electr CHRYSLER VOYAGER 2002 Service Manual

ULES/POWERTRAIN CONTROL MODULE -
DESCRIPTION) section for more DTC information.
The Check Gauges Lamp (if equipped) or Battery
Lamp monitors:charging system voltage,engine
coolant temperature and engine oil pressure. If an
extreme condition is indicated, the lamp will be illu-
minated. The signal to activate the lamp is sent via
the PCI bus circuits. The lamp is located on the
instrument panel. Refer to the Instrument Cluster
section for additional information.
The PCM uses the inlet air temperature sensor to
control the charge system voltage. This temperature,
along with data from monitored line voltage, is used
by the PCM to vary the battery charging rate. The
system voltage is higher at cold temperatures and is
gradually reduced as the calculated battery tempera-
ture increases.
The ambient temperature sensor is used to control
the battery voltage based upon ambient temperature
(approximation of battery temperature). The PCM
maintains the optimal output of the generator by
monitoring battery voltage and controlling it to a
range of 13.5 - 14.7 volts based on battery tempera-
ture.
DIAGNOSIS AND TESTING - ON-BOARD
DIAGNOSTIC SYSTEM
The Powertrain Control Module (PCM) monitors
critical input and output circuits of the charging sys-
tem, making sure they are operational. A Diagnostic
Trouble Code (DTC) is assigned to each input and
output circuit monitored by the OBD system. Some
circuits are checked continuously and some are
checked only under certain conditions.
If the OBD system senses that a monitored circuit
is bad, it will put a DTC into electronic memory. The
DTC will stay in electronic memory as long as the
circuit continues to be bad. The PCM is programmed
to clear the memory after 50 engine starts if the
problem does not occur again.
DIAGNOSTIC TROUBLE CODES
A DTC description can be read using the DRBIIIt
scan tool. Refer to the appropriate Powertrain Diag-
nostic Procedures manual for information.
A DTC does not identify which component in a cir-
cuit is bad. Thus, a DTC should be treated as a
symptom, not as the cause for the problem. In some
cases, because of the design of the diagnostic test
procedure, a DTC can be the reason for another DTC
to be set. Therefore, it is important that the test pro-
cedures be followed in sequence, to understand what
caused a DTC to be set.ERASING DIAGNOSTIC TROUBLE CODES
The DRBIIItScan Tool must be used to erase a
DTC.
The following procedures may be used to diagnose
the charging system if:
²the check gauges lamp or battery lamp is illumi-
nated with the engine running
²the voltmeter (if equipped) does not register
properly
²an undercharged or overcharged battery condi-
tion occurs.
Remember that an undercharged battery is often
caused by:
²accessories being left on with the engine not
running
²a faulty or improperly adjusted switch that
allows a lamp to stay on. Refer to Ignition-Off Draw
Test (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/
BATTERY - STANDARD PROCEDURE)
INSPECTION
The Powertrain Control Module (PCM) monitors
critical input and output circuits of the charging sys-
tem, making sure they are operational. A Diagnostic
Trouble Code (DTC) is assigned to each input and
output circuit monitored by the On-Board Diagnostic
(OBD) system. Some charging system circuits are
checked continuously, and some are checked only
under certain conditions.
Refer to Diagnostic Trouble Codes in; Powertrain
Control Module; Electronic Control Modules for more
DTC information. This will include a complete list of
DTC's including DTC's for the charging system.
To perform a complete test of the charging system,
refer to the appropriate Powertrain Diagnostic Proce-
dures service manual and the DRBIIItscan tool.
Perform the following inspections before attaching
the scan tool.
(1) Inspect the battery condition. Refer to the Bat-
tery section (Refer to 8 - ELECTRICAL/BATTERY
SYSTEM - DIAGNOSIS AND TESTING) for proce-
dures.
(2) Inspect condition of battery cable terminals,
battery posts, connections at engine block, starter
solenoid and relay. They should be clean and tight.
Repair as required.
(3) Inspect all fuses in both the fuseblock and
Power Distribution Center (PDC) for tightness in
receptacles. They should be properly installed and
tight. Repair or replace as required.
(4) Inspect generator mounting bolts for tightness.
Replace or tighten bolts if required. Refer to the Gen-
erator Removal/Installation section of this group for
torque specifications (Refer to 8 - ELECTRICAL/
CHARGING - SPECIFICATIONS).
RGCHARGING8Fa-21
CHARGING (Continued)
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(5) Inspect generator drive belt condition and ten-
sion. Tighten or replace belt as required. Refer to
Belt Tension Specifications(Refer to 7 - COOLING/
ACCESSORY DRIVE - SPECIFICATIONS).
(6) Inspect decoupler pulley (if equipped). Ensure
decoupler pulley is driving the alternator rotor.
(7) Inspect automatic belt tensioner (if equipped).
Refer to the Cooling System for more information.
(8) Inspect generator electrical connections at gen-
erator field, battery output, and ground terminal (if
equipped). Also check generator ground wire connec-
tion at engine (if equipped). They should all be clean
and tight. Repair as required.SPECIFICATIONS
GENERATOR
Type Engine Minimun Test
Amperage
Denso 2.4 L 125 Amp
Denso 3.3/3.8L 135 Amp or 145
Amp
Test Specification:
1. Engine RPM : 2500 RPM  20 RPM
2. Voltage Output : 14.0 V   0.5 V
3. Field Current : 5 amps   0.1 amps
Part number is located on the side of the generator.
TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Battery Hold Down Clamp
Bolt20 14.7 180
Generator B+ Nut 12.4 9.2 110
Battery Terminal Nut 4 35
Generator Mounting Bolt
2.4L28.2 20.8 250
Generator Mounting Bolts
3.3/3.8L54.2 40
Starter Solenoid Battery
Nut 3.3/3.8L11.3 8.3 100
Generator Decoupler 109.8 81
SPECIAL TOOLS
GENERATOR DECOUPLER 8433
8Fa - 22 CHARGINGRG
CHARGING (Continued)
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BATTERY TEMPERATURE
SENSOR
DESCRIPTION
The PCM incorporates a Battery Temperature Sen-
sor (BTS) on its circuit board.
OPERATION
The PCM uses the temperature of the battery area
to control the charge system voltage. This tempera-
ture, along with data from monitored line voltage, is
used by the PCM to vary the battery charging rate.
The system voltage is higher at cold temperatures
and is gradually reduced as temperature around the
battery increases.
The ambient temperature sensor is used to control
the battery voltage based upon ambient temperature
(approximation of battery temperature). The PCM
maintains the optimal output of the generator by
monitoring battery voltage and controlling it to a
range of 13.5 - 14.7 volts based on battery tempera-
ture.
The battery temperature sensor is also used for
OBD II diagnostics. Certain faults and OBD II mon-
itors are either enabled or disabled depending upon
the battery temperature sensor input (example: dis-
able purge and EGR, enable LDP). Most OBD II
monitors are disabled below 20ÉF.
REMOVAL
The battery temperature sensor is not serviced sep-
arately. If replacement is necessary, the PCM must
be replaced.
GENERATOR
DESCRIPTION
The generator is belt-driven by the engine. It is
serviced only as a complete assembly. The generator
produces DC voltage at the B+ terminal. If the gen-
erator is failed, the generator assembly subcompo-
nents (generator and decoupler pulley) must be
inspected for individual failure and replaced accord-
ingly.
OPERATION
As the energized rotor begins to rotate within the
generator, the spinning magnetic field induces a cur-
rent into the windings of the stator coil. Once the
generator begins producing sufficient current, it also
provides the current needed to energize the rotor.
The Y type stator winding connections deliver the
induced AC current to 3 positive and 3 negative
diodes for rectification. From the diodes, rectified DC
current is delivered to the vehicles electrical system
through the generator, battery, and ground terminals.
Excessive or abnormal noise emitting from the gen-
erator may be caused by:
²Worn, loose or defective bearings
²Loose or defective drive pulley (2.4L) or decou-
pler (3.3/3.8L)
²Incorrect, worn, damaged or misadjusted drive
belt
²Loose mounting bolts
²Misaligned drive pulley
²Defective stator or diode
²Damaged internal fins
REMOVAL
REMOVAL - 2.4L
(1) Release hood latch and open hood.
(2) Disconnect battery negative cable.
(3) Disconnect the Inlet Air Temperature sensor.
(4) Remove the Air Box, refer to the Engine/Air
Cleaner for more information.
(5) Remove the EVAP Purge solenoid from its
bracket and reposition.
(6) Disconnect the push-in field wire connector
from back of generator.
(7) Remove nut holding B+ wire terminal to back
of generator.
(8) Separate B+ terminal from generator.
(9) Remove accessory drive belt, refer to the Cool-
ing System section for proper procedures.
(10) Remove the generator.
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(7) Remove the 2 upper clevies bolts.
(8) Remove axle from knuckle (Fig. 13).
(9) Remove the right front splash shield.
(10) Remove the accessory drive belt (Fig. 14),
refer to the cooling section.
(11) Disconnect the generator positive battery
cable.
(12) Unlock the electrical connector for the field
connector (Fig. 15).(13) Disconnect the field connector.
(14) Remove the axle from vehicle, oil will leak
from transmission.
(15) Remove the 3 mounting bolts for generator.
(16) Remove generator from vehicle (Fig. 16).
INSTALLATION
INSTALLATION - 2.4L
(1) Install the generator.
(2) Install the accessory drive belt, refer to the
Cooling System section for proper procedures.
(3) Connect B+ terminal to generator.
(4) Install nut holding B+ wire terminal to back of
generator.
Fig. 13 AXLE AND KNUCKLE
Fig. 14 ACCESSORY DRIVE BELT
Fig. 15 GENERATOR CONNECTORS
Fig. 16 GENERATOR REMOVEL/INSTALLATION
RGCHARGING8Fa-27
GENERATOR (Continued)
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INSTALLATION
(1) Install the Generator Decoupler to the genera-
tor shaft.
(2) Use Special Tool #8433 (Fig. 20) to tighten the
Generator Decoupler (Fig. 21). Refer to the torque
chart for the proper torque.
(3) Install the Air Box, refer to the Engine section
for more information.
(4) Raise vehicle and support.
(5) Install accessory drive belt, refer to the Cooling
System section for proper procedures (Fig. 18).
(6) Install the right front lower splash shield.
(7) Lower vehicle.
(8) Connect battery negative cable.
VOLTAGE REGULATOR
DESCRIPTION
The Electronic Voltage Regulator (EVR) is not a
separate component. It is actually a voltage regulat-
ing circuit located within the Powertrain Control
Module (PCM). The EVR is not serviced separately. If
replacement is necessary, the PCM must be replaced.
OPERATION
The amount of DC current produced by the gener-
ator is controlled by EVR circuitry contained within
the PCM. This circuitry is connected in series with
the generators second rotor field terminal and its
ground.
Voltage is regulated by cycling the ground path to
control the strength of the rotor magnetic field. The
EVR circuitry monitors system line voltage (B+) and
calculated battery temperature or inlet air tempera-
ture sensor (refer to Inlet Air Temperature Sensor, if
equipped, for more information ). It then determines
a target charging voltage. If sensed battery voltage is
lower than the target voltage, the PCM grounds the
field winding until sensed battery voltage is at the
target voltage. A circuit in the PCM cycles the
ground side of the generator field at 250 times per
second (250Hz), but has the capability to ground the
field control wire 100% of the time (full field) to
achieve the target voltage. If the charging rate can-
not be monitored (limp-in), a duty cycle of 25% is
used by the PCM in order to have some generator
output. Also refer to Charging System Operation for
additional information.
Fig. 21 DECOUPLER INSTALLATION (Litens)
8Fa - 30 CHARGINGRG
GENERATOR DECOUPLER PULLEY (Continued)
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Remove the starter relay from the PDC as
described in this group to perform the following tests:
(1) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 2. If not OK, replace the faulty relay.
(2) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 75  5 ohms. If OK, go to Step
3. If not OK, replace the faulty relay.
(3) Connect a battery B+ lead to terminals 86 and
a ground lead to terminal 85 to energize the relay.
The relay should click. Also test for continuity
between terminals 30 and 87, and no continuity
between terminals 87A and 30. If OK, refer to Relay
Circuit Test procedure. If not OK, replace the faulty
relay.CAV FUNCTION
30 B (+)
85 P/N POSITION SW.SENSE
86 IGNITION SWITCH OUTPUT
87 STARTER RELAY OUTPUT
87A NO CONNECT
RELAY CIRCUIT TEST
(1) The relay common feed terminal cavity (30) is
connected to battery voltage and should be hot at all
times. If OK, go to Step 2. If not OK, repair the open
circuit to the PDC fuse as required.
(2) The relay normally closed terminal (87A) is
connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3.
(3) The relay normally open terminal (87) is con-
nected to the common feed terminal (30) in the ener-
gized position. This terminal supplies battery voltage
to the starter solenoid field coils. There should be
continuity between the cavity for relay terminal 87
and the starter solenoid terminal at all times. If OK,
go to Step 4. If not OK, repair the open circuit to the
starter solenoid as required.
(4) The coil battery terminal (86) is connected to
the electromagnet in the relay. It is energized when
the ignition switch is held in the Start position and
the clutch pedal is depressed (manual trans). Check
for battery voltage at the cavity for relay terminal 86
with the ignition switch in the Start position and the
clutch pedal is depressed (manual trans), and no
voltage when the ignition switch is released to the
On position. If OK, go to Step 5. If not OK, check for
an open or short circuit to the ignition switch and
repair, if required. If the circuit to the ignition switch
is OK, see the Ignition Switch Test procedure in this
group.
(5) The coil ground terminal (85) is connected to
the electromagnet in the relay. It is grounded
through the transmission range sensor only when the
gearshift selector lever is in the Park or Neutral
positions. Check for continuity to ground at the cav-
ity for relay terminal 85. If not OK with an auto-
matic transmission, check for an open or short circuit
to the transmission range sensor and repair. It is
grounded by the PCM if the conditions are right to
start the car. For automatic trans. cars the PCM
must see Park Neutral switch and near zero engine
rpm. For manual trans. cars the PCM only needs to
see near zero engine rpm. To diagnose the Park Neu-
tral switch of the trans range sensor refer to the
transaxle section for more information. Check for
continuity to ground while the ignition switch is in
the start position. If not OK and the vehicle has an
automatic trans. verify Park Neutral switch opera-
Starter Relay Pinout
Starter Relay Pinout
RGSTARTING8Fa-35
STARTING (Continued)
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REMOVAL - 3.3/3.8L
(1) Release hood latch and open hood.
(2) Disconnect and isolate the battery negative
cable.
(3) Hoist and support vehicle on safety stands.
(4) Remove nut holding B+ terminal to starter
solenoid (Fig. 7).
(5) Disconnect solenoid connector from starter.
(6) Remove bolts holding starter to transaxle bell-
housing (Fig. 8).(7) Remove starter from bellhousing (Fig. 9).
(8) Separate starter spacer from transaxle bell-
housing.
REMOVAL - 3.5L
(1) Disconnect the negative battery cable.
(2) Raise vehicle and support
(3) Disconnect the battery positive cable at starter
(Fig. 10).
Fig. 7 Starter
1 - SOLENOID CONNECTOR
2 - B+ CONNECTOR
Fig. 8 Starter Bolts
1-STARTER
2 - STARTER BOLTS
3 - TRANSAXLE
4 - ENGINE MOUNT
Fig. 9 STARTER 3.3/3.8L
1 - BELL HOUSING PLATE
2 - FLYWHEEL
3 - ENGINE MOUNT
4-STARTER
5 - SPACER
Fig. 10 ELECTRICAL CONNECTIONS
RGSTARTING8Fa-39
STARTER MOTOR (Continued)
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(4) Disconnect the solenoid connector (Fig. 10).
(5) Turn front wheels to the left and use long
extension to reach the upper mounting bolt (Fig. 11).
(6) Remove the ground wires from the upper
mounting bolt.
(7) Remove the upper mounting bolt.
(8) Remove the middle mounting bolts (Fig. 12).(9) Remove the lower mounting bolt (Fig. 13).
(10) Remove starter.
REMOVAL - 2.5L
(1) Disconnect the negative battery cable.
(2) Raise vehicle and support.
(3) Remove the lower engine splash shield.
(4) Remove the electrical connectors from the
starter (Fig. 14).
Fig. 11 STARTER BOLTS AND STUD
Fig. 12 MIDDLE BOLT
Fig. 13 LOWER BOLT
Fig. 14 STARTER LOCATION
8Fa - 40 STARTINGRG
STARTER MOTOR (Continued)
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(5) Remove the starter mounting bolts (Fig. 15).
(6) Remove the starter.
INSTALLATION
INSTALLATION - 2.4L
(1) Place starter in position on vehicle.
(2) Install the lower bolts to hold starter to trans-
axle bellhousing.
(3) Install the upper bolt and ground wire (Fig. 6).
(4) Place solenoid and B+ wires in position on
starter terminals (Fig. 5).
(5) Install nut to hold B+ wire to terminal.
(6) Connect solenoid wire connector onto terminal.
(7) Connect battery negative cable.(8) Verify starter operation.
INSTALLATION - 3.3/3.8L
(1) Place starter spacer in position on transaxle
bellhousing, flange toward flywheel.
(2) Place starter in position on bellhousing.
(3) Install bolts and ground wire (Fig. 6) to hold
starter to transaxle bellhousing.
(4) Connect solenoid connector into starter.
(5) Install nut to hold B+ terminal to starter sole-
noid.
(6) Lower vehicle.
(7) Connect battery negative cable.
(8) Verify starter operation.
INSTALLATION - 3.5L
(1) Install starter.
(2) Install the middle (Fig. 12) and lower (Fig. 13)
mounting bolts.
Turn front wheels to the left and use long exten-
sion to reach the upper mounting bolt (Fig. 11).
(3) Install the upper mounting bolt.
(4) Install the ground wires to the upper mounting
bolt.
(5) Connect the solenoid connector (Fig. 10).
(6) Connect the battery positive cable at starter
(Fig. 10).
(7) Lower vehicle.
(8) Connect the negative battery cable.
INSTALLATION - 2.5L
(1) Raise vehicle and support.
(2) Install the starter.
(3) Install the starter mounting bolts (Fig. 15).
(4) Install the electrical connectors to the starter
(Fig. 14).
(5) Install the lower engine splash shield.
(6) Connect the negative battery cable.
(7) Lower vehicle.
Fig. 15 STARTER MOUNTING BOLTS
1 - Starter
2 - Mounting Bolts
RGSTARTING8Fa-41
STARTER MOTOR (Continued)
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The electrically heated Rear Window Defogger (Fig.
1), Heated Power Side View Mirrors, and Heated
Windshield Wiper De-icer (Fig. 2)is available on
select models.
OPERATION
The Rear Window Defogger(Refer to 8 - ELECTRI-
CAL/HEATED GLASS - DESCRIPTION) system con-
sists of two vertical bus bars linked by a series of
grid lines on the inside surface of the rear window.
The electrical circuit consists of the rear defogger
switch in the HVAC control assembly and a relay
with timer switch to turn OFF the system after ten
minutes. The main feed circuit is protected by fuse
13 (40 amp) in the Power Distribution Center (PDC)
which is connected directly to the front control mod-
ule (FCM) to form an integrated unit called an Inte-
grated Power Module (IPM). The rear defogger
switch and relay also activates the heated power side
view mirrors. The rear defogger switch also activates
the heated windshield wiper de-icer which is powered
by the RUN/ACC relay in the IPM and feed thru fuse
#11 (20 amp) in the PDC. The heated mirror circuit
is protected by a non-servicable Positive Temperature
Coefficient (PTC) located inside the PDC. The heated
windshield wiper de-icer circuit is protected by fuse
11 (20 amp) in the PDC.
The Heated Windshield Wiper Deicer is also acti-
vated when the DEFROST mode is selected on the
HVAC. In the DEFROST mode the rear defogger
timout is bypassed, the heated windshield wiper de-
icer will stay ON until the another mode is selected.
For circuit information and component location refer
to appropriate section for Wiring Diagrams.
CAUTION:
Since grid lines can be damaged or scraped off
with sharp instruments, care should be taken in
cleaning the glass or removing foreign materials,
decals or stickers. Normal glass cleaning solvents
or hot water used with rags or toweling is recom-
mended.
DEFOGGER RELAY
DESCRIPTION
There is no heated windshield wiper de-icer relay.
The grid is powered directly from fuse #11 in the
PDC and is controlled directly from the HVAC con-
trol assembly.
REAR WINDOW DEFOGGER
GRID
STANDARD PROCEDURE - GRID LINE REPAIR
REAR
For Grid repair procedure for the rear window
defogger (Refer to 8 - ELECTRICAL/HEATED
GLASS/WINDSHIELD GRID - STANDARD PROCE-
DURE).
REAR WINDOW DEFOGGER
SWITCH
DESCRIPTION
The rear window defogger switch is integrated into
the HVAC control panel assembly (Fig. 3)
OPERATION
A LED indicator will illuminate when the switch is
activated. The switch energizes the HVAC control
assembly when it requests the Front Control Module
(FCM) to activate the rear window defogger relay.
The relay controls the current to flow to the grids of
the rear window defogger, heated power side view
mirrors and the heated windshield wiper de-icer. The
defogger relay will be on for approximately 10 min-
utes or until the control switch or ignition is turned
off.
Fig. 3 HVAC CONTROL PANEL
1 - TRIM BEZEL
2 - ACT SENSOR
3 - A/C REQUEST SWITCH
4 - REAR WINDOW DEFOGGER/HEATED MIRRORS SWITCH
COMBO
5 - FRONT WINDOW DEFROSTER MODE SELECTOR
8G - 2 HEATED GLASSRS
HEATED GLASS (Continued)
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