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Test D: Charge Warning Lamp System

NOTE: Do NOT start this test unless directed by a symptom diagnosis in CHARGING SYSTEM GAUGE/WARNING LAMP  under TROUBLE SHOOTING.
  1. Check the 10A Meter fuse located in the interior fuse panel. Is the fuse OK? If yes, go to step  4 . If no, go to next step.
  2. Turn key to OFF position. Replace the 10A Meter fuse. Turn key to ON position. Inspect the fuse. Does the fuse fail again? If yes, go to next step. If no, go to step  4 .
  3. Turn key to OFF position. Remove the 10A Meter fuse. Remove the instrument cluster. See ELECTRONIC INSTRUMENT CLUSTER  under REMOVAL & INSTALLATION. Locate and disconnect the 20-pin instrument cluster connector. Measure the resistance of the Gray/Blue wire between the right terminal of the 10A Meter fuse and ground. Is the resistance less than 5 ohms? If yes, service the Gray/Blue wire between the interior fuse panel and the instrument cluster. If no, replace fuse and go to next step.
  4. Turn key to OFF position. Disconnect the 20-pin instrument cluster connector. Turn key to ON position. Measure the voltage on terminal "M" Gray/Blue wire at the 20-pin instrument cluster connector. See CONNECTOR IDENTIFICATION  . Is the voltage greater than 10 volts? If yes, go to next step. If no, service the Gray/Blue wire between the interior fuse panel and the instrument cluster.
  5. Turn key to OFF position. Disconnect the 20-pin instrument cluster connector. Connect a test lamp between the Gray/Blue and Yellow/Blue wires of the 20-pin instrument cluster connector. Turn key to ON position. Does the test lamp illuminate? If yes, go to next step. If no, go to step  7 .
  6. Turn key to OFF position. Remove the charge warning lamp bulb. Measure the resistance between the terminals of the charge warning lamp bulb. Is the resistance approximately 6 ohms? If yes, replace the instrument cluster. See ELECTRONIC INSTRUMENT CLUSTER  under REMOVAL & INSTALLATION. If no, replace the charge warning lamp bulb.
  7. Turn key to OFF position. Disconnect the 20-pin instrument cluster connector. Disconnect the top Black diode strip at the diode junction box located behind the instrument cluster. Measure the resistance of the Yellow/Blue wire between the 20-pin instrument cluster connector and terminal No. 2 of the diode junction box connector. See Figure . Measure the resistance of the Yellow/Blue wire between the 20-pin instrument cluster connector and ground. Is the resistance less than 5 ohms between the instrument cluster connector and the diode junction box connector, and greater than 10,000 ohms between the instrument cluster connector and ground? If yes, go to next step. If no, service the Yellow/Blue wire.
  8. Turn key to OFF position. Reconnect the top Black diode strip at the diode junction box. Reconnect the 20-pin instrument cluster connector. Disconnect the generator/voltage regulator connector located on the generator. Ground the Yellow/Black wire at the generator/voltage regulator connector. Turn key to ON position. Does the charge warning lamp illuminate? If yes, check the generator/voltage regulator. If no, go to next step.
  9. Turn key to OFF position. Disconnect the top Black diode strip at the diode junction box. Disconnect the generator/voltage regulator connector. Measure the resistance of the Yellow/Black wire terminal No. 5 of the diode junction box connector and the generator/voltage regulator connector. Measure the resistance of the Yellow/Black wire between terminal No. 5 of the diode junction box connector and ground. Is the resistance less than 5 ohms between the diode junction box connector and the generator/voltage regulator connector, and greater than 10,000 ohms between the diode junction box connector and ground? If yes, replace the top Black diode strip at the diode junction box connector. If no, service the Yellow/Black wire.
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