Charging System - Battery Not Charging/Cranks Slow
Date: May 29, 2009Order No.: T-B-54.21/204c
Supersedes: T-B-54.21/204b dated March 31, 2009
Group: 54
Revision History
Revision Date Purpose
c 5/29/09 Parts Information Updated
b 3/31/09 Notes Added (Under step 7) Pertaining to Correct Parts Information
a 3/9/09 Subject Description Updated
- 9/25/08 Initial issue
SUBJECT:
Model 164.172/186/871/886, Up to VIN A360677
Model 251.156/165, Up to VIN A076568
Battery Not Charging, Vehicle Cranks Slow and/or Failed Alternator Test
If you receive customer reports in the above model vehicles of the battery going dead or vehicle cranks slowly, this may be due to a malfunctioning alternator or malfunctioning starter/alternator cable. Follow the steps below to resolve.
Note:
A malfunctioning starter / alternator cable can lead to a failed alternator SDS test. Before replacing alternator, follow steps below then retest.
Checking the Starter/Alternator Wiring Harness (two multimeters will be needed):
1. Connect a current clamp/multimeter (1) to the ground line of the negative terminal of the battery to measure charging current. Do not use an inline measurement method, as starter current may exceed the meter's capacity.
2. Connect multimeter (2) between the connector "circuit 30" on the starter and the B1 connector (circuit 30) at the prefuse box (F32) to measure voltage drop. If possible, use the memory function of the meter (example: min/max - hold).
3. Start the engine
4. Place a load on the system by turning on accessories, examples: heated seats, front/rear defrost, lights, etc.
5. The measured charging current from meter (1) must be between 3-5 Amps, wait until the specified charging current is reached.
6. Using meter (2) review maximum measured voltage drop between circuit 30 at the starter and the B1 (Circuit 30) connector at the prefuse box. The maximum measured voltage drop must not exceed 0.4V.
7. If the measured voltage drop is greater than 0.4V, replace the starter/alternator wiring harness. Refer to parts list for applicable part number.
Note:
^ For Model 164.1xx: Do not use t-style harness, part number A164 540 15 30 or A164 540 25 30 (Figure 1). Refer to parts list for correct part numbers (Figure 2).
^ For Model 164.8xx: Do not use t-style harness, part number A164 540 26 30 (Figure 1). Refer to parts list for correct part numbers (Figure 2).
^ For Model 251: Do not use t-style harness, part number A251 540 15 30 (Figure 1). Refer to parts list for correct part numbers (Figure 2).
Note:
On Model 164 vehicles, up to VIN A139638, and Model 251 vehicles, up to VIN A032961, if it is determined that the harness needs to be replaced then the alternator (A272 154 01 02 80) will need to be replaced with alternator (A013 154 56 02). The replacement harness will not fit the A272 154 01 02 80 alternator in early production vehicles (Figures 3 and 4).
Note:
If it is determined that the alternator needs to be replaced on later VINs, (164 - A139639 and 251 - A032962), it is necessary to follow the process outlined in S-B-15.40/60b (or latest version).
Parts Information
Note:
The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has been generated on April 22, 2009. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
In Case of Warranty, use the table above.