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Home >> Chevrolet >> 1998 >> Astro Van Cargo, AWD >> Repair and Diagnosis >> Electrical >> Charging Systems >> On-Vehicle Testing >> Complete System Check

Complete System Check

  1. Turn ignition off. Check battery voltage. If voltage is more than 12 volts, go to step 4). If voltage is 12 volts or less, go to next step.
  2. Charge and load test battery. Replace as needed. Go to next step.
  3. Check for parasitic load. Repair as needed. Go to next step.
  4. Turn ignition on. If charge indicator light illuminates, go to next step. If charge indicator light does not illuminate, go to step 34).
  5. Start engine. Turn off all accessories. If charge indicator light goes off and stay off, go to step 8). If charge indicator light does not go off and stay off, go to next step.
  6. Check voltage at generator BATT terminal. If battery voltage exists, go to step 20). If battery voltage does not exist, go to next step.
  7. Repair open circuit between generator and starter solenoid. See WIRING DIAGRAMS  . Recheck system.
  8. Raise engine speed to 2500 RPM. Check voltage at battery terminals. If voltage is more than 16 volts, go to next step. If voltage is 16 volts or less, go to step 10).
  9. Replace generator. See GENERATOR  under REMOVAL & INSTALLATION. Recheck system.
  10. If voltage checked in step 8) is less than 13 volts, go to next step. If voltage is 13 volts or more, go to step 14).
  11. Check voltage at generator BATT terminal. If battery voltage exists, go to next step. If battery voltage does not exist, go to step 13).
  12. Replace generator. See GENERATOR  under REMOVAL & INSTALLATION. Recheck system.
  13. Repair open in Red wire between starter solenoid and generator. Recheck system.
  14. Load test charging system with engine at 2500 RPM. If system produces 73 amps, go to step 16). If system does not produce 73 amps, go to next step.
  15. Replace generator. See GENERATOR  under REMOVAL & INSTALLATION. Recheck system.
  16. If voltage during load test is more than 13 volts, go to step 17). If voltage is 13 volts or less, go to step 21).
  17. During load test, check voltage drop between generator BATT terminal and battery positive terminal. If voltage drop is more than .5 volt, go to next step. If voltage drop is .5 volt or less, go to step 19).
  18. Turn ignition off. Remove load tester. Clean all circuit connections. Repair wiring as needed. Recheck system.
  19. During load test, check voltage drop between generator case (ground) and battery negative terminal. If voltage is more than .5 volt, go to next step. If voltage is .5 volt or less, system is okay.
  20. Turn ignition off. Remove load tester. Clean all circuit connections. Repair wiring as needed. Recheck system.
  21. During load test, check voltage between generator case (ground) and generator BATT terminal. If voltage is more than 13 volts, go to step 17). If voltage is 13 volts or less, go to next step.
  22. Replace generator. See GENERATOR  under REMOVAL & INSTALLATION. Recheck system.
  23. Disconnect generator 4-pin connector. Turn ignition on. Using fused jumper wire, connect harness connector terminal "B" (Brown wire) to ground. If charge indicator light illuminates, go to next step. If charge indicator light does not illuminate, go to step 27).
  24. Turn ignition off. Using ohmmeter, check resistance between engine block and battery negative terminal. If resistance is 5 ohms or less, go to step 26). If resistance is more than 5 ohms, go to next step.
  25. Repair open circuit between battery negative terminal and engine block. See WIRING DIAGRAMS  . Retest system.
  26. Replace generator. See GENERATOR  under REMOVAL & INSTALLATION. Recheck system.
  27. Remove and check charge indicator light bulb. If bulb is faulty, go to next step. If bulb is okay, go to step 29).
  28. Replace bulb. Recheck system.
  29. Install bulb. Disconnect instrument panel connector. Using ohmmeter, check continuity between instrument panel harness connector terminal B16 (Brown wire) and generator 4-pin harness connector terminal "B" (Brown wire). If continuity exists, go to step 31). If continuity does not exist, go to next step.
  30. Repair open in Brown wire. Recheck system.
  31. Check voltage at instrument panel harness connector terminal B17 (Pink wire). If battery voltage exists, go to next step. If battery voltage does not exist, go to step 33).
  32. Replace instrument cluster. See INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. Recheck system.
  33. Repair open in Pink wire. Recheck system.
  34. Ensure ignition is on. Disconnect generator 4-pin connector. If charge indicator light goes off, go to next step. If charge indicator light is still illuminated, go to step 36).
  35. Replace generator. See GENERATOR  under REMOVAL & INSTALLATION. Recheck system.
  36. Repair short in Brown wire between instrument panel and generator. Recheck system.
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