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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.
    NOTE: Inspect the vehicle for aftermarket accessories that may exceed the generator system output.
  1. Turn the 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®, read the DTC's and record the related freeze frame data. If the good trip counter is displayed and equal to zero, see INTERMITTENT CONDITION (NGC)  under SYSTEM TESTS. Perform POWERTRAIN VERIFICATION TEST VER-3 (NGC)  under VERIFICATION TESTS. If the good trip counter is not displayed or equal to zero, go to next step.
    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.
    NOTE: Ensure all wires are clear of the engine's moving parts.
  2. Start the engine. Warm the engine to operating temperature. Measure the voltage between the generator B+ output terminal and the battery positive post. If the voltage is above .4 volt, repair the high resistance in the battery positive circuit between the generator and battery. Perform POWERTRAIN VERIFICATION TEST VER-3 (NGC)  under VERIFICATION TESTS. If the voltage is not above .4 volt, 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.
    NOTE: Ensure all wires are clear of the engine's moving parts.
  3. Measure the voltage between the generator case and battery ground post. If the voltage is above .1 volt, repair high resistance in the generator case ground. Perform POWERTRAIN VERIFICATION TEST VER-3 (NGC)  under VERIFICATION TESTS. If the voltage is not above .1 volt, go to next step.
  4. Turn the ignition off. Disconnect the generator field harness connector. Using a 12-volt test light, jump it across the generator field harness connector. Turn the ignition on, engine not running. With the DRBIII®, actuate the generator field driver circuit. If the test light illuminates brightly and flashes on and off, replace the generator. Perform POWERTRAIN VERIFICATION TEST VER-3 (NGC)  under VERIFICATION TESTS. If the light does not illuminate or flash on and off, go to next step.
  5. Turn the ignition off. Using a 12-volt test connected to battery voltage, probe the (Z13) generator ground circuit in the generator field harness connector. If the test light illuminates, go to next step. If the test light does not illuminate, repair the open in the (Z13) generator ground circuit. Perform POWERTRAIN VERIFICATION TEST VER-3 (NGC)  under VERIFICATION TESTS.
  6. Disconnect the PCM harness connectors. Turn ignition on, engine not running. Measure the voltage on the (K20) gen field control circuit at the generator field harness connector. If the voltage is above one volt, repair the short to voltage in the (K20) gen field control circuit. Perform POWERTRAIN VERIFICATION TEST VER-3 (NGC)  under VERIFICATION TESTS. If the voltage is not above one volt, 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) gen field control from the generator field harness connector to the appropriate terminal of the Miller Special Tool (8815). If the resistance is below 5 ohms, go to next step. If the resistance is not below 5 ohms, repair the short to ground in the (K20) gen field control circuit. Perform POWERTRAIN VERIFICATION TEST VER-3 (NGC)  under VERIFICATION TESTS.
  8. Measure the resistance between ground and the (K20) gen field control circuit in the generator field harness connector. If the resistance is below 100 ohms, repair the short to ground in the (K20) gen field control circuit. Perform POWERTRAIN VERIFICATION TEST VER-3 (NGC)  under VERIFICATION TESTS. If the resistance is not below 100 ohms, go to next step.
    9. NOTE: Before continuing, check the PCM harness connector terminals for corrosion, damage, or pushed out terminals. Repair as necessary.
  9. Using the schematics as a guide, inspect the wire harness and connectors. Pay particular attention to all power and ground circuits. If there are no possible causes remaining, replace and program the PCM. See PROGRAMMING . Perform POWERTRAIN VERIFICATION TEST VER-3  under VERIFICATION TESTS.
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