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Home >> Chrysler >> 2011 >> 300 C, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1575 (6.7L Diesel - DTCS P24A2 To U3017 - 2500 Hd) >> DTC Troubleshooting >> P2504-Charging System Output High >> Diagnostic Test

Diagnostic Test

WARNING: This page is about a different car, the 2017 RAM 2500 HD. However, it is still accessible from the selected car via links, so may be relevant.
  1. CHECK FOR AN ACTIVE DTC 
    NOTE:

    Batteries must be fully charged and capable of passing a battery load test. The generator belt tension must be within specification. Inspect the vehicle for any aftermarket equipment that may exceed the maximum Generator output.

    1. Turn the ignition on.
    2. With the scan tool, erase DTCs.
    3. Turn the ignition off for 75 seconds.
    4. Start the engine and let idle for up to five minutes.
    5. With the scan tool, read DTCs.

      Did the DTC return as Active or Pending?

      Yes 

      • Go To  2

      No 

  2. INSPECT THE BATTERY TERMINALS FOR DIRTY OR LOOSE CONNECTIONS 
    NOTE:

    In a dual Battery system, this visual inspection will have to be performed on both Batteries.

    NOTE:

    In a dual Battery system, the left side Battery is sometimes referred to as the 'Primary' Battery and the right side Battery is sometimes referred to as the 'Auxiliary' Battery. The two Batteries are actually routed in series. So, technically, there is no 'Primary' or 'Auxiliary'. For location clarification, please Refer to BATTERY, DESCRIPTION .

    1. Visually inspect the positive and negative connections at the Battery.
    2. Visually inspect the Battery negative connections at the engine block.

      Are the connections tight and free of corrosion?

      Yes 

      • Go To  3

      No 

      • Clean and/or tighten the connections as needed. Then, perform the environmental conditions shown in Set Conditions to duplicate this DTC. If the DTC does not return, perform the Powertrain Verification Test. If the DTC returns, Go To  3
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  3. CHECK FOR ADD-ON OR ACCESSORY WIRES AT THE BATTERY TERMINAL 
    NOTE:

    In a dual Battery system, this visual inspection will have to be performed on both Batteries.

    NOTE:

    In a dual Battery system, the left side Battery is sometimes referred to as the 'Primary' Battery and the right side Battery is sometimes referred to as the 'Auxiliary' Battery. The two Batteries are actually routed in series. So, technically, there is no 'Primary' or 'Auxiliary'. For location clarification, please refer to the image in BATTERY, DESCRIPTION

    1. Check for add-on or accessory wiring at B+ Battery post.

      Are there any add-on or accessory wires at the Battery?

      Yes 

      • Remove defective or incorrectly routed add-on or accessory wiring from Battery. Then, perform the environmental conditions shown in Set Conditions to duplicate this DTC. If the DTC does not return, perform the Powertrain Verification Test. If the DTC returns, Go To  4
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

      No 

      • Go To  4
  4. CHECK THE CONDITION OF THE BATTERY(S) 
    NOTE:

    In a dual Battery system, the left side Battery is sometimes referred to as the 'Primary' Battery and the right side Battery is sometimes referred to as the 'Auxiliary' Battery. The two Batteries are actually routed in series. So, technically, there is no 'Primary' or 'Auxiliary'. For location clarification, please refer to the image in BATTERY, DESCRIPTION . In a dual Battery system, the Battery load test will have to be performed twice (once for each Battery). Inspect the vehicle for aftermarket accessories that may exceed the Alternator System output. This DTC does not necessarily indicate an overcharging condition. It merely indicates that the Alternator Sense signal is greater than the Alternator output supplied to the Battery and PDC.

    1. Use the (special tool #GR8-1220KIT-CHRY, AGM Battery Tester/Charger Station) or equivalent to load test the Battery.

      Did the Battery pass or fail?

      Passed 

      • Go To  5

      Failed 

      • Perform the appropriate repair according to the Battery tester.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  5. CHECK THE (A801) GENERATOR B+ CIRCUIT FOR AN OPEN/HIGH RESISTANCE 
    NOTE:

    The Generator B+ circuit will usually have a Maxi-fuse mounted in-line and located near the Battery.

    NOTE:

    In a dual Battery system, the left side Battery is sometimes referred to as the 'Primary' Battery and the right side Battery is sometimes referred to as the 'Auxiliary' Battery. The two Batteries are actually routed in series. So, technically, there is no 'Primary' or 'Auxiliary'. For location clarification, please refer to the image in BATTERY, DESCRIPTION .

    1. Perform a voltage drop test along the (A801) Generator B+ circuit from the Generator to the right side Battery. Measure the voltage between the B+ post of the generator and the B+ post of the right side battery while the engine is running.

      Is the voltage above 0.4 Volts?

      Yes 

      • Repair the (A801) Generator B+ circuit for an open or high resistance.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

      No 

      • Go To  6
  6. CHECK THE (A1) BATTERY B+ CROSSOVER CABLE FOR AN OPEN/HIGH RESISTANCE 
    NOTE:

    In a dual Battery system, the left side Battery is sometimes referred to as the 'Primary' Battery and the right side Battery is sometimes referred to as the 'Auxiliary' Battery. The two Batteries are actually routed in series. So, technically, there is no 'Primary' or 'Auxiliary'. For location clarification, please refer to the image in BATTERY, DESCRIPTION . .

    1. Perform a voltage drop test along the (A1) Battery B+ Crossover Cable. Measure the voltage between the B+ post of the right side Battery and the B+ post of the left side Battery while the engine is running.

      Is the voltage above 0.4 Volts?

      Yes 

      • Repair the (A1) Battery B+ cross over cable for an open or high resistance.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to .

      No 

      • Go To  7
  7. CHECK THE GENERATOR GROUND FOR AN OPEN/HIGH RESISTANCE 
    NOTE:

    In a dual Battery system, the left side Battery is sometimes referred to as the 'Primary' Battery and the right side Battery is sometimes referred to as the 'Auxiliary' Battery. The two Batteries are actually routed in series. So, technically, there is no 'Primary' or 'Auxiliary'. For location clarification, please refer to the image BATTERY, DESCRIPTION .

    1. Perform a voltage drop test along the Generator Ground circuit from the Generator to the right side Battery. Measure the voltage between the Generator case and the B- post of the right side Battery.

      Is the voltage above 0.2 Volts?

      Yes 

      • Repair the Generator Ground circuit for an open or high resistance.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

      No 

      • Go To  8
  8. CHECK THE GENERATOR FOR PROPER OPERATION 
    1. Turn the ignition off.
    2. Disconnect the Generator field harness connector.
      NOTE:

      Check connectors - Clean/repair as necessary.

    3. Measure the resistance between the generator field terminals at the Generator.

      Is the resistance between 0.5 and 15.0 Ohms?

      Yes 

      • Go To  9

      No 

      • Replace the Generator in accordance with the Service Information.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  9. CHECK RELATED HARNESS CONNECTIONS 
    1. Disconnect all PCM harness connectors.
    2. Disconnect all related in-line harness connections (if equipped).
    3. Disconnect the related component harness connectors.
    4. Inspect harness connectors, component connectors, and all male and female terminals for the following conditions:
      • Proper connector installation.
      • Damaged connector locks.
      • Corrosion.
      • Other signs of water intrusion.
      • Weather seal damage (if equipped).
      • Bent terminals.
      • Overheating due to a poor connection (terminal may be discolored due to excessive current draw).
      • Terminals that have been pushed back into the connector cavity.
      • Check for spread terminals and verify proper terminal tension.

      Repair any conditions that are found.

    5. Connect all PCM harness connectors. Be certain that all harness connectors are fully seated and the connector locks are fully engaged.
    6. Connect all in-line harness connectors (if equipped). Be certain that all connectors are fully seated and the connector locks are fully engaged.
    7. Connect all related component harness connectors. Be certain that all connectors are fully seated and the connector locks are fully engaged.
    8. With the scan tool, erase DTCs.
    9. Test drive or operate the vehicle in accordance with the when monitored and set conditions.
    10. With the scan tool, read DTCs.

      Did the DTC return?

      Yes 

      No 

      • The wiring or poor connection problem has been repaired.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
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