battery replacement CHEVROLET DYNASTY 1993 Service Manual

inside of the hood in the engine compartment and
Group 25, Emission Control Systems for proper ser-
vice procedures.
BATTERY
Inspect battery tray, hold down and terminal con-
nections when other under hood service is performed.
For proper diagnostic procedures refer to Group 8A,
Battery/Starting/Charging System Diagnostics. For
service and cleaning procedures refer to Group 8B,
Battery/Starter Service.
RUBBER AND PLASTIC COMPONENT INSPECTION
CAUTION: Plastic hoses or wire harness covers will
melt or deform when exposed to heat from exhaust
system or engine manifolds. Position plastic or rubber components away from
moving parts in engine compartment or under vehi-
cle, or damage will result. Do not allow rubber engine mounts or other com-
ponents to become oil contaminated, repair cause
of oil contamination and clean area. All rubber and plastic components should be in-
spected when engine compartment or under vehicle
service is performed. When evidence of deterioration
exists, replacement is required. To reduce deteriora-
tion of rubber components, Chrysler Corporation rec-
ommends Mopar Foamy Engine Degreaser or
equivalent be used to clean engine compartment of
oil and road grime.
EXHAUST SYSTEM ISOLATOR AND HANGER
The exhaust system should be inspected when un-
der vehicle service is performed. The exhaust system
should not make contact with under body, brake ca-
bles, brake/fuel lines, fuel tank or suspension compo-
nents. Slight cracking in rubber isolator or hanger is
acceptable. Severely cracked or broken rubber compo-
nents must be replaced. For proper service proce-
dures see Group 11, Exhaust System and Intake
Manifold.
Ä LUBRICATION AND MAINTENANCE 0 - 15

earlier in this service manual supplement. Then follow
the diagnostic procedures outlined in this section. Many conditions that generate customer complaints
may be normal operating conditions, but are judged to
be a problem due to not being familiar with the ABS
system. These conditions can be recognized without
performing extensive diagnostic work, given adequate
understanding of the operating principles and perfor-
mance characteristics of the ABS system.
DEFINITIONS
Several abbreviations are used in this manual. They
are presented here for reference.
² CABÐController Antilock Brake
² ABSÐAntilock Brake System
² PSIÐPounds per Square Inch (pressure)
² WSSÐWheel Speed Sensor
² ACÐAlternating Current
ABS COMPUTER SYSTEM SERVICE PRECAUTIONS
The ABS system uses an electronic control module,
the CAB. This module is designed to withstand normal
current draws associated with vehicle operation. How-
ever care must be taken to avoid overloading the CAB
circuits. In testing for open or short circuits, do
not ground or apply voltage to any of the circuits
unless instructed to do so by the appropriate
diagnostic procedure. These circuits should only be
tested using a high impedance multi-meter, special
tools or the DRB II tester as described in this section.
Power should never be removed or applied to any
control module with the ignition in the ON position.
Before removing or connecting battery cables, fuses, or
connectors, always turn the ignition to the OFF posi-
tion.
ABS GENERAL SERVICE PRECAUTIONS
TEST DRIVING ABS COMPLAINT VEHICLES
Most ABS complaints will require a test drive as a
part of the diagnostic procedure. The purpose of the
test drive is to duplicate the condition. Remember conditions that result in the turn-
ing on of the Red Brake Warning Lamp may
indicate reduced braking ability. The following
procedure should be used to test drive an ABS
complaint vehicle. Before test driving a brake complaint vehicle, note
whether the Red or Amber Brake Warning Lamp is
turned on. If the Red Brake Warning Lamp, is
turned on, refer to the base brake Control Valves
Section in the Front Wheel Drive, chassis service
manual. If the Amber Antilock Warning light was or
is on, read record and erase the faults. While the
Amber ABS Warning Lamp is on the ABS system is
not functional. The standard brake system and abil- ity to stop the car is not affected, if only the Amber
Antilock Warning Lamp is on.
(1) Turn ignition key to the off position and then
back to the on position. Note whether the Amber ABS
Warning Lamp continues to stay on. If it does refer to
the 1994 Bendix Antilock 4 Brake System Diagnostic
Manual for the required diagnostic test procedures. (2) If the Amber ABS Warning Lamp goes out, shift
vehicle into gear and drive car to a speed of 5 mph to
complete the ABS drive-off cycle. If at this time, the
Amber ABS Warning Lamp goes on refer to the 1994
Bendix Antilock 4 Brake System Diagnostic Manual. (3) If the Amber ABS Warning Lamp remains OUT,
continue to drive the vehicle a short distance. During
this test drive be sure that the vehicle achieves at least
25 mph. Brake to at least one complete stop and again
accelerate to 25 mph. (4) If a functional problem with the ABS system is
determined while test driving a vehicle. Refer to the
Bendix Antilock 4 Brake System Diagnostics Manual
for required diagnostic test procedures and proper use
of the DRB II tester.
ABS BRAKE SYSTEM ON VEHICLE SERVICE
The following are general precautions which
should be observed whenever servicing and or
diagnosing the ABS system and other vehicle
electronic systems. Failure to observe these pre-
cautions may result in ABS system damage. (1) If welding work is to be performed on a vehicle
using an arc welder. The wiring harness connector
should be disconnected from the CAB before beginning
any welding operation. (2) The CAB 60 way connector and modulator as-
sembly 10 way connector, should never be connected or
disconnected with the ignition in the on position. (3) Some components of Bendix Antilock 4 Brake
System assemblies can not be serviced separately from
the assembly and will require replacement of the
complete assembly for servicing. Do not disassemble
any component which is designated as non-serviceable.
CAUTION: Brake fluid will damage painted surfaces.
If brake fluid is spilled on any painted surfaces, wash
off with water immediately.
WHEEL SPEED SENSOR CABLES
Proper installation and routing of the Wheel Speed
Sensor Cables is critical to continued system opera-
tion. Be sure that cables are installed, routed and
clipped properly. Failure to install speed sensor ca-
bles as shown in the on car service section of this
Ä ANTILOCK 4 BRAKE SYSTEM 5 - 23

MASTER CYLINDER AND POWER BOOSTER
REMOVAL AND INSTALLATION If the Master Cylinder or Power Booster need to be
removed for replacement or servicing of other vehicle
components. Refer to Master Cylinder or Power
Brake Service section in group 5 of the 1993 M.Y.
Front Wheel Drive Car service manual. After servicing master cylinder, refer back to this
service manual supplement for the appropriate proce-
dure and sequence used to bleed the base and Anti-
lock portion of the brake system.
PROPORTIONING VALVES (FIG. 1)
CAUTION: Proportioning valves should never be
disassembled.
REMOVAL (1) Disconnect and remove both battery cables
from battery. (2) Remove heat shield (Fig. 2) from the battery.
Then remove battery hold down clamp (Fig. 2) and
battery from battery tray.
Fig. 15 Battery Tray Installation And Attaching Bolts
Fig. 16 Vacuum Reservoir Installation And Attaching Bolts
Fig. 17 Battery Tray Access Shield Installed
Fig. 18 Battery Hold Down Clamp And Heat Shield Installed
Fig. 1 ABS Proportioning Valve Identification
5 - 38 ANTILOCK 4 BRAKE SYSTEM Ä

(3) Remove battery tray access cover (Fig. 3) from
battery tray. Do not discard, access cover MUST be
put back on battery tray, when battery is rein-
stalled.
(4) If equipped, remove the 2 bolts (Fig. 4) attaching
speed control vacuum reservoir to battery tray. Then
remove speed control vacuum reservoir (Fig. 4) from
the battery tray. Vacuum lines (Fig. 4) do not need
to be removed from vacuum reservoir. (5) Remove the 4 bolts attaching battery tray (Fig. 5)
to frame rail and fender shield of vehicle. Then remove
battery tray from vehicle. (6) Remove battery acid shield, (Fig. 6) from the ABS
modulator assembly. (7) Remove brake tube from the proportioning valve,
requiring removal from modulator assembly (Fig. 7). (8) Remove proportioning valve (Fig. 7) requiring
replacement from the modulator assembly. INSTALL
(1) Slightly moisten proportioning valve to modulator
assembly sealing O-Ring with fresh clean brake fluid.
(2) Install proportioning valve into modulator as-
sembly by hand, until O-Ring seal is fully seated
Fig. 4 Speed Control System Vacuum Reservoir
Fig. 5 Battery Tray And Attaching Bolts
Fig. 6 ABS Modulator Assembly Acid Shield
Fig. 2 Battery Heat Shield And Hold Down Clamp
Fig. 3 Battery Tray Shield
Ä ANTILOCK 4 BRAKE SYSTEM 5 - 39

BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
CONTENTS
page page
BATTERY TEST PROCEDURES ON-VEHICLE . . 3
FAULT CODESÐON BOARD DIAGNOSTICS . . 23
GENERAL INFORMATION .................. 1
GENERATOR TEST PROCEDURES ON VEHICLE.19 IGNITION OFF DRAW (IOD)
............... 9
SPECIFICATIONS ....................... 28
STARTER TEST PROCEDURES ON VEHICLE . 11
GENERAL INFORMATION
² For Battery, Starter or Generator replacement re-
fer to Group 8B, Battery/Starter/Generator Service.
This Group 8A will cover diagnostics only. The Battery, Starting, and Charging Systems oper-
ate with one another, and must be thoroughly tested
as a complete system. To enable the vehicle to start
and charge properly, it must have a battery that will
perform to specifications. The starter motor, genera-
tor, wiring, and electronics also must perform within
specifications. Group 8A will cover Starting (Fig. 1)
and Charging System (Fig. 2) diagnostic procedures.
These will be covered from the most basic conven-
tional methods to On Board Diagnostics (OBD) built
into the vehicle's electronics. The need for conven-
tional testing equipment has not been eliminated by
the introduction of OBD. Frequent use of an amme-
ter, volt/ohmmeter, battery charger, carbon pile rheo-
stat (load tester), and 12 volt (low wattage) test light
will be required. All front wheel drive vehicles are equipped with
OBD and all OBD sensing systems are monitored by
the Powertrain Control Module. The Powertrain Con-
trol module will store in electronic memory, any de-
tectable failure within the monitored circuits. It will
retain this information for a period of 50 engine
starts, then erase the memory if the failure does not
reoccur during that period. This also will translate a
monitored failure as a FAULT CODE when a read-
out command is given. A readout command can be
made by turning the ignition switch to ON-OFF-ON-
OFF-ON without starting the engine. The Malfunc-
tion Indicator (CHECK ENGINE) Lamp on the
instrument cluster will flash in preset sequences to
show Fault Codes. However, the Malfunction Indica-
tor (Check Engine) Lamp cannot express fault codes
for all failures. Fault codes are easier to obtain and
more complete with the use of Diagnostic Tool (DRB
II). This tool is plugged into the diagnostic connector located in the engine compartment (Fig. 2). Refer to
the instructions provided with the (DRB II) tool be-
ing used. For numbered Fault Codes pertaining to compo-
nents within this Group, refer to Failure CodesÐOn
Board Diagnostics in Group 8A. For other Fault
Codes which, do not pertaining to this Group 8A, re-
fer to Group 14, Fuel System, On Board Diagnostics.
Fig. 1 Starting System Components
Ä BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 1

relay to starter solenoid for loose or corroded connec-
tions. Particularly at starter terminals.
² Repeat test. If engine still fails to crank properly,
trouble is within starter or starter mounted solenoid,
and it must be removed for repairs. Refer to Group
8B, Battery/Starter/Generator Service, Starter re-
placement.
STARTER RELAY TEST
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN PARK OR NEUTRAL WITH THE
PARKING BRAKE APPLIED
(1) Verify battery condition. Battery must be in
good condition with a full charge before performing
any starter tests. Refer to Battery Tests. (2) Perform the preceding starter solenoid tests
BEFORE performing starter relay tests. Refer to
Starter Solenoid Test. (3) Locate and remove the starter relay. For
starter relay locations, refer to Starter Solenoid Test
(Fig. 13 or 14). (4) After the starter relay has been located and re-
moved, refer to Starter Relay Tests (Fig. 15).
NEUTRAL STARTING AND BACK-UP SWITCH
AUTOMATIC TRANSMISSION ONLY
For electrical diagnostics, when checking starter
circuits, refer to Starter Relay Tests (Fig. 15). For replacement of switch, refer to Group 21, Tran-
saxle, Neutral Starting and Switch Replacement.
STARTER INTERLOCK SWITCHÐCLUTCH PEDAL MOUNTED
MANUAL TRANSMISSION ONLY
For electrical diagnostics, refer to the Starter Relay
Tests. For replacement and/or adjustment of the switch,
refer to Group 6, Manual Transaxle Clutch, Manual
Transaxle Starter Interlock Switch.
IGNITION SWITCH TEST
After testing the starter solenoid and relay, test ig-
nition switch and wiring. Refer to Group 8D, Ignition
Systems, or the Front Wheel Drive Car Wiring Dia-
grams Service Manual. Check all wiring for opens or
shorts, and all connectors for being loose or corroded.
BENCH TESTING STARTER SOLENOID
(1) Disconnect field coil wire from field coil termi-
nal (Fig. 16 or 17). (2) Check for continuity between solenoid terminal
and field coil terminal with a continuity tester. Con-
tinuity should be detected (Fig. 18 or 19). (3) Check for continuity between solenoid terminal
and solenoid housing (Fig. 20 or 21). Continuity
should be detected. If continuity is detected, solenoid
is good. (4) If continuity is not detected in either test, sole-
noid has an open circuit and is defective. If equipped
with:
² BOSCH STARTER: Replace the solenoid.
² NIPPONDENSO STARTER: Replace the starter
assembly.
8A - 16 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS Ä

(2) Adjust the carbon pile and engine speed in
steps until an engine speed of 1250 rpm, and a volt-
meter reading of 15 volts is obtained.
CAUTION: Do not allow the battery voltage to ex-
ceed 16 volts. (3) The generator amperage must meet the output
requirements for the particular generator being
tested. Refer to Generator Specifications for genera-
tor identification and amperage outputs.
RESULTS
(1) If amperage reading is less than specified, and
generator output wire resistance is not found exces-
sive from the previous tests, generator should be re-
placed. Refer to Group 8B, Battery/Starter/Generator
Service, Generator Replacement. These generators
are not intended to be disassembled for service. It
must be replaced as an assembly. (2) After current output test is completed, reduce
engine speed, turn off carbon pile, and turn off igni-
tion switch. (3) Disconnect battery negative cable.
(4) Remove test ammeter, voltmeter, tachometer
and carbon pile. (5) Remove jumper wire between K20 circuit ter-
minal and ground. (6) Connect output wire to B+ terminal.
(7) Connect negative battery cable.
(8) Connect fresh air hose between powertrain con-
trol module and air cleaner if removed.
Fig. 5 Generator Current Output Test
Fig. 6 Volt/Amp Tester Connections
8A - 22 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS Ä

BATTERY/STARTER/GENERATOR SERVICE
CONTENTS
page page
BATTERY REMOVAL, INSTALLATION AND SERVICE ............................. 1
GENERATOR ............................ 9 SPECIFICATIONS
....................... 12
STARTER ............................... 4
BATTERY REMOVAL, INSTALLATION AND SERVICE
GENERAL INFORMATION
This first section will cover Battery replacement and
service procedures only. For Battery diagnostic proce-
dures, refer to Group 8A, Battery/Starting/Charging
Systems Diagnostics. Factory installed batteries (Fig. 1) do not have re-
movable battery cell caps. Water cannot be added to
factory installed battery. Battery is sealed, except for
small vent holes in the top. Chemical composition
inside the battery produces an extremely small amount
of gases at normal charging voltages. The factory
installed battery is equipped with a test indicator that
displays a colored ball to show the battery's state of
charge.
² Green Indicator = Full charge
² Black Indicator = Discharged
² Yellow Indicator = Battery replacement required.
BATTERY VISUAL INSPECTION AND SERVICE
(1) Make sure ignition switch is in OFF position and
all accessories are OFF. (2) Disconnect and remove the battery cable termi-
nals from the battery posts. Remove negative cable
first (Fig. 2). WARNING: TO PROTECT THE HANDS FROM BAT-
TERY ACID, A SUITABLE PAIR OF HEAVY DUTY
RUBBER GLOVES, NOT THE HOUSEHOLD TYPE,
SHOULD BE WORN WHEN REMOVING OR SERVIC-
ING A BATTERY. SAFETY GLASSES ALSO SHOULD
BE WORN.
(3) Lift battery heat shield off battery, if equipped
(Fig. 3). (4) Remove battery hold down nut and clamp.
Fig. 1 Maintenance Free Battery
Fig. 2 Remove Battery Cables
Fig. 3 Battery Hold-Down
Ä BATTERY/STARTER/GENERATOR SERVICE 8B - 1

STARTER INDEX
page page
General Information ........................ 4
Neutral Starter and Back-Up Switch ........... 8
Starter Component Replacement .............. 5
Starter Interlock Switch: Clutch Pedal Mounted/ Manual Transmission Only ................. 7 Starter Motor Replacement
.................. 4
Starting System ........................... 4
Supply Circuit and Control Circuit ............. 4
GENERAL INFORMATION
This section will cover Starter replacement and
service procedures only. For starter diagnostic proce-
dures, refer to Group 8A, Battery/Starting/Charging
Systems Diagnostics.
STARTING SYSTEM
The starting system has:
² Ignition switch
² Starter relay
² Neutral starting and back-up switch with auto-
matic transmissions
² Clutch pedal mounted starter interlock switch
with manual transmissions
² Wiring harness
² Battery
² Starter motor with an integral solenoid
BOSCH STARTERS
²A Bosch permanent magnet starter motor is avail-
able on 2.2L, 2.5L and 3.0L engines on all vehicles.
A planetary gear train transmits power between
starter motor and pinion shaft. The fields consist of
six permanent magnets.
NIPPONDENSO STARTERS
² A Nippondenso reduction gear-field coil starter
motor is available on 3.0L, 3.3L and 3.8L engines.
SUPPLY CIRCUIT AND CONTROL CIRCUIT
Both starter systems consist of two separate cir-
cuits:
² A high amperage supply to feed the starter motor.
² A low amperage circuit to control the starter sole-
noid. For additional information on starter motor supply
and control circuits, refer to Group 8A, Battery/Start-
ing/Charging Systems Diagnostics.
STARTER MOTOR REPLACEMENT
BOSCH STARTERÐ2.2L/2.5L ENGINE
(1) Disconnect battery negative cable (Fig. 1).
(2) Raise vehicle. (3) Remove heat shield clip from the starter and
heat shield is clipped to starter (Fig. 2). For easier
servicing, do not remove the wiring from starter at
this time.
(4) Remove two bolts and one nut attaching starter
to engine (Fig. 3). (5) Remove starter/starter solenoid assembly from
engine. Position the starter to gain access to the wir-
ing connectors. (6) Disconnect the positive battery cable and wir-
ing at the starter. (7) Remove the starter from vehicle.
Fig. 1 Remove or Install Battery Cable
Fig. 2 Starter Heat ShieldÐ4 Cylinder Engines
8B - 4 BATTERY/STARTER/GENERATOR SERVICE Ä

(8) For installation, reverse above procedures.
Clean corrosion/dirt from the cable and wire termi-
nals before installing wiring to the solenoid.
BOSCH OR NIPPONDENSO STARTERÐ3.0L/ 3.3L/3.8L ENGINE
(1) Disconnect NEGATIVE battery cable (Fig. 1).
(2) Raise vehicle.
(3) Remove three starter attaching bolts at engine/
transaxle (Fig. 4).
(4) Remove the two wire connector terminal nuts
and remove wiring connector (Bosch, Fig. 5) (Nippon-
denso, Fig. 6 or 7). (5) Remove starter from vehicle (Bosch, Fig. 8)
(Nippondenso, Fig. 9). (6) For installation, reverse above procedures.
Clean corrosion/dirt from the cable and wire termi-
nals before installing wiring to the solenoid.
STARTER COMPONENT REPLACEMENT
Caution: When servicing the starter assembly off
the vehicle, do not clamp the starter to a vice. In-
ternal damage may result.
Fig. 3 Bosch StarterÐ2.2L/2.5L Engine
Fig. 4 Remove or Install Attaching BoltsÐTypical
Fig. 5 Wire Terminal ConnectionsÐBosch Starter
Fig. 6 Wire Terminal ConnectionsÐ3.0L EngineÐNippondenso Starter
Fig. 7 Wire Terminal ConnectionsÐ3.3L/3.8L EngineÐNippondenso Starter
Ä BATTERY/STARTER/GENERATOR SERVICE 8B - 5