2005 Chevrolet Aveo LS, 4D Sedan, StandardFACTORY OEM SERVICE PROCEDURE

Charging System Test

Charging System Test

Step Action Values Yes No
1 Did you review the Battery Description and Operation , the Starting System Description and Operation  and the Charging System Description and Operation  and perform the necessary inspections? - Go to Step 2  Go to Symptoms - Engine Electrical 
2
  1. Turn OFF all electrical loads.
  2. Start the engine.
  3. Install a scan tool.
  4. With the scan tool view the Battery Voltage parameter in the engine data list.
Does the scan tool indicate the voltage is within the specified value?		 11-15.5 V Go to Step 3  Go to Testing for Intermittent Conditions and Poor Connections in Wiring Systems
3
  1. Turn OFF the ignition.
  2. Connect a charging system tester to the battery, follow the manufacturer's instructions.
  3. Operate the engine at 2,500 RPM.
  4. Adjust the carbon pile as necessary in order to obtain the maximum current output.
Is the generator output within 10 A of the specified value?		 85 A Go to Step 9  Go to Step 4 
4
  1. Maintain the engine speed at 2,500 RPM and continue to operate the generator at the load test value.
  2. Measure the voltage drop between the generator output terminal and the battery positive terminal.
Is the voltage above the specified value?		 0.5 V Go to Step 6  Go to Step 5 
5
  1. Maintain the engine speed at 2,500 RPM and continue to operate the generator at the load test value.
  2. Measure the voltage drop between the battery negative terminal and the generator metal housing.
Is the voltage above the specified value?		 0.5 V Go to Step 7  Go to Step 8 
6 Test the battery positive circuit between the generator output terminal and the battery positive terminal for a high resistance. Refer to Circuit Testing and Wiring Repairs in Wiring Systems.
Did you find and correct the condition?		 - Go to Step 9  Go to Step 7 
7 Repair the high resistance in the ground circuit between the generator housing and the battery negative terminal. Refer to Circuit Testing and Wiring Repairs in Wiring Systems.
Did you complete the repair?		 - Go to Step 9  -
8 Replace the generator. Refer to Generator Replacement .
Did you complete the repair?		 - Go to Step 9  -
9 Operate the system in order to verify the repair.
Did you correct the condition?		 - System OK Go to Step 3 
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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