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Current Output Test

NOTE: CURRENT OUTPUT TEST determines if alternator is capable of delivering its rated current output.
  1. Before performing this test, ensure battery is fully charged. Disconnect negative battery cable. Disconnect alternator output wire at alternator BAT terminal. See Figure.
  2. Using a 0-150 ampere scale DC ammeter, connect positive ammeter lead to alternator BAT terminal and negative ammeter lead to disconnected alternator output BAT wire. See Fig 1.
  3. Using a voltmeter (0-18 volts range minimum), connect positive voltmeter lead to alternator BAT terminal and negative lead to good ground.
    CAUTION: Alternator has one field terminal (Dark Green wire) and one ignition terminal (Dark Blue wire). DO NOT  connect a grounded jumper wire to ignition terminal (Dark Blue wire), or severe wiring damage will result. See Figure.
  4. Remove air duct hose between PCM and air cleaner. Connect one end of jumper wire to ground, and other end to alternator field terminal (Dark Green wire) at rear of alternator. Alternator is now full fielded.
  5. Connect tachometer to engine. Reconnect negative battery cable. Ensure carbon pile rheostat or load tester is in OFF position, then connect leads to battery terminals.
  6. Start engine and immediately reduce engine speed to idle. Adjust carbon pile and engine speed in small increments until engine speed is 1250 RPM and voltmeter reads 15 volts. DO NOT  allow voltage to exceed 16 volts.
  7. Ammeter should read within specification. Refer to the ALTERNATOR MINIMUM OUTPUT  table. If alternator amperage reads less than specified and alternator output BAT wire resistance is not excessive, alternator should be replaced. After CURRENT OUTPUT TEST is completed, reduce engine speed, turn off carbon pile. Turn off ignition switch.
  8. Disconnect negative battery cable. Remove test ammeter, voltmeter, tachometer and carbon pile. Remove jumper wire from between alternator field terminal (Dark Green wire) and ground. Reconnect alternator output wire to alternator BAT terminal. Reconnect negative battery cable. Install air duct hose between PCM and air cleaner.
ALTERNATOR MINIMUM OUTPUT

Engine/Application (1) Case Number Pulley Grooves (2) Minimum Output
2.5L 4557431 4 84
3.0L 4557432 6 86
(1) Located on tag on bottom of alternator case.
(2) Amps measured at 1250 RPM when alternator is full fielded.
Fig 1: Alternator Current Output Test
G93A39883Courtesy of CHRYSLER CORP.
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