charging CHEVROLET CAMARO 1982 Repair Guide

GM – CAMARO 1982-1992 – Repair Guide (Checked by WxMax) 141
4. To isolate the short, probe a test point
at either end of the isolated circuit
(the light should be on or the mete r should indicate continuity).
5. Leave the test light probe engaged and sequentiall y open connectors or
switches, remove parts, etc. until t he light goes out or continuity is
broken.
6. When the light goes out, the shor t is between the last two circuit
components which were opened.
VOLTAGE
This test determines voltage available fr om the battery and should be the first
step in any electrical troubleshooting pr ocedure after visual inspection. Many
electrical problems, especially on co mputer controlled systems, can be caused
by a low state of charge in the battery. Excessive corrosion at the battery cable
terminals can cause poor contact that will prevent proper charging and f\
ull
battery current flow.
1. Set the voltmeter selector switch to the 20V position.
2. Connect the multimeter negative lead to the battery's negative (-) post or
terminal and the positive lead to t he battery's positive (+) post or
terminal.
3. Turn the ignition switch ON to provide a load.
4. A well charged battery should register over 12 volts. If the meter reads
below 11.5 volts, the battery power may be insufficient to operate the
electrical system properly.
VOLTAGE DROP

Fig. 2: This voltage drop test revealed high resistance (low voltage) in the circuit

GM – CAMARO 1982-1992 – Repair Guide (Checked by WxMax) 160
damage, and legal considerations (such as t
he fact that it is a federal crime to
vent refrigerant into the atmosphere), dictate that the A/C components on your
vehicle should be serviced only by a Motor Vehicle Air Conditioning (MVAC)
trained, and EPA certified aut omotive technician.
If your vehicle's A/C system uses R-12 re frigerant and is in need of recharging,
the A/C system can be c onverted over to R-134a refrigerant (less
environmentally harmful and expensive). Refer to General Information &
Maintenance for additional information on R- 12 to R-134a conversions, and for
additional considerations dealing with your vehicle's A/C system.
CONTROL CABLES
REMOVAL & INSTALLATION
Some of the following cables will not be used on all models and model years.
Left and Right Air Vent Cables 1. Remove the left and right sound insulators.
2. Remove the screws attaching the cabl es to the steering column cover.
3. Disengage the cable clamps at the vent ducts.
4. Disengage the Z-shaped c able ends from the vent valve levers.
5. Remove the air vent cables notin g their positions for installation.
To install: 6. Place the cables in posi tion under the instrument panel.
7. Engage the Z-shaped cable ends to the vent valve levers.
8. Snap the cable clamps into the slot of the bracket formed on the vent
ducts.
9. Attach the air vent cables at the steering column cover.
10. Install the sound insulators and test cable operation.

Fig. 1: Cable attachment at the steering column cover

GM – CAMARO 1982-1992 – Repair Guide (Checked by WxMax) 223
FUSIBLE LINKS
In addition to circuit breakers and fuses,
the wiring harness incorporates fusible
links to protect the wiring. Links are used rather than a fuse, in wiring circuits
that are not normally fused, such as th e ignition circuit. The fusible links are
color coded red in the charging and load circuits to match the color coding of
the circuits they protect. Each link is four gauges smaller than the cable it
protects, and is marked on the insulation with the gauge size because the
insulation makes it appear heavier than it really is. The engine compartment
wiring harness has several fusible links. The same size wire with a special
Hypalon insulation must be used w hen replacing a fusible link.
For more details, see the information on fusible links at the beginning of this
section.
The links are located in the following areas:
1. A molded splice at the starter solenoid Bat terminal, a 14 gauge red wire.
2. A 16 gauge red fusible link at the j unction block to protect the unfused
wiring of 12 gauge or larger wire. This link stops at the bulkhead
connector.
3. The alternator warning light and fiel d circuitry is protected by a 20 gauge
red wire fusible link used in the batte ry feed-to-voltage regulator number
3 terminal. The link is installed as a molded splice in the circuit at the
junction block.
4. The ammeter circuit is protected by two 20 gauge fusible links installed
as molded splices in the circuit at t he junction block and battery to starter
circuit.
REPLACEMENT 1. Determine the circuit that is damaged.
2. Disconnect the negative battery terminal.
3. Cut the damaged fuse link from the harness and discard it.
4. Identify and procure the proper fuse link and butt connectors.
5. Strip the wire about
1/2 in. (13mm) on each end.
6. Connect the fusible link and crimp the butt connectors making sure that the wires are secure.
7. Solder each connection with resin core solder, and wrap the connections
with plastic electrical tape.
8. Reinstall the wir e in the harness.
9. Connect the negative battery terminal and test the system for proper
operation.
CIRCUIT BREAKERS

Various circuit breakers are located under the instrument panel. In order to gain
access to these components, it may be ne cessary to first remove the under
dash padding. Most of the circuit breakers are located in the convenience
center or the fuse panel.

GM – CAMARO 1982-1992 – Repair Guide (Checked by WxMax) 344
ENGINE & ENGINE OVERHAUL

ENGINE ELECTRICAL

ENGINE ELECTRICAL
The engine electrical system can be brok en down into three inter-related, but
distinct systems:
1. The starting system.
2. The charging system.
3. The ignition system.
BATTERY AND STARTING SYSTEM
The battery is the first link in the chai n of mechanisms which work together to
provide cranking of the autom obile engine. In most modern cars, the battery is a
lead-acid electrochemical device consis ting of six two-volt (2V) subsections
connected in series so the unit is c apable of producing approximately 12V of
electrical pressure. Each subsection, or ce ll, consists of a series of positive and
negative plates held a short distance apart in a solution of sulfuric acid and
water. The two types of plates are of di ssimilar metals. This causes a chemical
reaction to be set up, and it is this reacti on which produces current flow from the
battery when its positive and negative te rminals are connected to an electrical
appliance such as a lamp or motor.
The continued transfer of electrons would ev entually convert the sulfuric acid in
the electrolyte to water and make t he two plates identical in chemical
composition. As electrical energy is removed from the battery, its voltage output
tends to drop. Thus, measuring batte ry voltage and battery electrolyte
composition are two ways of checking the ability of the unit to supply power.
During the starting of the eng ine, electrical energy is removed from the battery.
However, if the charging circuit is in good condition and the operating conditions
are normal, the power removed from the battery will be replaced by the
generator (or alternator) which will forc e electrons back through the battery,
reversing the normal flow, and restoring the ba ttery to its original chemical state.
The battery and starting motor are linked by very heavy electrical cable\
s
designed to minimize resistance to the flow of current. Generally, the major
power supply cable that leaves the batte ry goes directly to the starter, while
other electrical system needs are supplied by a smaller cable. During the starter
operation, power flows from the battery to the starter and is grounded through
the car's frame and the batte ry's negative ground strap.
The starting motor is a specially designed, direct current electric motor capable
of producing a very great am ount of power for its size. One thing that allows the
motor to produce a great deal of power is its tremendous rotating speed. It
drives the engine through a ti ny pinion gear (attached to the starter's armature),
which drives the very large flywheel ring gear at a greatly reduced speed.
Another factor allowing it to produce so much power is that only intermittent

GM – CAMARO 1982-1992 – Repair Guide (Checked by WxMax) 345
operation is required of it. Thus, little a
llowance for air circulation is required,
and the windings can be built into a very small space.
The starter solenoid is a magnetic dev ice which employs the small current
supplied by the starting switch circuit of the ignition switch. This magnetic action
moves a plunger which mechanically engages the starter and electrically closes
the heavy switch which connects it to t he battery. The starting switch circuit
consists of the starting switch cont ained within the ignition switch, a
transmission neutral safety switch or clutch pedal switch, and the wiring
necessary to connect these with the starter solenoid or relay.
A pinion, which is a small gear, is m ounted to a one-way drive clutch. This
clutch is splined to the starter armature shaft. When the ignition switch is moved
to the start position, the solenoid plunger slides the pinion toward the flywheel
ring gear via a collar and spring. If t he teeth on the pinion and flywheel match
properly, the pinion will engage the flywheel immediately. If the gear teeth butt
one another, the spring will be compressed and will force the gears to mesh as
soon as the starter turns far enough to a llow them to do so. As the solenoid
plunger reaches the end of it s travel, it closes the contacts that connect the
battery and starter and then the engine is cranked.
As soon as the engine star ts, the flywheel ring gear begins turning fast enough
to drive the pinion at an ex tremely high rate of speed. At this point, the one-way
clutch begins allowing the pi nion to spin faster than the starter shaft so that the
starter will not operate at excessive speed. When the i gnition switch is released
from the starter position, the solenoid is de-energized, and a spring contained
within the solenoid assembly pulls the gear out of mesh and interrupts the
current flow to the starter.
Some starters employ a separate relay, mounted away from the starter, to
switch the motor and solenoid current on and off. The relay thus replaces the
solenoid electrical switch, but does not eliminate the need for a solenoid
mounted on the starter used to mechanica lly engage the starter drive gears.
The relay is used to reduce the amount of current the starting switch must carry.
THE CHARGING SYSTEM
The automobile charging system provides electrical power for operation of the
vehicle's ignition and star ting systems and all the electrical accessories. The
battery serves as an electrical surge or storage tank, storing (in chemical form)
the energy originally pr oduced by the engine driven gen erator. The system also
provides a means of regulating alternat or output to protect the battery from
being overcharged and to avoid excess ive voltage to the accessories.
The storage battery is a chemical device in corporating parallel lead plates in a
tank containing a sulfuric acid-water solution. Adjacent plates are slightly
dissimilar, and the chemical reaction of the two dissimilar plates produces
electrical energy when the battery is connected to a load such as the starter
motor. The chemical reaction is reversible, so that when the generator i\
s
producing a voltage (electrical pressure ) greater than that produced by the

GM – CAMARO 1982-1992 – Repair Guide (Checked by WxMax) 351
alternating current developed
within the stator windings to a direct (DC) current
at the output (BAT) terminal. Three of these diodes are negative and are
mounted flush with the end frame while t he other three are positive and are
mounted into a strip called a heat sink. The positive diodes are easily identified
as the ones within small cavities or depressions.
The alternator charging system is a negative (-) ground system which consists
of an alternator, a regulat or, a charge indicator, a storage battery and wiring
connecting the components, and fuse link wire.
The alternator is belt-driven from t he engine. Energy is supplied from the
alternator/regulator system to the rotati ng field through two brushes to two slip-
rings. The slip-rings are mounted on the rotor shaft and are connected t\
o the
field coil. This energy supplied to the ro tating field from the battery is called
excitation current and is used to init ially energize the field to begin the
generation of electricity. Once the alter nator starts to generate electricity, the
excitation current comes from its ow n output rather than the battery.
The alternator produces power in the form of alternating current. The alternating
current is rectified by 6 diodes into dire ct current. The direct current is used to
charge the battery and power the rest of the electrical system.
When the ignition key is turned ON, current flows from the battery, through the
charging system indicator light on the in strument panel, to the voltage regulator,
and to the alternator. Since the alternat or is not producing any current, the
alternator warning light comes on. When the engine is started, the alternator
begins to produce current and turns the alte rnator light off. As the alternator
turns and produces current, the current is divided in two ways: part to the
battery(to charge the battery and power the electrical components of the
vehicle), and part is returned to the alte rnator (to enable it to increase its
output). In this situation, the alternator is receiving current from the battery and
from itself. A voltage regulat or is wired into the current supply to the alternator
to prevent it from receiving too much cu rrent which would cause it to put out too
much current. Conversely, if the voltage regulator does not allow the alternator
to receive enough current, the battery will not be fully charged and will
eventually go dead.
The battery is connected to the alternator at all times, whether the ignition key is
turned ON or not. If the battery were shorted to ground, the alternator would
also be shorted. This woul d damage the alternator. To prevent this, a fuse link
is installed in the wiring between the battery and the alternator. If the battery is
shorted, the fuse link melts, protecting the alternator.
An alternator is better that a convent ional, DC shunt generator because it is
lighter and more compact, because it is designed to supply the battery and
accessory circuits through a wide range of engine speeds, and because it
eliminates the necessary maintenance of replacing brushes and servicing
commutators.
PRECAUTIONS

GM – CAMARO 1982-1992 – Repair Guide (Checked by WxMax) 352
To prevent serious damage to the alte
rnator and the rest of the charging
system, the following precauti ons must be observed:
• Never reverse the battery connections.
• Booster batteries for starting must be connected properly: positive-to-
positive and negative-to-ground.
• Disconnect the battery cables before using a fast charger; the charger
has a tendency to force current through the diodes in the opposite
direction for which they were designed. This burns out the diodes.
• Never use a fast charger as a booster for starting the vehicle.
• Never disconnect the voltage regulator while the engine is running.
• Avoid long soldering times when replacing diodes or transistors.
Prolonged heat is damaging to AC alternators.
• Do not use test lamps of more t han 12 volts (V) for checking diode
continuity.
• Do not short across or ground any of the terminals on the AC alternator.
• The polarity of the battery, alter nator, and regulator must be matched
and considered before making any elec trical connections within the
system.
• Never operate the alternator on an open circuit. make sure that all
connections within the circ uit are clean and tight.
• Disconnect the battery terminals when performing any service on the
electrical system. This wil l eliminate the possibility of accidental reversal
of polarity.
• Disconnect the battery ground cable if arc welding is to be done on any
part of the car.
CHARGING SYSTEM TROUBLESHOOTING
There are many possible ways in whic h the charging system can malfunction.
Often the source of a problem is diffi cult to diagnose, requiring special
equipment and a good deal of experience. However, when the charging system
fails completely and causes the dash boar d warning light to come on or the
battery to become dead the following items may be checked:
1. The battery is known to be good and fully charged.
2. The alternator belt is in good condition and adjusted to the proper
tension.
3. All connections in t he system are clean and tight.
REMOVAL & INSTALLATION

GM – CAMARO 1982-1992 – Repair Guide (Checked by WxMax) 810

Fig. 14: After the bearings are adjusted, install the dust cap by gently tapping on
the flange - DO NOT damage the c ap by hammering on the center
JUMP STARTING A DEAD BATTERY
Whenever a vehicle is jump started, pr ecautions must be followed in order to
prevent the possibility of personal inju ry. Remember that batteries contain a
small amount of explosive hydrogen gas which is a by-product of battery
charging. Sparks should always be av oided when working around batteries,
especially when attaching jumper cabl es. To minimize the possibility of
accidental sparks, follow the procedure carefully.

Fig. 1: Connect the jumper cables to the batteries and engine in the order
shown

GM – CAMARO 1982-1992 – Repair Guide (Checked by WxMax) 811
CAUTION
- NEVER hook the batteries up in a series circuit or the entire
electrical system will go up in smoke, including the starter!
Vehicles equipped with a diesel engine may utilize two 12 volt batteries. If so,
the batteries are connected in a parallel circuit (positive terminal to positive
terminal, negative terminal to negative te rminal). Hooking the batteries up in
parallel circuit increases battery cranki ng power without increasing total battery
voltage output. Output remains at 12 vo lts. On the other hand, hooking two 12
volt batteries up in a series circuit (positive terminal to negative terminal,
positive terminal to negative terminal) incr eases total battery output to 24 volts
(12 volts plus 12 volts).
JUMP STARTING PRECAUTIONS
• Be sure that both batteries are of t he same voltage. Vehicles covered by
this information and most vehicles on the road today utilize a 12 volt
charging system.
• Be sure that both batteries are of the same polarity (have the same
terminal, in most cases NEGATIVE grounded).
• Be sure that the vehicles are not touching or a short could occur.
• On serviceable batteries, be sure the v ent cap holes are not obstructed.
• Do not smoke or allow sparks anywhere near the batteries.
• In cold weather, make sure the battery electrolyte is not frozen. This can
occur more readily in a battery that has been in a state of discharge.
• Do not allow electrolyte to c ontact your skin or clothing.
JUMP STARTING PROCEDURE 1. Make sure that the voltages of the 2 batteries are the same. Most
batteries and charging systems are of the 12 volt variety.
2. Pull the jumping vehicle (with t he good battery) into a position so the
jumper cables can reach the dead battery and that vehicle's engine.
Make sure that the ve hicles do NOT touch.
3. Place the transmissions of both vehicles in Neutral (MT) or P (AT), as
applicable, then firmly set their parking brakes.
If necessary for safety reasons, the hazard lights on both vehicles may be
operated throughout the entir e procedure without significantly increasing the
difficulty of jumping the dead battery.
4. Turn all lights and accessories OFF on both vehicles. Make sure the ignition switches on both vehicles are turned to the OFF position.
5. Cover the battery cell caps with a rag, but do not cover the terminals.
6. Make sure the terminals on both batte ries are clean and free of corrosion
or proper electrical connection wil l be impeded. If necessary, clean the
battery terminals before proceeding.
7. Identify the positive (+) and negat ive (-) terminals on both batteries.
8. Connect the first jumper cable to the positive (+) terminal of the dead
battery, then connect the other end of that cable to the positive (+)
terminal of the booster (good) battery.