesses and/or switches. Check for
a broken or partially broken wire inside insulation, which could cause system malfunction but prove good in a continuity/voltage check with
system disconnected. Ensure any aftermarket electronic equipment is properly installed. If fault is found, repair as necessary. If no fault is
found, perform self-diagnostics. See SELF-DIAGNOSTIC SYSTEM .

SYSTEM OPERATION CHECK

NOTE: Before making electrical checks, visually inspect all terminals for clean, tight connections. Ensure all charging system
related fuses are okay. Check generator mounting bolts and drive belt tension. Ensure battery is fully charged and in good
condition prior to testing charging system. See BATTERY TESTING & INSPECTION under ON-VEHICLE TESTING.
Ensure battery cable connections are in good condition and free of corrosion. Ensure starting system is okay. See
appropriate STARTERS article in ELECTRICAL.

SELF-DIAGNOSTIC SYSTEM

NOTE: Diagnostic trouble code tests are written specifically for use with Tech 2 scan tool. Generic scan tool can be used but may
have limited functions. This article only covers portion of those systems which relates to charging system diagnosis. For
further information, see appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.

RETRIEVING DIAGNOSTIC TROUBLE CODES

See RETRIEVING DIAGNOSTIC TROUBLE CODES under SELF-DIAGNOSTIC SYSTEM under SELF-DIAGNOSTICS article in ENGINE
PERFORMANCE.

CLEARING DIAGNOSTIC TROUBLE CODES

See CLEARING DIAGNOSTIC TROUBLE CODES under SELF-DIAGNOSTIC SYSTEM under SELF-DIAGNOSTICS article in ENGINE
PERFORMANCE.

DIAGNOSTIC TROUBLE CODE DEFINITIONS

DIAGNOSTIC TROUBLE CODE DEFINITIONS

DTC 1 Description

P0560 Voltage Out Of Range

P0620 Fault Detection Circuit Malfunction

1 Codes listed in this table are only for testing covered in this article. For complete DTC listing, see appropriate BODY CONTROL
MODULES article in ACCESSSORIES & EQUIPMENT.

DIAGNOSTIC TESTS

DTC P0560: VOLTAGE OUT OF RANGE

Circuit Description
The PCM monitors the system voltage to make sure that the voltage stays within the proper range. Damage to components, and incorrect
data input can occur when the voltage is out of range. The PCM monitors the system voltage over an extended length of time. If the PCM
detects a system voltage outside an expected range for the calibrated length of time, DTC P0560 will set.

Conditions For Running DTC

• System voltage below 11 volts.
• Engine speed above 1500 RPM.
• Vehicle speed below 25 MPH.
Conditions For Setting DTC
The PCM detects a system voltage out of range for 2 seconds.

Action Taken When DTC Sets

• The PCM will not illuminate the Malfunction Indicator Lamp (MIL).
• The PCM will command a message to be displayed.
• The PCM will store conditions which were present when the DTC set as Fail Records data only.

Conditions For Clearing DTC

• The PCM will command the message OFF after one trip in which the diagnostic test has been run and passed.
• The history DTC will clear after 40 consecutive warm-up cycles have occurred without a malfunction.
• The DTC can be cleared by using the scan tool Clear DTC Information function.

Diagnostic Procedure

1. If diagnostic system check was performed, go to next step. If diagnostic system check was not performed, go to ENGINE
ELECTRICAL DIAGNOSTIC SYSTEM CHECK under ON-VEHICLE TESTING.
2. Connect scan tool to Data Link Connector (DLC). DLC is located under instrument panel, near steering column. Turn ignition switch
to RUN position. Using scan tool, observe the Ignition 1 Signal parameter in the PCM data list. If scan tool indicate that the Ignition 1
Signal parameter is greater than 11.0 volts, go to step . If scan tool indicates that the Ignition 1 Signal parameter is not greater than
11.0 volts, go to next step.
3. Using a scan tool compare battery voltage parameter in the DIM data list with the Ignition 1 Signal parameter in the PCM data list. If
DIM battery voltage and PCM Ignition 1 readings differ by more than 0.5 volt, go to next step. If DIM battery voltage and PCM
Ignition 1 readings do not differ by more than 0.5 volt, go to TEST A: CHARGING SYSTEM TEST .
4. Test the battery positive voltage circuit of the PCM for a high resistance. See WIRING DIAGRAMS . If problem is detected, repair as
necessary. Then, got to step . If no problem is detected, go to next step.
5. Inspect PCM harness connector for poor connections. If problem is detected, repair as necessary. Then, got to step . If no problem
is detected, go to next step.
6. Replace PCM. After replacement, reprogram PCM. See REMOVAL, OVERHAUL & INSTALLATION article in ENGINE
PERFORMANCE. After repair, go to next step.
7. Review and record scan tool Fail Records data. Using scan tool, clear DTCs. Operate vehicle within Fail Records conditions as
noted. Using scan tool, observe Specific DTC information for DTC P0560. If scan tool indicates DTC P0560 failed this ignition, go to
step . If scan tool indicates DTC P0560 passed this ignition, system is okay.

DTC P0620: FAULT DETECTION CIRCUIT MALFUNCTION

Circuit Description
The Powertrain Control Module (PCM) uses the generator turn on signal circuit to control the generator. A high side driver within the PCM
allows the PCM to turn the generator ON and OFF. When Generator operation is desired, the PCM sends a 5 volt signal to the voltage
regulator via the generator turn on signal circuit. This causes the voltage regulator to begin controlling the generator field circuit. Once the
Generator is enabled by the PCM, the voltage regulator controls generator output independently of the PCM. Under certain operating
conditions, the PCM can turn Off the generator by turning Off the 5 volt signal on the generator turn on signal circuit. The PCM has fault
detection circuitry which monitors the state of the generator turn on signal circuit. If the fault detection circuit senses a voltage other than
what is expected, this DTC will set. The voltage regulator also contains fault detection circuitry. If the regulator detects a problem, the
regulator will ground the generator turn on signal circuit, pulling the voltage low. This also causes the PCM to set the DTC.
The PCM receives generator output feedback via the generator field duty cycle signal circuit. The voltage regulator generates a Pulse
Width Modulated (PWM) signal on the field control circuit. The regulator varies the pulse width of this signal in order to control generator
output. This signal is also sent to the PCM via the generator field duty cycle signal circuit. The pulse width of the signal is proportional to
generator output. The PCM expects generator output to be within a predetermined range under certain operating conditions. If the PCM
detects that the PWM signal on the generator field duty cycle signal circuit is not within the expected range, this DTC will set.
When this DTC sets, the PCM sends a class 2 serial data message to the IPC illuminating the Charge indicator lamp.

Conditions For Running DTC

Engine is running

Conditions For Setting DTC

 • The generator turn on signal circuit voltage is low while the PCM is commanding the generator on.
• The above condition is present for more than 30 seconds.

Or
• The generator field duty cycle signal PWM is less than 5 percent.
• The engine RPM is less than 2500.
• The above conditions are present for more than 30 seconds.

Action Taken When DTC Sets

• The PCM stores the DTC information into memory when the diagnostic runs and fails.
• The malfunction indicator lamp (MIL) will not illuminate.
• The PCM records the operating conditions at the time the diagnostic fails. The PCM stores this information in the Failure Records.

Conditions For Clearing DTC

• A History DTC will clear after forty consecutive warm-up cycles, if no failures are reported by this or any other non-emission related
diagnostic.
• The current DTC will clear when the diagnostic runs and does not fail.
• Use a scan tool in order to clear the MIL diagnostic trouble code.

Diagnostic Procedure

1. If diagnostic system check was performed, go to next step. If diagnostic system check was not performed, go to ENGINE
ELECTRICAL DIAGNOSTIC SYSTEM CHECK under ON-VEHICLE TESTING.
2. Connect scan tool to Data Link Connector (DLC). See COMPONENT LOCATIONS . Start engine. Using scan tool, observe GEN F-
Terminal parameter in PCM data list. If GEN F-Terminal parameter is within 5-95 percent, go to next step. If GEN F-Terminal
parameter is not within 5-95 percent, go to step .
3. Using scan tool, command generator Off. If GEN F-Terminal is not 0 percent, go to next step. If GEN F-Terminal is 0 percent,
problem may be intermittent. Check wiring and connections, see PRELIMINARY INSPECTION under TROUBLE SHOOTING.
4. Turn ignition switch to OFF position. Disconnect generator 4-pin harness connector. Start engine. Using DVOM measure voltage
between ground and generator turn-on signal circuit, generator harness connector terminal "B" (Red wire). Using scan tool,
command generator On and Off. With generator off voltage reading should be 0 volts. With generator On, voltage reading should be
5 volts. If voltage reading is as specified, go to next step. If voltage reading is not as specified, go to step .
5. Turn ignition switch to RUN position. Using test light connect to battery voltage, repeatedly probe generator field duty cycle signal
circuit, generator harness connector terminal "C" (Gray wire), while observing GENERATOR PWM on scan tool. If GENERATOR
PWM display is affected, go to step . If not, go to step .
6. Test generator turn-on signal circuit, generator harness connector terminal "B" (Red wire), for a short or an open. If problem exists,
repair circuit as necessary and go to step . If no problem exists, go to step .
7. Test generator field duty cycle signal circuit, generator harness connector terminal "C" (Gray wire), for a short or an open. If problem
exists, repair circuit as necessary and go to step . If no problem exists, go to step .
8. Inspect generator harness connector for poor connections. If problem exists, repair circuit as necessary and go to step . If no
problem exists, go to TEST A: CHARGING SYSTEM TEST under SYSTEM TESTS.
9. Inspect PCM harness connector for poor connections. If no problem exists, go to next step. If problem exists, repair circuit as
necessary and go to step .
10. Replace PCM. After replacement, reprogram PCM. See REMOVAL, OVERHAUL & INSTALLATION article in ENGINE
PERFORMANCE. After repair, go to next step.
11. Review and record scan tool Fail Records data. Using scan tool, clear DTCs. Operate vehicle within Fail Records conditions as
noted. Using scan tool, observe Specific DTC information for DTC P0620. If scan tool indicates DTC P0620 failed this ignition, go to
step . If scan tool indicates DTC P0620 passed this ignition, system is okay.

SYSTEM TESTS

SYMPTOM INDEX

Symptom 1 Perform Test

 Symptom 1 Perform Test

Charging System Test A

Charge Indicator Always On B

Charge Indicator Inoperative C

Generator Noisy D

1 If symptom is related to a no start or slow engine cranking condition, see appropriate STARTERS article in ELECTRICAL.

TEST A: CHARGING SYSTEM TEST

1. If diagnostic system check was not performed, go to ENGINE ELECTRICAL DIAGNOSTIC SYSTEM CHECK under ON-VEHICLE
TESTING. If diagnostic system check was performed, go to next step.
2. Start engine and observe charge indicator on Instrument Panel Cluster (IPC), or charge message in Driver Information Center
(DIC). If charge indicator light illuminates, or DIC displays a charging system message, go to next step. If charge indicator light does
not illuminate or no message is present, problem is intermittent. Check wiring and connections.

NOTE: Green POWER light on tester should remain illuminated while tester is being used.

3. Turn ignition switch to LOCK position. Using CS Electronic Generator Tester (J-41450-B), connect Red lead to generator output
terminal and Black lead to metal generator housing. If Green POWER light illuminates, go to step . If Green POWER light does not
illuminate, go to next step.
4. Measure voltage between output terminal of generator and generator housing. If battery voltage is present, go to step . If battery
voltage is not present, go to next step.
5. Measure voltage from generator output terminal to negative battery terminal. If battery voltage is present, go to step . If battery
voltage is not present, go to step .

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 Electronic Generator Tester and connect it to generator. If Red DIAGNOSTIC
light on tester illuminates, go to next step. If Red DIAGNOSTIC light does not illuminate, go to step .
7. Start engine and allow to idle for 30 seconds. 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 .
8. Maintain engine speed at 2500 RPM. Turn on load of carbon pile tester and increase load until generator output is greater than or
equal to generator load test value. See GENERATOR SPECIFICATIONS . If Red DIAGNOSTIC light illuminates, go to step . If Red
DIAGNOSTIC light does not illuminate, go to next step.
9. Maintain engine speed at 2500 RPM and continue to operate generator at test load value. Measure voltage drop between generator
output terminal and positive battery terminal. If voltage drop is greater than 0.5 volt, go to step . If voltage drop is less than 0.5 volt,
go to next step.
10. Maintain engine speed at 2500 RPM and continue to operate generator at test load value. Measure voltage drop between generator
metal housing and negative battery terminal. If voltage drop is greater than 0.5 volt, go to step . If voltage drop is less than 0.5 volt,
go to step .
11. Repair high resistance or open in generator output circuit between generator output terminal and positive battery terminal. See
WIRING DIAGRAMS . Repair circuit as necessary, then go to step .
12. Repair high resistance or open in ground circuit of generator. See WIRING DIAGRAMS . Repair circuit as necessary, then go to
step .
13. Disconnect generator harness connector from generator, but leave alligator clips connected so Green POWER light remains on.
Connect a jumper wire with an in-line 100 ohm resister between harness connector terminal "B" and a good ground. See Fig. 1 . If
Red DIAGNOSTIC light illuminates, go to step . If Red DIAGNOSTIC light does not illuminate, go to next step.
14. There is a problem with CS Electronic Generator Tester (J-41450-B). Refer to manufacturers instructions, how to test J-41450-B for
proper operation. If tester has been repaired or replaced, go to step .
15. Replace generator. See GENERATOR under REMOVAL & INSTALLATION. Once replacement is complete, go to next step.
 16. Retest system to verify repair. If condition was corrected, system is okay. If condition was not corrected, go to step .

Fig. 1: Identifying Generator Harness Connector Terminals

TEST B: CHARGE INDICATOR ALWAYS ON

1. If diagnostic system check was not performed, go to ENGINE ELECTRICAL DIAGNOSTIC SYSTEM CHECK under ON-VEHICLE
TESTING. If diagnostic system check was performed, go to next step.
2. Start engine. If battery charge indicator remains illuminated after 5 second bulb check, go to next step. If battery charge indicator
does not remain illuminated after 5 second bulb check, problem is intermittent. Check wiring and connections.
3. Connect scan tool to Data Link Connector (DLC). DLC is located under instrument panel, near steering column. Use scan tool to
observe Ignition 0 parameter in PCM data list. If voltage measures 10-15 volts, go to next step. If voltage does not measure 10-15
volts, go to TEST A: CHARGING SYSTEM TEST .
4. Replace IPC. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. Go to next step.
5. Operate system to verify repair. If condition was corrected, system is okay. If condition was not repaired, go to step .

TEST C: CHARGE INDICATOR INOPERATIVE

1. If diagnostic system check was not performed, go to ENGINE ELECTRICAL DIAGNOSTIC SYSTEM CHECK under ON-VEHICLE
TESTING. If diagnostic system check was performed, go to next step.
2. Turn ignition switch to RUN position. If battery charge indicator illuminates during 5 second bulb check, problem is intermittent.
Check wiring and connections. If battery charge indicator does not illuminate during 5 second bulb check, go to next step.
3. Replace Instrument Panel Cluster (IPC). See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. Go to
next step.
4. Operate system to verify repair. If condition was corrected, system is okay. If condition was not repaired, go to step .
TEST D: GENERATOR NOISY
1. Test generator for proper operation. See TEST A: CHARGING SYSTEM TEST . If generator is operating properly, go to next step. If
generator is not operating properly, go to step .
2. Start engine. Verify that generator noise can be heard. Turn engine off. Disconnect 4-pin connector from generator. Start engine.
Listen for generator noise. If noise has stopped, go to step . If noise is still present, go to next step.
3. Turn engine off. Remove drive belt. Spin generator pulley by hand. If pulley rotates smoothly and no noise is present, go to next
step. If pulley rotates roughly and/or noise is present, go to step .
4. Inspect pulley for looseness, or loose pulley nut. If pulley and nut are okay, go to next step. If pulley and/or nut is loose, go to step .
5. Loosen all generator mounting bolts. Tighten generator mounting bolts to specification. See TORQUE SPECIFICATIONS . Install
drive belt. Start engine and listen for noise. If noise has decreased or stopped, system is okay. If noise is still present, go to next
step.
6. Check for stretched generator connections, or hoses or other equipment rubbing on generator. Go to next step.
7. Reroute electrical connections, hoses, etc., away from generator. Start engine and listen for noises. If noise has decreased or
stopped, system is okay. If noise is still present, go to next step.
8. Check drive belt for proper tension. If drive belt is loose, go to next step. If drive belt is okay, go to step .
9. Replace drive belt tensioner. See appropriate ENGINE article in ENGINES. Start engine and listen for noise. If noise has decreased
or stopped, system is okay. If noise is still present, go to step .
10. Check comparable vehicle for similar noise. If noise is present in similar vehicle, system is okay. If noise not present in similar
vehicle, go to next step.
11. If no definite generator problems were found, ensure all other possible sources of noise are eliminated. If all possibilities have been
eliminated, replace generator. See GENERATOR under REMOVAL & INSTALLATION. Go to next step.
12. Start engine and verify that noise is reduced or eliminated. If noise is still objectionable, go to step .

ON-VEHICLE TESTING

WARNING: Vehicles are equipped with air bag supplemental restraint system. Before attempting any repairs involving steering
column, instrument panel or related components, see DISABLING & ACTIVATING AIR BAG SYSTEM in AIR BAG
RESTRAINT SYSTEMS article in RESTRAINTS.

CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may
exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in
GENERAL INFORMATION before disconnecting battery.

NOTE: Before making electrical checks, visually inspect all terminals for clean, tight connections. Ensure all charging system
related fuses and fusible links are okay. Check generator mounting bolts and drive belt tension. Ensure battery is fully
charged and in good condition prior to testing charging system. Ensure starter is okay. See appropriate STARTERS article
in ELECTRICAL.

NOTE: Manufacturer recommends using CS Electronic Generator Tester (J-41450-B) to test charging system. Follow instructions
provided with tester.

BATTERY TESTING & INSPECTION

NOTE: Manufacturer recommends using Battery Tester (J-42000) for testing battery. Follow instructions provided with tester.

1. Inspect battery for a cracked, broken or damaged case. If battery case is okay, go to next step. If battery case is not okay, go to step
.
2. Compare battery Cold Cranking Amperage (CCA) and Reserve Capacity (RC) rating to Original Equipment (OE) specifications. See
BATTERY SPECIFICATIONS table. If battery meets or exceeds OE specifications, go to next step. If battery does not meet or
exceed OE specifications, go to step .
3. Inspect battery hydrometer display. If hydrometer display shows a Yellow dot, go to next step. If hydrometer display does not show a
Yellow dot, go to step .
 4. Using a small screwdriver, tap top of hydrometer display to dislodge any air bubbles inside. If hydrometer display does not show a
Yellow dot, go to next step. If hydrometer display still shows a Yellow dot, go to step .
5. Turn ignition switch to LOCK position. Attempt to rotate negative battery cable clockwise with light finger pressure. If negative
battery cable rotates, go to next step. If negative battery cable does not rotate, go to step .
6. Using an INCH-lb. torque wrench, record torque value while loosening negative battery cable bolt. If torque is less than 89 INCH lbs.
(10 N.m), go to next step. If torque is more than 89 INCH lbs. (10 N.m), go to step .
7. Disconnect negative battery cable and go to step .
8. Disconnect negative battery cable. Inspect battery and cable terminals for corrosion and defects. Repair as necessary then, go to
next step.
9. Attempt to rotate positive battery cable clockwise with light finger pressure. If battery cable rotates, go to next step. If battery cable
does not rotate, go to step .
10. Using an INCH-lb. torque wrench, record torque value while loosening positive battery cable bolt. If torque is less than 89 INCH lbs.
(10 N.m), go to next step. If torque is more than 89 INCH lbs. (10 N.m), go to step .
11. Disconnect positive battery cable and go to step .
12. Disconnect positive battery cable. Inspect battery and cable terminals for corrosion and defects. Repair as necessary then, go to
next step.
13. Clean and wire brush lead face of both battery terminals and metal contact surfaces on both cable ends. Remove bolts from both
battery cables and inspect for corrosion and defects. Repair or replace as necessary. If battery and cables terminals are clean and
in good condition, go to next step.
14. Connect positive battery cable to battery and tighten bolt to 11 ft. lbs. (15 N.m). Go to next step.
15. Connect negative battery cable to battery and tighten bolt to 11 ft. lbs. (15 N.m). Go to next step.
16. Ensure all electrical loads are off. Follow manufacturers instructions and connect Battery Tester (J-42000) to vehicle battery. Follow
instructions displayed on battery tester. If battery tester passed battery, go to next step. If battery tester did not pass battery, go to
step .
17. Press CODE button on battery tester. Record displayed code on vehicle repair order for warranty purposes. battery is okay.
18. Press CODE button on battery tester. Record displayed code on vehicle repair order for warranty purposes. Replace battery.
19. Replace battery.

BATTERY SPECIFICATIONS

BATTERY SPECIFICATIONS

Application Specification

Replacement Battery Number 75-6YR

Cold Cranking Amps 600 Amps

Reserve Capacity Rating 90 Minutes

ENGINE ELECTRICAL DIAGNOSTIC SYSTEM CHECK

Test Description
The numbers below refer to the step numbers on the diagnostic procedure.
• 3 - Lack of communication may be because of a partial malfunction of the class 2 serial data circuit or due to a total malfunction of
the class 2 serial data circuit. The specified procedure will determine the particular condition.
• 4 - The symptom list in Symptoms will determine the correct diagnostic procedure to use. See SYMPTOM INDEX .
• 5 - The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will
collect all the available information before you perform tests.

Diagnostic Procedure

1. Perform battery test and inspection. See BATTERY TESTING & INSPECTION under ON-VEHICLE TESTING. If battery passed
test, go to next step. If battery did not pass test, replace battery.
2. Connect scan tool to Data Link Connector (DLC). Turn ignition switch to RUN position. If scan tool powers up, go to next step. If
scan tool does not power up, diagnose communication system. See appropriate BODY CONTROL MODULES article in
 ACCESSORIES & EQUIPMENT.
3. Turn ON the ignition, with the engine OFF. Attempt to communicate with the Powertrain Control Module (PCM). If scan tool
communicates with PCM on the class 2 serial data circuit, go to next step. If scan tool does not communicate with modules,
diagnose communication system. See appropriate BODY CONTROL MODULES article in ACCESSORIES & EQUIPMENT.
4. Select DISPLAY DTCS function for the Powertrain Control Module (PCM). Record all DTCs displayed and DTC status. If scan tool
displayed DTCs, go to next step. If scan tool does not display DTCs, diagnose charging system by symptom. See SYMPTOM
INDEX table under SYSTEM TESTS.
5. If scan tool does not display DTCs that begin with "U", perform appropriate test in accordance with DTCs retrieved. See
DIAGNOSTIC TROUBLE CODE DEFINITIONS tables. If scan tool displays DTCs that begin with "U", diagnose communication
system. See appropriate BODY CONTROL MODULES article in ACCESSORIES & EQUIPMENT.

BENCH TESTING

NOTE: Bench testing procedures are not available from manufacturer.

REMOVAL & INSTALLATION

WARNING: Vehicles are equipped with air bag supplemental restraint system. Before attempting any repairs involving steering
column, instrument panel or related components, see DISABLING & ACTIVATING AIR BAG SYSTEM in AIR BAG
RESTRAINT SYSTEMS article in RESTRAINTS.

CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may
exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in
GENERAL INFORMATION before disconnecting battery.

NOTE: Use correct fastener in correct location. Replacement fasteners must be correct part number for that application.
Fasteners requiring replacement or fasteners requiring use of thread locking compound or sealant are identified in service
procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage fastener. Use correct tightening
sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

GENERATOR

NOTE: Generator does not require periodic lubrication. The rotor shaft is mounted on bearings. Each bearing contains a
permanent grease supply. Periodically check mounting bolts for tightness, and drive belt tension. The drive belt is self-
adjusting, within operating limits of tensioner. CS-130D generator is serviced as a complete unit.

Removal

1. Disconnect negative battery cable.

2. Remove drive belt from generator.
3. Place coolant recovery reservoir aside for access.
4. Remove bolts (1, 2, 3) from generator. See Fig. 2 .
5. Disconnect electrical connector from generator.
6. Remove protective boot from generator output BAT terminal.
7. Remove generator output BAT terminal nut and remove positive battery lead from generator.
8. Remove generator.

Fig. 2: Removing Generator (3.1L)

Installation

1. Position generator to engine.

2. Install positive battery lead to generator.
3. Install generator output BAT terminal nut. Tighten generator output BAT terminal nut to 15 ft. lbs. (20 N.m).
4. Install protective boot to generator output BAT terminal.
5. Connect electrical connector to generator.

NOTE: Do not tighten bolts.

6. Install generator bolts (2, 3) to generator. See Fig. 2 .

NOTE: Do not tighten bolt.

7. Install generator pivot bolt (1) to generator.

8. Tighten generator bolts in order described. See TORQUE SPECIFICATIONS . The following is a mandatory torque sequence:
• Tighten generator pivot bolt (1).
• Tighten generator bolt (2).
• Tighten generator bolt (3).

9. Install coolant recovery reservoir.

10. Install drive belt.
11. Connect negative battery cable.
OVERHAUL

NOTE: All generators are serviced by replacement only.

GENERATOR SPECIFICATIONS

GENERATOR SERVICE SPECIFICATIONS

Application Specification

Generator Model CS130D

Rated Output 105 Amps

Load Test Output 73 Amps

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application Ft. Lbs. (N.m)

Battery Hold Down Retainer Bolt 13 (18)

Battery Negative Cable Bolt 11 (15)

Battery Positive Cable Bolt 11 (15)

Generator Bolt 37 (50)

Generator Nut 22 (30)

Starter Motor Bolt 37 (50)

INCH Lbs. (N.m)

Cable to Solenoid Nut 106 (12)

WIRING DIAGRAMS
For system wiring diagrams, see SYSTEM WIRING DIAGRAMS .

Created/Modified Date: 8/24/2009 1:22:27 AM