Power system CHRYSLER VOYAGER 2004 Manual PDF

the START position. If voltage reads above 0.2 volt,
correct poor starter to engine ground.
(a) Connect the positive voltmeter lead to the
battery positive terminal, and negative lead to bat-
tery cable terminal on starter solenoid. Rotate and
hold the ignition switch in the START position. If
voltage reads above 0.2 volt, correct poor contact at
battery cable to solenoid connection. If reading is
still above 0.2 volt after correcting poor contacts,
replace battery positive cable.
(b) If resistance tests do not detect feed circuit
failures, replace the starter motor.
DIAGNOSIS AND TESTING - FEED CIRCUIT
TEST
NOTE: The following results are based upon the
vehicle being at room temperature.
The following procedure will require a suitable
volt-ampere tester (Fig. 1).
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.(1) Check battery before performing this test. Bat-
tery must be fully charged.
(2) Connect a volt-ampere tester to the battery ter-
minals. Refer to the operating instructions provided
with the tester being used.
(3) To disable the ignition and fuel systems, dis-
connect the Automatic Shutdown Relay (ASD). The
ASD relay is located in the Power Distribution Cen-
ter (PDC). Refer to the PDC cover for proper relay
location.
(4) Verify that all lights and accessories are OFF,
and the transmission shift selector is in the PARK
and SET parking brake.
CAUTION: Do not overheat the starter motor or
draw the battery voltage below 9.6 volts during
cranking operations.
(5) Rotate and hold the ignition switch in the
START position. Observe the volt-ampere tester (Fig.
1).
²If voltage reads above 9.6 volts, and amperage
draw reads above 280 amps, check for engine seizing
or faulty starter.
²If voltage reads 12.4 volts or greater and amper-
age reads 0 to 10 amps, check for corroded cables
and/or bad connections.
²Voltage below 9.6 volts and amperage draw
above 300 amps, the problem is the starter. Replace
the starter refer to starter removal.
(6) After the starting system problems have been
corrected, verify the battery state-of-charge and
charge battery if necessary. Disconnect all testing
equipment and connect ASD relay. Start the vehicle
several times to assure the problem has been cor-
rected.
SPECIFICATIONS
Torques
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Starter Mounting Bolts 47.4 35
Starter Solenoid Battery
Nut11.3 8.3 100
Fig. 1 Volt Ampere Tester
RSSTARTING8F-33
STARTING (Continued)

²Battery Holddown - The battery holddown
hardware secures the battery in the battery tray in
the engine compartment. ² Battery Thermowrap - The battery thermow-
rap insulates the battery to protect it from engine
compartment temperature extremes. ² Battery Tray - The battery tray provides a
secure mounting location in the vehicle for the bat-
tery and an anchor point for the battery holddown
hardware. For battery system maintenance schedules and
jump starting procedure, see the owner's manual in
the vehicle glove box. Optionally, refer to the Lubri-
cation and Maintenance section of this manual for
the recommended battery maintenance schedules and
for the proper battery jump starting procedure. While
battery charging can be considered a maintenance
procedure, the battery charging procedure and
related information are located later in this section of
this service manual. This was done because the bat-
tery must be fully-charged before any battery system
diagnosis or testing procedures can be performed.
OPERATION
The battery system is designed to provide a safe,
efficient, reliable and mobile means of delivering and
storing electrical energy. This electrical energy is
required to operate the engine starting system, as
well as to operate many of the other vehicle acces-
sory systems for limited durations while the engine
and/or the charging system are not operating. The
battery system is also designed to provide a reserve
of electrical energy to supplement the charging sys-
tem for short durations while the engine is running
and the electrical current demands of the vehicle
exceed the output of the charging system. In addition
to delivering, and storing electrical energy for the
vehicle, the battery system serves as a capacitor and
voltage stabilizer for the vehicle electrical system. It
absorbs most abnormal or transient voltages caused
by the switching of any of the electrical components
or circuits in the vehicle.
DIAGNOSIS AND TESTING - BATTERY SYSTEM
The battery, starting, and charging systems in the
vehicle operate with one another and must be tested
as a complete system. In order for the engine to start
and the battery to maintain its charge properly, all of
the components that are used in these systems must
perform within specifications. It is important that
the battery, starting, and charging systems be thor-
oughly tested and inspected any time a battery needs
to be charged or replaced. The cause of abnormal bat-
tery discharge, overcharging or early battery failure
must be diagnosed and corrected before a battery is
replaced and before a vehicle is returned to service. The service information for these systems has been
separated within this service manual to make it eas-
ier to locate the specific information you are seeking.
However, when attempting to diagnose any of these
systems, it is important that you keep their interde-
pendency in mind.
The diagnostic procedures used for the battery,
starting, and charging systems include the most
basic conventional diagnostic methods, to the more
sophisticated On-Board Diagnostics (OBD) built into
the Powertrain Control Module (PCM). Use of an
induction-type milliampere ammeter, a volt/ohmme-
ter, a battery charger, a carbon pile rheostat (load
tester) and a 12-volt test lamp may be required. All
OBD-sensed systems are monitored by the PCM.
Each monitored circuit is assigned a Diagnostic Trou-
ble Code (DTC). The PCM will store a DTC in elec-
tronic memory for any failure it detects. Refer to
Charging System for the proper charging system on-
board diagnostic test procedures.
MICRO 420 BATTERY TESTER
The Micro 420 automotive battery tester is
designed to help the dealership technicians diagnose
the cause of a defective battery. Follow the instruc-
tion manual supplied with the tester to properly
diagnose a vehicle. If the instruction manual is not
available refer to the standard procedure in this sec-
tion, which includes the directions for using the
Micro 420 battery tester.
8Fs - 2 BATTERY SYSTEMRS
BATTERY SYSTEM (Continued)

SPECIAL TOOLS
BATTERY SYSTEM SPECIAL TOOLS
BATTERY
DESCRIPTION
There are three different batteries available on this
model. Vehicles equipped with a diesel engine utilize
a spiral wound plate designed battery with recombi-
nation technology. This is a maintenance-free battery
that is capable of delivering more power than a con-
ventional battery. This additional power is required
by a diesel engine during cold cranking. Vehicles
equipped with a gasoline engine utilize a conven-
tional battery. Refer to the following information for
detailed differences and descriptions of these batter-
ies.
SPIRAL PLATE BATTERY - DIESEL ENGINE
Spiral plate technology takes the elements of tradi-
tional batteries - lead and sulfuric acid - to the next
level. By tightly winding layers of spiral grids and
acid-permeated vitreous separators into cells, the
manufacturer has developed a battery with more
power and service life than conventional batteries the
same size. The spiral plate battery is completely, per-
manently sealed. Through gas recombination, hydro-
gen and oxygen within the battery are captured
during normal charging and reunited to form the
water within the electrolyte, eliminating the need to
add distilled water. Therefore, these batteries have non-removable battery vent caps (Fig. 4). Water
can-
not be added to this battery.
The acid inside a spiral plate battery is bound
within the vitreous separators, ending the threat of
acid leaks. This feature allows the battery to be
installed in any position anywhere in the vehicle. Spiral plate technology is the process by which the
plates holding the active material in the battery are
wound tightly in coils instead of hanging flat, like
conventional batteries. This design has a lower inter-
nal resistance and also increases the active material
surface area.
WARNING: NEVER EXCEED 14.4 VOLTS WHEN
CHARGING A SPIRAL PLATE BATTERY. PERSONAL
INJURY AND/OR BATTERY DAMAGE MAY RESULT.
Due to the maintanance-free design, distilled water
cannot be added to this battery. Therefore, if more
than 14.4 volts are used during the spiral plate bat-
tery charging process, water vapor can be exhausted
through the pressure-sensitive battery vents and lost
for good. This can permanently damage the spiral
plate battery. Never exceed 14.4 volts when charging
a spiral plate battery. Personal injury and/or battery
damage may result.
CONVENTIONAL BATTERY - GASOLINE ENGINE
Low-maintenance batteries are used on export
vehicles equipped with a gasoline engine, these bat-
teries have removable battery cell caps (Fig. 5).
Water canbe added to this battery. Under normal
Micro 420 Battery Tester
Fig. 4 MAINTENANCE-FREE DIESEL ENGINE
BATTERY
RS BATTERY SYSTEM8Fs-7
BATTERY SYSTEM (Continued)

CONVENTIONAL BATTERY CHARGING TIME TABLECharging
Amperage 5 Amps10
Amps 20 Amps
Open Circuit Voltage Hours Charging @ 21É C (70É
F)
12.25 to 12.49 6 hours 3 hours 1.5 hours
12.00 to 12.24 10 hours 5 hours 2.5 hours
10.00 to 11.99 14 hours 7 hours 3.5 hours
Below 10.00 18 hours 9 hours 4.5 hours
STANDARD PROCEDURE - OPEN-CIRCUIT
VOLTAGE TEST
A battery open-circuit voltage (no load) test will
show the approximate state-of-charge of a battery.
This test can be used if no other battery tester is
available. Before proceeding with this test, completely charge
the battery. Refer to Standard Procedures for the
proper battery charging procedures. (1) Before measuring the open-circuit voltage, the
surface charge must be removed from the battery.
Turn on the headlamps for fifteen seconds, then
allow up to five minutes for the battery voltage to
stabilize. (2) Disconnect and isolate both battery cables, neg-
ative cable first. (3) Using a voltmeter connected to the battery
posts (see the instructions provided by the manufac-
turer of the voltmeter), measure the open-circuit volt-
age (Fig. 9).
See the Open-Circuit Voltage Table. This voltage
reading will indicate the battery state-of-charge, but
will not reveal its cranking capacity. If a battery has
an open-circuit voltage reading of 12.4 volts or greater, it may be load tested to reveal its cranking
capacity. Refer to Standard Procedures for the proper
battery load test procedures.
OPEN CIRCUIT VOLTAGE TABLE
Open Circuit Voltage Charge Percentage 11.7 volts or less 0% 12.0 volts 25%
12.2 volts 50%
12.45 volts 75%
12.65 volts or more 100%
STANDARD PROCEDURE - IGNITION-OFF
DRAW TEST
The term Ignition-Off Draw (IOD) identifies a nor-
mal condition where power is being drained from the
battery with the ignition switch in the Off position. A
normal vehicle electrical system will draw from fif-
teen to twenty-five milliamperes (0.015 to 0.025
ampere) with the ignition switch in the Off position,
and all non-ignition controlled circuits in proper
working order. Up to twenty-five milliamperes are
needed to enable the memory functions for the Pow-
ertrain Control Module (PCM), digital clock, electron-
ically tuned radio, and other modules which may
vary with the vehicle equipment. A vehicle that has not been operated for approxi-
mately twenty-one days, may discharge the battery
to an inadequate level. When a vehicle will not be
used for twenty-one days or more (stored), remove
the IOD fuse from the Integrated Power Module
(IPM). This will reduce battery discharging. Excessive IOD can be caused by:
² Electrical items left on.
² Faulty or improperly adjusted switches.
² Faulty or shorted electronic modules and compo-
nents. ² An internally shorted generator.
² Intermittent shorts in the wiring.
If the IOD is over twenty-five milliamperes, the
problem must be found and corrected before replac-
ing a battery. In most cases, the battery can be
charged and returned to service after the excessive
IOD condition has been corrected. (1) Verify that all electrical accessories are off.
Turn off all lamps, remove the ignition key, and close
all doors. If the vehicle is equipped with an illumi-
nated entry system or an electronically tuned radio,
allow the electronic timer function of these systems
to automatically shut off (time out). This may take
up to twenty minutes. (2) Disconnect the battery negative cable.
(3) Set an electronic digital multi-meter to its
highest amperage scale. Connect the multi-meter
Fig. 9 Testing Open-Circuit Voltage - Typical
RS BATTERY SYSTEM8Fs-13
BATTERY (Continued)

between the disconnected battery negative cable ter-
minal clamp and the battery negative terminal post.
Make sure that the doors remain closed so that the
illuminated entry system is not activated. The multi-
meter amperage reading may remain high for up to
three minutes, or may not give any reading at all
while set in the highest amperage scale, depending
upon the electrical equipment in the vehicle. The
multi-meter leads must be securely clamped to the
battery negative cable terminal clamp and the bat-
tery negative terminal post. If continuity between the
battery negative terminal post and the negative cable
terminal clamp is lost during any part of the IOD
test, the electronic timer function will be activated
and all of the tests will have to be repeated.(4) After about three minutes, the high-amperage
IOD reading on the multi-meter should become very
low or nonexistent, depending upon the electrical
equipment in the vehicle. If the amperage reading
remains high, remove and replace each fuse or circuit
breaker in the Integrated Power Module (IPM), one
at a time until the amperage reading becomes very
low, or nonexistent. Refer to the appropriate wiring
information in this service manual for complete Inte-
grated Power Module fuse, circuit breaker, and cir-
cuit identification. This will isolate each circuit and
identify the circuit that is the source of the high-am-
perage IOD. If the amperage reading remains high
after removing and replacing each fuse and circuit
breaker, disconnect the wire harness from the gener-
ator. If the amperage reading now becomes very low
or nonexistent, refer to Charging System for the
proper charging system diagnosis and testing proce-
dures. After the high-amperage IOD has been cor-
rected, switch the multi-meter to progressively lower
amperage scales and, if necessary, repeat the fuse
and circuit breaker remove-and-replace process to
identify and correct all sources of excessive IOD. It is
now safe to select the lowest milliampere scale of the
multi-meter to check the low-amperage IOD.
CAUTION: Do not open any doors, or turn on any
electrical accessories with the lowest milliampere
scale selected, or the multi-meter may be damaged.
(5) Allow twenty minutes for the IOD to stabilize
and observe the multi-meter reading. The low-amper-
age IOD should not exceed twenty-five milliamperes
(0.025 ampere). If the current draw exceeds twenty-
five milliamperes, isolate each circuit using the fuse
and circuit breaker remove-and-replace process in
Step 4. The multi-meter reading will drop to within
the acceptable limit when the source of the excessive
current draw is disconnected. Repair this circuit as
required; whether a wiring short, incorrect switch
adjustment, or a component failure is at fault.STANDARD PROCEDURE - CHECKING BATTERY
ELECTROLYTE LEVEL
The following procedure can be used to check the
electrolyte level in a low-maintenance lead-acid bat-
tery. (1) Unscrew and remove the battery cell caps with
a flat-bladed screw driver (Fig. 10).
WARNING: NEVER PUT YOUR FACE NEAR A GAS-
SING, HOT OR SWELLED BATTERY. SERIOUS PER-
SONAL INJURY MAY RESULT.
(2) Wearing safety glasses, look through the bat-
tery cell cap holes to determine the level of the elec-
trolyte in the battery. The electrolyte should be above
the hooks inside the battery cells (Fig. 11). (3) Add only distilled water until the electrolyte
is above the hooks inside the battery cells (Fig. 11).
REMOVAL - BATTERY
WARNING: A SUITABLE PAIR OF HEAVY DUTY
RUBBER GLOVES AND SAFETY GLASSES SHOULD
BE WORN WHEN REMOVING OR SERVICING A
BATTERY.
Fig. 10 BATTERY CELL CAP REMOVAL/
INSTALLATION - LOW-MAINTENANCE BATTERY ONLY
1 - BATTERY CELL CAP
2 - BATTERY CASE
8Fs - 14 BATTERY SYSTEMRS
BATTERY (Continued)

WARNING: REMOVE METALLIC JEWELRY TO
AVOID INJURY BY ACCIDENTAL ARCING OF BAT-
TERY CURRENT.(1) Verify that the ignition switch and all accesso-
ries are OFF. (2) Disconnect the battery cables from the battery
posts, negative first (Fig. 12). (3) Remove the battery hold down retaining nut.
(4) Remove the battery hold down bracket.
(5) Remove the battery from the vehicle.
INSTALLATION
(1) Position the battery in the battery tray.
(2) Install the battery hold down bracket and
retaining nut. Torque the nut to 20 N´m (180 in. lbs.). (3) Connect the battery cables to the battery posts,
positive cable first. Torque terminal fasteners to 5
N´m (40 in. lbs.).
BATTERY HOLDDOWN
DESCRIPTION
The battery hold down hardware consists of a
molded plastic lip that is integral to the outboard
edge of the battery tray and support unit, a molded
steel hold down bracket and a single hex nut with a
coned washer. When installing a battery into the battery tray, be
certain that the hold down hardware is properly
installed and that the fasteners are tightened to the
proper specifications. Improper hold down fastener
tightness, whether too loose or too tight, can result in
damage to the battery, the vehicle or both. Refer to
Battery Hold Downs in this section of this service
manual for the location of the proper battery hold
down installation procedures, including the proper
hold down fastener tightness specifications.
OPERATION
The battery holddown secures the battery in the
battery tray. This holddown is designed to prevent
battery movement during the most extreme vehicle
operation conditions. Periodic removal and lubrica-
tion of the battery holddown hardware is recom-
mended to prevent hardware seizure at a later date.
NOTE: Never operate a vehicle without a battery
holddown device properly installed. Damage to the
vehicle, components and battery could result.
REMOVAL
All of the battery hold down hardware can be ser-
viced without removal of the battery or the battery
tray and support unit. (1) Turn the ignition switch to the Off position. Be
certain that all electrical accessories are turned off.
Fig. 11 HOOK INSIDE BATTERY CELLS - LOW- MAINTENANCE BATTERY ONLY
1 - TOP OF BATTERY
2 - HOOK INSIDE BATTERY CELLS
Fig. 12 BATTERY POSITION & ORIENTATION
1 - BATTERY THERMOWRAP (IF EQUIPPED)
2 - INTEGRATED POWER MODULE
3 - FRONT CONTROL MODULE
RS BATTERY SYSTEM8Fs-15
BATTERY (Continued)

(2) Remove the nut with washer that secures the
battery hold down bracket to the battery tray and
support unit. (3) Remove the battery hold down bracket from
the battery tray and support unit.
INSTALLATION
(1) Install the battery hold down bracket in the
battery tray and support unit. (2) Install the nut with washer that secures the
battery hold down bracket to the battery tray and
support unit. Torque to 20 N´m (180 in. lbs.).
BATTERY CABLES
DESCRIPTION
The battery cables are large gauge, stranded cop-
per wires sheathed within a heavy plastic or syn-
thetic rubber insulating jacket. The wire used in the
battery cables combines excellent flexibility and reli-
ability with high electrical current carrying capacity.
Refer to Wiring Diagrams in the index of this ser-
vice manual for the location of the proper battery
cable wire gauge information. A clamping type female battery terminal made of
stamped metal is attached to one end of the battery
cable wire. A square headed pinch-bolt and hex nut
are installed at the open end of the female battery
terminal clamp. Large eyelet type terminals are
crimped onto the opposite end of the battery cable
wire and then solder-dipped. The battery positive
cable wires have a red insulating jacket to provide
visual identification and feature a larger female bat-
tery terminal clamp to allow connection to the larger
battery positive terminal post. The battery negative
cable wires have a black insulating jacket and a
smaller female battery terminal clamp. The battery cables cannot be repaired and, if dam-
aged or faulty they must be replaced. Both the bat-
tery positive and negative cables are available for
service replacement only as a unit with the battery
wire harness, which may include portions of the wir-
ing circuits for the generator and other components
on some models. Refer to Wiring Diagramsin the
index of this service manual for the location of more
information on the various wiring circuits included in
the battery wire harness for the vehicle being ser-
viced.
OPERATION
The battery cables connect the battery terminal
posts to the vehicle electrical system. These cables
also provide a path back to the battery for electrical
current generated by the charging system for restor-
ing the voltage potential of the battery. The female battery terminal clamps on the ends of the battery
cable wires provide a strong and reliable connection
of the battery cable to the battery terminal posts.
The terminal pinch bolts allow the female terminal
clamps to be tightened around the male terminal
posts on the top of the battery. The eyelet terminals
secured to the opposite ends of the battery cable
wires from the female battery terminal clamps pro-
vide secure and reliable connection of the battery
cables to the vehicle electrical system.
The battery positive cable terminal clamp is
attached to the ends of two wires. One wire has an
eyelet terminal that connects the battery positive
cable to the B(+) terminal stud of the Integrated
Power Module (IPM), and the other wire has an eye-
let terminal that connects the battery positive cable
to the B(+) terminal stud of the engine starter motor
solenoid. The battery negative cable terminal clamp
is also attached to the ends of two wires. One wire
has an eyelet terminal that connects the battery neg-
ative cable to the vehicle powertrain through a stud
on the left side of the engine cylinder block. The
other wire has an eyelet terminal that connects the
battery negative cable to the vehicle body through a
ground screw on the left front fender inner shield,
near the battery.
DIAGNOSIS AND TESTING - BATTERY CABLE
A voltage drop test will determine if there is exces-
sive resistance in the battery cable terminal connec-
tions or the battery cable. If excessive resistance is
found in the battery cable connections, the connec-
tion point should be disassembled, cleaned of all cor-
rosion or foreign material, then reassembled.
Following reassembly, check the voltage drop for the
battery cable connection and the battery cable again
to confirm repair. When performing the voltage drop test, it is impor-
tant to remember that the voltage drop is giving an
indication of the resistance between the two points at
which the voltmeter probes are attached. EXAM-
PLE: When testing the resistance of the battery pos-
itive cable, touch the voltmeter leads to the battery
positive cable terminal clamp and to the battery pos-
itive cable eyelet terminal at the starter solenoid
B(+) terminal stud. If you probe the battery positive
terminal post and the battery positive cable eyelet
terminal at the starter solenoid B(+) terminal stud,
you are reading the combined voltage drop in the
battery positive cable terminal clamp-to-terminal
post connection and the battery positive cable.
VOLTAGE DROP TEST
The following operation will require a voltmeter
accurate to 1/10 (0.10) volt. Before performing this
8Fs - 16 BATTERY SYSTEMRS
BATTERY HOLDDOWN (Continued)

test, be certain that the following procedures are
accomplished:² The battery is fully-charged and load tested.
Refer to Standard Procedures for the proper battery
charging and load test procedures. ² Fully engage the parking brake.
² If the vehicle is equipped with an automatic
transmission, place the gearshift selector lever in the
Park position. If the vehicle is equipped with a man-
ual transmission, place the gearshift selector lever in
the Neutral position and block the clutch pedal in the
fully depressed position. ² Verify that all lamps and accessories are turned
off. ² To prevent the engine from starting, remove the
Automatic Shut Down (ASD) relay. The ASD relay is
located in the Intelligent Power Module (IPM), in the
engine compartment. See the fuse and relay layout
label affixed to the underside of the IPM cover for
ASD relay identification and location. (1) Connect the positive lead of the voltmeter to
the battery negative terminal post. Connect the neg-
ative lead of the voltmeter to the battery negative
cable terminal clamp (Fig. 13). Rotate and hold the
ignition switch in the Start position. Observe the
voltmeter. If voltage is detected, correct the poor con-
nection between the battery negative cable terminal
clamp and the battery negative terminal post.
(2) Connect the positive lead of the voltmeter to
the battery positive terminal post. Connect the nega-
tive lead of the voltmeter to the battery positive cable
terminal clamp (Fig. 14). Rotate and hold the ignition
switch in the Start position. Observe the voltmeter. If
voltage is detected, correct the poor connection
between the battery positive cable terminal clamp
and the battery positive terminal post. (3) Connect the voltmeter to measure between the
battery positive cable terminal clamp and the starter
solenoid B(+) terminal stud (Fig. 15). Rotate and hold
the ignition switch in the Start position. Observe the
voltmeter. If the reading is above 0.2 volt, clean and
tighten the battery positive cable eyelet terminal con-
nection at the starter solenoid B(+) terminal stud.
Repeat the test. If the reading is still above 0.2 volt,
replace the faulty battery positive cable.
(4) Connect the voltmeter to measure between the
battery negative cable terminal clamp and a good
clean ground on the engine block (Fig. 16). Rotate
and hold the ignition switch in the Start position.
Observe the voltmeter. If the reading is above 0.2
volt, clean and tighten the battery negative cable
Fig. 13 Test Battery Negative Connection Resistance - Typical
1 - VOLTMETER
2 - BATTERY
Fig. 14 Test Battery Positive Connection Resistance - Typical
1 - VOLTMETER
2 - BATTERY
Fig. 15 Test Battery Positive Cable Resistance -Typical
1 - BATTERY
2 - VOLTMETER
3 - STARTER MOTOR
RS BATTERY SYSTEM8Fs-17
BATTERY CABLES (Continued)

CHARGING
TABLE OF CONTENTS
page page
CHARGING DESCRIPTION - CHARGING SYSTEM .......20
OPERATION - CHARGING SYSTEM .........20
DIAGNOSIS AND TESTING - ON-BOARD DIAGNOSTIC SYSTEM .................21
SPECIFICATIONS GENERATOR ........................22
TORQUE ............................22
SPECIFICATIONS - BATTERY TEMPERATURE SENSOR ...............22
SPECIAL TOOLS .......................23
BATTERY TEMPERATURE SENSOR DESCRIPTION .........................23
OPERATION ...........................23
REMOVAL .............................23
GENERATOR DESCRIPTION .........................23
OPERATION ...........................23 REMOVAL
REMOVAL - 2.4L ......................23
REMOVAL - 2.5L ......................24
REMOVAL - 3.3/3.8L ...................25
INSTALLATION INSTALLATION - 2.4L ..................26
INSTALLATION - 2.5L ..................26
INSTALLATION - 3.3/3.8L ................26
GENERATOR DECOUPLER PULLEY DESCRIPTION .........................27
OPERATION ...........................27
DIAGNOSIS AND TESTING - GENERATOR DECOUPLER PULLEY ..................27
REMOVAL .............................28
INSTALLATION .........................28
VOLTAGE REGULATOR DESCRIPTION .........................29
OPERATION ...........................29
CHARGING
DESCRIPTION - CHARGING SYSTEM
The charging system consists of:
²Generator
² Decoupler Pulley (If equipped)
² Electronic Voltage Regulator (EVR) circuitry
within the Powertrain Control Module (PCM) ² Ignition switch (refer to the Ignition System sec-
tion for information) ² Battery (refer to the Battery section for informa-
tion) ² Ambient Air Temperature (If equipped)
² Inlet Air Temperature (calculated battery tem-
perature)(If equipped) ² Voltmeter (refer to the Instrument Cluster sec-
tion for information if equipped) ² Wiring harness and connections (refer to the
Wiring section for information) ² Accessory drive belt (refer to the Cooling section
for more information) ² Battery Temperature sensor (if equipped)
OPERATION - CHARGING SYSTEM
The charging system is turned on and off with the
ignition switch. The system is on when the engine is
running and the ASD relay is energized. The ASD
relay is energized when the PCM grounds the ASD
control circuit. This voltage is connected through the PCM or IPM (intelligent power module) (if equipped)
and supplied to one of the generator field terminals
(Gen. Source +) at the back of the generator.
The generator is driven by the engine through a
serpentine belt and pulley or decoupler pulley
arrangement. The amount of DC current produced by the gener-
ator is controlled by the EVR (field control) circuitry
contained within the PCM. This circuitry is con-
nected in series with the second rotor field terminal
and ground. An Ambient air temperature sensor is used to cal-
culate the temperature near the battery. This tem-
perature data, along with data from monitored line
voltage (battery voltage sense circuit), is used by the
PCM to vary the battery charging rate. This is done
by cycling the ground path to control the strength of
the rotor magnetic field. The PCM then compensates
and regulates generator current output accordingly
to maintain system voltage at the targeted system
voltage based on battery temperature. All vehicles are equipped with On-Board Diagnos-
tics (OBD). All OBD-sensed systems, including EVR
(field control) circuitry, are monitored by the PCM.
Each monitored circuit is assigned a Diagnostic Trou-
ble Code (DTC). The PCM will store a DTC in elec-
tronic memory for certain failures it detects and
illuminate the (MIL) lamp. Refer to On-Board Diag-
nostics in the Electronic Control Modules(Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MOD-
8Fs - 20 CHARGINGRS

ULES/POWERTRAIN CONTROL MODULE -
DESCRIPTION) section for more DTC information.The Charging system ªBatteryº light indicates
problems with the charging system (voltage too high/
low, generator failure, etc.). If an extreme condition is
indicated, the lamp will be illuminated. 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 infor-
mation. The PCM uses the ambient air temperature sensor
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 the calculated battery
temperature 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 40 good trip if the problem
does not occur again.
DIAGNOSTIC TROUBLE CODES
A DTC description can be read using the DRBIII t
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 DRBIII tScan Tool must be used to erase a
DTC. The following procedures may be used to diagnose
the charging system if: ² the check gauges lamp or battery lamp is illumi-
nated with the engine running ² the voltmeter (if equipped) does not register
properly ² an undercharged or overcharged battery condi-
tion occurs. Remember that an undercharged battery is often
caused by: ² accessories being left on with the engine not
running ² a faulty or improperly adjusted switch that
allows a lamp to stay on. Refer to Ignition-Off Draw
Test (Refer t o 8 - ELECTRICAL/BATTERY SYSTEM/
BATTERY - STANDARD PROCEDURE) ² loose generator belt.
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 DRBIII tscan tool.
Perform the following inspections before attaching
the scan tool. (1) Inspect the battery condition. Refer to the Bat-
tery section (Refer t o 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) or IPM (if
equipped) 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
RS CHARGING8Fs-21
CHARGING (Continued)