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DTC P2503: Charging System Output Low: Testing

WARNING: This page is about a different car, the 2003 Dodge Dakota. However, it is still accessible from the selected car via links, so may be relevant.
  1. Inspect the vehicle for aftermarket accessories that may exceed the generator system output. Ignition on, engine not running. The battery must be fully charged. The generator belt tension and condition must be checked before continuing. With the DRBIII® scan tool, read the DTCs and record the related freeze frame data. Is the Good Trip Counter displayed and equal to zero. If yes, go to next step. If no, see INTERMITTENT CONDITION  under SELF-DIAGNOSTIC SYSTEM.
    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.
  2. Ignition on, engine not running. Ensure all wires are clear of the engines moving parts. Start the engine. Measure the voltage between the generator B+ terminal and the battery positive post. Is the voltage above 0.4 of a volt? If yes, repair the battery positive circuit for high resistance between the generator and battery. If no, go to next step.
    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.
  3. Start the engine. Warm the engine to operating temperature. Ensure all wires are clear of the engines moving parts. Measure the voltage between the generator case and battery ground post. Is the voltage above 0.1 of a volt? If yes, repair generator ground for high resistance, generator case to battery ground side. If no, go to next step.
  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® scan tool, actuate the generator field control circuit. Does the test light illuminate brightly and flash on and off? If yes, replace the generator. If no, go to next step.
  5. Turn the ignition off. Using a 12-volt test connected to battery voltage, probe the (Z13) generator field ground circuit in the generator field harness connector. Does the test light illuminate brightly? If yes, go to next step. If no, repair the open in the (Z13) generator field ground circuit.
  6. Disconnect the PCM harness connectors. Ignition on, engine not running. Measure the voltage on the (K20) generator field control circuit at the generator field harness connector. Is the voltage above 1.0 volt? If yes, repair the short to voltage in the (K20) generator field control circuit. If no, go to next step.
    7. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install Miller Special Tool (8815) to perform diagnosis.
  7. Turn the ignition off. Measure the resistance of the (K20) generator field control circuit from the generator field harness connector to the appropriate terminal of the Miller Special Tool (8815). Is the resistance below 5.0 ohms? If yes, go to next step. If no, repair the open in the (K20) generator field control circuit.
  8. Measure the resistance between ground and the (K20) generator field control circuit in the generator field harness connector. Is the resistance below 100 ohms? If yes, repair the (K20) generator field control circuit for a short to ground. If no, go to next step.
    9. NOTE: Before continuing, disconnect the PCM harness connectors and check the related wiring terminals for corrosion, damage or terminal push out. Repair as necessary.
  9. Using the wiring diagram as a guide, inspect the wire harness and connectors. Visually inspect the related wire harness. Look for any chafed, pierced, pinched, or partially broken wires. Visually inspect both the component and the PCM connectors. Pay particular attention to all power and ground circuits. If there are no possible causes remaining, replace and program the PCM. See PROGRAMMING .
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