Check for a broken (or partially broken) wire inside of the insulation which could cause system malfunction but prove "GOOD" in a continuity/voltage check with a system disconnected. These circuits may be intermittent or resistive when loaded, and if possible, should be checked by monitoring for a voltage drop with the system operational (under load).
you may have corrosion inside the alternator or battery wiring. hard to see due to the insulation. At idle, vehicle electrical loads may exceed the low speed current (amperage) output of the generator and when this happens the shortfall comes from the battery. This will result in a drop in the electrical system voltage as the battery delivers the additional electrical current to meet the demand. This is equivalent to the brown outs experienced by homes and businesses when the electrical demand is more than the supply.As the engine/generator speed changes, so will the current (amperage) output of the generator. As a vehicle slows, engine/generator RPM slows and the current (amperage) output of the generator may not be sufficient to supply the loads, the vehicle system voltage will drop and the lights will dim. Dimming of the lights is an indication that current is being pulled from the battery. If the battery is in a low state-of-charge (discharged condition), the driver will notice a more pronounced dimming than a vehicle with a fully charged battery.
When high current loads (blower, rear defogger, headlamps, cooling fan, heated seats, power seats, electric "AIR" pump, or power windows) are operating or cycled "ON", the generator's voltage regulator can delay the rise in output. This effect, usually at lower engine speeds, can take up to ten seconds to ramp up the generator output. This is done to avoid loading the engine severely. To increase current (amperage) output, additional torque is consumed by the generator. The engine computer (ECM/PCM) will ramp up engine/generator speed in small steps so engine speed variations are not noticeable to the driver.
