check engine DODGE TRUCK 1993 Service Workshop Manual

7 - 34
COOLING SYSTEM

•
WARNING;
DO NOT
REMOVE
THE
CYLINDER
BLOCK DRAIN PLUGS
OR
LOOSEN
THE
RADIATOR
DRAINCOCK
WITH
THE
SYSTEM
HOT AND
UNDER

PRESSURE.
SERIOUS BURNS FROM COOLANT
CAN OCCUR.

(2) Drain the cooling system. Refer to Draining
Cooling System in this group. (3) Remove hose clamps and hoses from radiator.
Remove coolant reserve/overflow tank hose from ra­ diator filler neck nipple.
(4) Remove fan shroud retaining clips. The shroud
has two tabs that fit into clips in the bottom of the radiator. Lift the shroud up and position it back onto
the engine (Fig. 46).
Fig. 46 Radiator and Fan
Shroud—5.9L
Diesel Engine
(5) Remove radiator top mounting brackets. The
brackets fit over support dowels on the radiator inlet
tank (Fig. 46).
(6) The bottom of the radiator has two dowels that
fit into holes in the lower support panel. Taking care not to damage radiator cooling fins or tubes, lift ra­
diator straight up out of engine compartment
INSTALLATION (1) Position shroud rearward on engine.
(2) Lower radiator into position. The dowels on the
bottom of the radiator fit into alignment holes in the lower support panel.
(3) Install top mounting brackets. Tighten mount­
ing bolts to 23 N*m (17 in. lbs.) torque. (4) Connect radiator hoses. Install hose clamps.
(5) Position fan shroud on radiator flange. Install
retaining clips. (6) Place heater controls in full heat position.
(7) Fill cooling system with coolant. Refer to Refill­
ing Cooling System in this group.
(8) Operate engine until it reaches normal temper­
ature. Check cooling system. RADIATOR DRAINCOCK SERVICE
The radiator draincock is replaceable. Unscrew the
draincock in a clockwise direction and remove from
radiator. Install replacement draincock.

COOLING SYSTEM HOSES
Rubber hoses route coolant to and from the radia­
tor, intake manifold and heater core. Radiator lower
hoses are spring-reinforced to prevent collapse from
water pump suction at moderate and high engine speeds. Inspect the hoses at regular intervals. Replace
hoses that are cracked, feel brittle when squeezed or swell excessively when system is pressurized. The
use of molded replacement hoses is recommended.
When performing a hose inspection, inspect radiator lower hose for proper position and condition of spring.

RADIATOR

J9207-35

Fig. 47 Radiator Hoses—Typical
HOSE CLAMPS Constant tension hose clamps are used on some
cooling system hoses. The clamp size is identified by a letter stamped on the tongue. Special Clamp Tool
number 6094 (Fig. 48) may be used to remove the
constant tension clamps.
Ordinary worm gear type hose clamps (when
equipped) can be removed with a straight screw­
driver or a hex socket. To prevent damage to
hoses or clamps, the hose clamps should be
tightened to 4 N«m (34 in. lbs.) torque. Do not
over tighten hose clamps.

7 - 36
COOLING
SYSTEM

• (4) Connect coolant hoses to cooler.

(5)
Connect battery cable to battery.

(6)
Fill cooling system. Refer to Refilling Cooling
System in this section. (7) Check transmission oil level and fill as neces­
sary.

TRANSMISSION
OIL/TO-AIR
COOLER
Oil to air transmission coolers are mounted ahead
of the radiator and operate in conjunction with the
main cooler (Figs, 52 or 53). The transmission oil is
routed through the main cooler first, then the auxil­ iary cooler, before returning to the transmission.
FRONT
OIL-TO-AIR
COOLER

RADIATOR
RADIATOR GRILL SUPPORT RETURN JO

_
TRANSMISSION

*
PRESSURE

(FROM BOTTOM COOLER)
VIEW
IN
CIRCLE J9007-75 Fig.
52
Transmission
Oil-to-Air Cooler—Except

Diesel—
Typical

AUXILIARY
OIL TO AIR
COOLER
J9107-73
Fig.
53
Transmission
Oil-to-Air
Cooler—Diesel

Engine—Typical
COOLING
SYSTEM FAN—GAS ENGINES

Also refer to Viscous Fan Drive in this group for
additional information.
REMOVAL (1) Disconnect negative battery cable from battery.
(2) Remove throttle cable at top of fan shroud.
(3) Unsnap coolant reserve/overflow tank from fan
shroud and lay aside. The tank is held to shroud
with T-shaped slots. Do not disconnect hose or drain
coolant from tank.
(4) The thermal Viscous Fan Drive/Fan Blade As­
sembly is attached (threaded) to water pump hub
shaft (Fig. 54). Remove fan blade/viscous fan drive
assembly from water pump by turning mounting nut
counterclockwise as viewed from front. Threads on
viscous fan drive are RIGHT HAND. A Snap-On 36
MM Fan Wrench (number SP346 from Snap-On Cummins Diesel Tool Set number 2017DSP) can be
used. Place a bar or screwdriver between water pump
pulley bolts (Fig. 54) to prevent pulley from rotating. Do not attempt to remove fan/viscous fan drive as­
sembly from vehicle at this time.
FAN BLADE

ASSEMBLY

THREADED NUT WATER
PUMP

PULLEY
PULLEY
BOLTS
WATER PUMP
THREADED SHAFT
(WATER PUMP HUB)
VISCOUS
FAN DRIVE CRANKSHAFT
PULLEY
J9307-32

Fig.
54 Fan
Blade/Viscous
Fan
Drive—Gas
Engines
Do not unbolt fan blade assembly (Fig. 54) from
viscous fan drive at this time.
(5) Remove fan shroud attaching hardware (two
bolts at bottom-two clips at top). (6) Remove fan shroud and fan blade/viscous fan
drive assembly as a complete unit from vehicle.
After removing fan blade/viscous fan drive assem­
bly, do not place viscous fan drive in horizontal po­ sition. If stored horizontally, silicone fluid in the
viscous fan drive could drain into its bearing assem­
bly and contaminate lubricant.

ENGINE ACCESSORY DRIVE BELTS

INDEX

page

Automatic Belt Tensioner
45
Belt Diagnosis
40

Belt Removal/Installation
. 40
page

Belt Schematics
40
Belt Tension
40

General
Information
40

GENERAL
INFORMATION
All vehicles are available with either
a
3.9L (V-6),
a 5.2L (V-8),
a
5.9L (gas V-8) or
a
5.9L (in-line 6 cyl­
inder diesel) engine. The accessory drive components
are
operated
by a

single, crankshaft driven, serpentine drive belt on all
engines. An automatic belt tensioner
is
used to main­
tain correct belt tension
at all
times. Refer
to
Auto­ matic Belt Tensioner proceeding
in
this group.

BELT DIAGNOSIS SERPENTINE DRIVE BELT DIAGNOSIS-ALL
ENGINES
When diagnosing serpentine drive belts, small
cracks that run across ribbed surface of belt from rib
to rib (Fig. 1), are considered normal. These are not
a

reason
to
replace belt. However, cracks running along
a rib (not
across)
are not
normal.
Any
belt
with cracks running along
a rib
must
be
replaced (Fig.
1).
Also replace belt
if it has
excessive wear,
frayed cords
or
severe glazing.
Refer to the Serpentine Drive Belt Diagnosis charts
for further belt diagnosis. Also refer
to
Automatic Belt Tensioner proceeding
in
this group.

BELT SCHEMATICS
The following belt routing schematics
are
pub­
lished from
the
latest information available
at the

time
of
publication.
If
anything differs between
these schematics
and the
Belt Routing Label,
use
the
schematics
on
Belt Routing Label. This
label
is
located
in
the engine compartment.

BELT TENSION

ALL
ENGINES
Correct accessory drive belt tension
is
required
to

be sure
of
optimum performance
of
belt driven
en­
gine accessories.
If
specified tension
is not
main­
tained, belt slippage may cause; engine overheating, lack
of
power steering assist, loss
of
air conditioning
capacity, reduced generator output rate and greatly
reduced belt life.
It
is
not necessary
to
adjust belt tension on any en­
gine.
All
engines
are
equipped with
an
automatic
belt tensioner. The tensioner maintains correct belt tension
at all
times. For other tensioner information
NORMAL CRACKS
BELT
OK
NOT NORMAL CRACKS

REPLACE
BELT
J9007-44

Fig. 1 Serpentine Accessory Drive Belt Wear Patterns
and removal/installation procedures, refer
to
Auto­
matic Belt Tensioner proceeding
in
this group.
Due

to use
of
this belt tensioner, do not attempt
to
use
a

belt tension gauge
on
any engine.

BELT REMOVAL/INSTALLATION

Caution:
Do not
attempt
to
check belt tension with
a
belt
tension gauge
on
vehicles equipped with
an
automatic belt tensioner. Refer
to
Automatic Belt

Tensioner
in
this
group.

3.9L/5,2U5*9L
LDC-GAS ENGINES

REMOVAL
Drive belts
on
these engines
are
equipped with
a

spring loaded automatic belt tensioner (Fig.
7).
This
belt tensioner will
be
used on
all
belt configurations, such
as
with
or
without power steering
or
air condi­
tioning.
For
more information, refer
to
Automatic Belt Tensioner, proceeding
in
this group.
(1) Attach
a
socket/wrench
to
pulley mounting bolt
of automatic tensioner (Fig.
7).

7 - 42 COOLING SYSTEM
• SERPENTINE DRIVE BELT DIAGNOSIS-DIESEL ENGINE

Condition

Possible
Cause
Correction

RIB
CHUNKING (1) Foreign objects imbedded in
(1) Remove foreign objects from

(ONE
OR
MORE
RIBS
(1)
pulley grooves.
pulley
grooves.
Replace
belt.

HAS
SEPARATED
pulley grooves.
Replace
belt.

FROM
BELT BODY) (2) Installation damage.
(2) Replace
belt.

RIB
OR
BELT
WEAR
(1) Pulley(s) misaligned.
(1)

Align
pulley(s).
(2) Abrasive environment.
(2)
Clean pulley(s). Replace
(2)

belt
if necessary.
(3)
Rusted
pulley(s).
(3) Clean rust from pulley(s).
(4)
Sharp
or jagged pulley groove tips.
(4)
Replace pulley.
(5) Rubber
deteriorated.

(5)
Replace
belt.

LONGITUDINAL
(1) Belt has mistracked from
(1)
Replace
belt.

BELT
CRACKING
(1)
pulley groove. Replace
belt.

(CRACKS
BETWEEN

TWO
RIBS)
pulley groove.
Replace
belt.

(CRACKS
BETWEEN

TWO
RIBS)
(2) Pulley groove tip has worn away
(2) Replace
belt.

(2)
rubber to tensile member.

BELT
SLIPS
(1) Belt slipping because of
0) Replace tensioner.
(1)
insufficient tension.
(2) Incorrect
belt.

(2)
Replace
belt.

(3) Belt or pulley subjected to
(3)
Replace
belt
and clean pulleys.

substance
(belt
dressing,
oil,

ethylene
glycol)
that
has reciuced friction.
(4) Driven component bearing
failure.

(4)
Replace
faulty
component bearing.
(5) Belt glazed and hardened from
(5)
Replace
belt.

(5)

heat
and excessive slippage.

"GROOVE
JUMPING" (1) Belt tension
either
too
(1) Replace tensioner.

(BELT
DOES
NOT 5 (1)

high
or too low. Replace tensioner.

MAINTAIN
CORRECT
high
or too low.

POSITION
ON PULLEY) (2) Incorrect
belt.

(2) Replace
belt.

(3) Pulley(s) not
within
design
(3)
Replace pulley(s).
tolerance.
(4) Foreign object(s) in grooves.
(4)
Remove foreign objects
from grooves.
(5) Pulley misalignment.
(5)
Check and Replace.
(6) Belt cordline is broken.
(6)
Replace
belt.

BELT
BROKEN
0)
Excessive
tension.
0) Replace
belt
and

(NOTE:
IDENTIFY 0)
tensioner.

AND
CORRECT
PROBLEM
BEFORE
(2) Incorrect
belt.

(2) Replace
belt.

NEW
BELT
IS (2)
Replace
belt.

INSTALLED)
(3) Tensile members damaged during
(3) Replace
belt.

(3)

belt
installation.
(4) Severe misalignment.
(4)
Check and replace.
(5) Bracket, pulley, or bearing
(5)
Replace
defective
component
(5)

failure.
ana
belt.

NOISE
0) Belt slippage.
(1) Replace
belt
or
belt
tensioner.

(OBJECTIONAL
0)
Belt slippage.
Replace
belt
or
belt
tensioner.

SQUEAL,
SQUEAK,
(2) Bearing noise.
(2) Locate and
repair.

OR
RUMBLE
IS (2)
Bearing noise.

HEARD
OR FELT (3) Belt misalignment.
(3) Replace
belt.

WHILE
DRIVE
BELT (3)
Belt misalignment.
Replace
belt.

IS
IN OPERATION) (4) Belt-to-pulley mismatch.
(4) Install correct
belt.

J9107-74

7 - 44
COOLING
SYSTEM

•

Fig.
6 Belt Routing-5.9L Diesel-Without A/C
Fig.
7 Belt Tensioner-3.9L/5.2U5.9L
LDC-Gas
Engine
(3)
Rotate socket/wrench clockwise. Place belt over
idler pulley. Let tensioner rotate back into place. Re­
move wrench. Be sure belt is properly seated on all
pulleys.

(4)
Check belt indexing marks. Refer to the pro­
ceeding Automatic Belt Tensioner for more belt in­
formation. 5.9L
HDC-GAS
ENGINE

REMOVAL
Drive belts are equipped with a spring loaded au­
tomatic belt tensioner (Fig. 8). This belt tensioner
will be used on all belt configurations, such as with or without power steering or air conditioning. For
more information, refer to Automatic Belt Tensioner,
proceeding in this group.

Fig.
8 Belt Tensioner—5.9L
HDC-Gas Engine

(1) Attach a socket/wrench to pulley mounting bolt
of automatic tensioner (Fig. 8). (The threads on this
bolt are left hand).
(2) Relax the tension from the belt by rotating the
tensioner counterclockwise (as viewed from front) (Fig. 8). When all belt tension has been relaxed, re­
move belt from tensioner pulley first and other pul­ leys last.

INSTALLATION

CAUTION:
When installing serpentine
accessory

drive belt, belt must
be
routed correctly.
If not, en­
gine
may
overheat
due to
water pump rotating
in

wrong
direction. Refer
to
(Figs.
3 or 4) for
correct
engine
belt routing.
The
correct belt with correct length must
t^e
used.

CAUTION:
if the
pulley
is to be
removed from
the

tensioner,
its
mounting bolt
has left
hand threads.

(1) Position drive belt over all pulleys except ten­
sioner pulley. (2) Attach a socket/wrench to pulley mounting bolt
of automatic tensioner (Fig. 8).

•

COOLING
SYSTEM
7 - 45 (3) Rotate socket/wrench counterclockwise. Install
belt over tensioner pulley. Let tensioner rotate back into place. Remove wrench. Be sure belt is properly
seated on all pulleys.

5«9L
DIESEL ENGINE

REMOVAL
Drive belts on diesel engines are equipped with a
spring loaded automatic belt tensioner (Fig. 9). Fig­
ure 9 displays the tensioner for vehicles without air conditioning.
This belt tensioner will be used on all belt config­
urations, such as with or without air conditioning.
For more information, refer to Automatic Belt Ten­ sioner, proceeding in this group.
Fig.
9 Belt Tensioner—5.9L
Diesel
Engine—Typical
(1) A 3/8 inch square hole is provided in the auto­
matic belt tensioner (Fig. 9). Attach a 3/8 inch drive-
long handle ratchet to this hole.
(2) Rotate ratchet and tensioner assembly counter­
clockwise (as viewed from front) until tension has
been relieved from belt.
(3) Remove belt from water pump pulley first.
(4) Remove belt from vehicle.

INSTALLATION

CAUTION:
When installing serpentine
accessory

drive belt, belt must
be
routed correctly.
If not, en­

gine
may
overheat
due to
water pump rotating
in

wrong
direction. Refer
to
(Figs.
5 or 6) for
correct

engine
belt routing.
The
correct belt with correct
length
must
be
used.

(1) Position drive belt over all pulleys except wa­
ter pump pulley. (2) Attach a 3/8 inch ratchet to tensioner.
(3) Rotate ratchet and belt tensioner counterclock­

wise.
Place belt over water pump pulley. Let ten­ sioner rotate back into place. Remove ratchet. Be
sure belt is properly seated on all pulleys.

AUTOMATIC
BELT
TENSIONER
Drive belts on all engines are equipped with a
spring loaded automatic belt tensioner (Figs. 10, 11
or 12). This belt tensioner will be used with all belt configurations, such as with or without power steer­
ing or air conditioning.

Caution:
Do not
attempt
to
check belt tension with

a
belt tension
gauge
on
vehicles equipped with
an

automatic
belt tensioner. Fig.
10 Belt Tensioner—3.9U5.2U5.9L
LDC-Gas
Engine
On 3.9L/5.2L and 5.9L LDC-gas engines, the ten­
sioner is equipped with an indexing arrow (Fig. 13)
on back of tensioner and an indexing mark on ten­
sioner housing. If a new belt is being installed, arrow
must be within approximately 3 mm (1/8 in.) of in­ dexing mark (Point B—Fig. 13). Belt is considered
new if it has been used 15 minutes or less. If this
specification cannot be met, check for:
• The wrong belt being installed (incorrect length/
width)
• Worn bearings on an engine accessory (A/C com­
pressor, power steering pump, water pump, idler pul­ ley or generator)
• A pulley on an engine accessory being loose
• Misalignment of an engine accessory
• Belt incorrectly routed. Refer to (Figs. 2, 3 or 4) On 3.9L/5.2L and 5.9L LDC-gas engines, a used
belt should be replaced if tensioner indexing arrow
has moved beyond point A (Fig. 13).

7
- 4S
COOLING
SYSTEM

•
PULLEY BOLT IDLER
iUlLTPULLEY-
TENSIONER
MOUNTING
BOLT TENSIONER
ASSEMBLY
TENSIONER \
rULLC,\
, / ^ J9307-64 ,

Fig.
11 Beit Tensioner—5.9L
HDC-Gas
Engine

MOUNT.
BOLT
3/8
SQUARE HOLE
ACCESSORY

DRIVE
BELT AUTOMATIC
BELT

TENSIONER
J9307-59

Fig.
12 Belt Tensioner—5.9L
Diesel
Engine—Typical

3MLm.2Lm.9L
LDG°GA8
ENGINES

REMOVAL
(1) Remove accessory drive belt. Refer to Belt Re­
moval/Installation in this group. (2) Disconnect wiring and secondary cable from ig­
nition coil.
(3) Remove ignition coil from coil mounting
bracket (two bolts). Do not remove coil mounting
bracket from cylinder head. (4) Remove tensioner assembly from mounting
bracket (one nut) (Fig. 13).

WARNING: BECAUSE
OF
HIGH
SPRING
PRES­
SURE,
DO
NOT ATTEMPT
TO
DISASSEMBLE
AUTO­
MATIC
TENSIONER.
UNIT
IS
SERVICED
AS AN

ASSEMBLY
(EXCEPT
FOR
PULLEY).
TENSIONER
MOUNTING NUT
INDEXING ARROW
INDEXING MARK

J9207-17

Fig.
13 indexing Marks-3.9L/5.2L/5.9L
LDC-Gas
Engine
(5) Remove pulley bolt. Remove pulley from ten­
sioner.

INSTALLATION
(1) Install pulley and pulley bolt to tensioner.
Tighten bolt to 61 Nnn (45 ft. lbs.).
(2) Install tensioner assembly to mounting bracket.
An indexing tab is located on back of tensioner.
Align this tab to slot in mounting bracket. Tighten nut to 67 Nnn (50 ft. lbs.) torque.
(3) Connect all wiring to ignition coil. (4) Install coil to coil bracket. If nuts and bolts are
used to secure coil to coil bracket, tighten to 11 Nnn (100 in. lbs.) torque. If coil mounting bracket has
been tapped for coil mounting bolts, tighten bolts to 5 Nnn (50 in. lbs.) torque.

CAUTION:
To
prevent damage
to
coil case, coil mounting bolts must
be
torqued.

(5) Install drive belt. Refer to Belt Removal/Instal­
lation in this group. (6) Check belt indexing marks (Fig. 13).

SPECIFICATIONS

GENERAL
INFORMATION

The following specifications are published from the
latest information available at the time of publica­
tion. If anything differs between the specifica­
tions found on the Vehicle Emission Control
Information (VECI) label and the following spec­
ifications, use specifications on VECI label. The
VECI label is located in the engine compartment.
DRIVE
BELT
TENSION

All engines are equipped with a spring loaded au­
tomatic belt tensioner. Do not attempt to check belt
tension with a belt tension gauge on vehicles
equipped with an automatic belt tensioner. Refer to
Automatic Belt Tensioner in this group.

CAPACITIES

ENGINE
MODEL
DRIVE
CAPACITY

ENGINE
MODEL
DRIVE

QUARTS
LITERS

3.9L D150,
D250
2WD
15.1 14.0
5.2L D150, D250,
D350
2WD
17.0 16.0
5.2L
RAMCHARGER
4WD
16.5 15.7
5.2L W150, W250,
W350
4WD
17.0 16.0
5.9L D150, D250,
D350
AND
RAMCHARGER
2WD
15.5 14.7
5.9L
RAMCHARGER
4WD
15.0 14.0
5.9L W150, W250,
W350
4WD
15.5 14.7

DIESEL
ALL
MANUAL

16.0 15.1

DIESEL
ALL
AUTOMATIC

17.0 16.1

J9207-41

TORQUE

DISCMPflON
TORQUE

TORQUi
Automatic Belt Tensioner Pulley
Bolt-3.9l/2.5L/5.9LLDC

Gas
Engine
61
N-m (45
ft.
lbs.)

Automatic Belt Tensioner Pulley
Bolt
-
5.9L
HDC
Gas
Engine
88
N-m
(65
ft.
lbs.)

Automatic Belt Tensioner-to- Mounting Bracket
-
3.9L/5.2L/ 5.9L IDC
Gas
Engine
67
N-m
(50
ft.
lbs.)

Automatic Belt Tensioner-to- Mounting Bracket
-
5.9L

HDC
Gas
Engine
41
N-m
(30
ft.
lbs.)

Fan
Shroud
Mounting Nuts
11
N-m
(95
in. lbs.)

Hose
Clamps
4
N-m
(34
in. lbs.)

Idler
Pulley Mounting
Bolt
-
All
Gas
Engines
61
N-m
(45
ft.
lbs.)
Radiator Mounting
Bobs
11
N-m
(95
in. lbs.)
Radiator
Top
Mounting Brackets- Diesel Engine...... 23 N-m
(17
in. lbs.)

Thermal
Viscous
Fan-to-Hub- Diesel Engine
57
N-m
(42
ft.
lbs.)

Thermostat
Housing
Bolts
-
All Except Diesel 23 N-m (200 in. lbs.)
Thermostat
Housing
Bolts
-
Diesel Engine
24
N-m
(18
ft.
lbs.)

Water
Pump
Mounting
Bolts
-
All
Gas
Engines
40
N-m
(30
ft.
lbs.)

Water
Pump
Pulley
Bolts
-
All
Gas
Engines
27 N-m (20
ft.
lbs.)

Water
Pump
Mounting
Bolts
-
Diesel Engine
24
N-m(18ft.
lbs.) J9307-60

8A
- 12
ELECTRICAL

•

ENGINE
STARTER
RELAY
STARTER RELAY CONNECTIONS
GROUND SOLENOID (85) TERMINAL
(87) J928B-1

RELAY OPERATION/TESTING

OPERATION

• The Battery terminal is connected to battery volt­
age (B +
)
at all times.
• The Solenoid terminal is connected to the battery
terminal in the energized position which supplies
battery voltage to the operated device. • The Ignition terminal is connected to the electromag­
net and usually connected to a switched power source.
• The Ground terminal is connected to the electro­
magnet and is usually grounded by a switch or PCM.

TESTING
• Resistance value between the ground and ignition
terminals (electromagnet) is
75
±5 ohms for resistor
relays and 86±5 ohms for diode relays.
• Connect a battery to the ignition terminal and
connect ground to the ground terminal. There should
be continuity between the battery and solenoid ter­ minals (contact closed).
ENGINE STARTER RELAY REPLACEMENT The starter relay is located on the driver's side in­
ner fender (Fig. 8).
PART THROTTLE
A/C
CLUTCH STARTER AUTO SHUT
UNLOCK RELAY RELAY RELAY DOWN RELAY
Fig.
8
Starter
Relay
(1) Replace the relay as required.
(2) Test relay operation. IGNITION SWITCH TEST
After testing starter solenoid and relay and they
check out okay, trouble is probably with ignition
switch or its wiring. Check all wiring for opens and shorts and connec­
tions for being loose or corroded.
BENCH TESTING STARTER SOLENOID Refer to Group 8B - Battery Starter Service for
starter removal procedures. (1) Disconnect field coil wire from field coil termi­
nal (Fig. 9).

Fig.
9 Field
Coil
Wire
Terminal
(2) Check for continuity between solenoid terminal
and field coil terminal with a continuity tester.
There should be continuity (Fig. 10).

Fig.
10 Continuity Test Between
Solenoid
Terminal
and
Field
Coil
Terminal
(3) Check for continuity between solenoid terminal
and solenoid housing. There should be continuity
(Fig. 11).
SOLENOID

RR8BD33 Fig.
11 Continuity Test Between
Solenoid
Terminal

and Solenoid Case

(4) If there is continuity solenoid is good. If there
is no continuity in either test solenoid has an open
circuit and is defective. Replace the starter motor. (5) Install starter as described in Group 8B - Bat­
tery Starter Service. (6) Connect field coil wire to field coil terminal
(Fig. 9).

•

ELECTRICAL
8A - 13 GENERATOR TEST PROCEDURES ON
VEHICLE

INDEX

page
Current
Output
Test
......................
14
Diagnostic Procedures
13

General
Information
13
Generator
Output
Wire Resistance Test
.......
13
page
How
to
Use
Malfunction
Indicator
(Check Engine) Lamp
for
Fault
Codes
17

Operational Check
with
Voltmeter
............
13
Using
On-Board Diagnostic System
15

GENERAL
INFORMATION
The generator
is
belt-driven
by the
engine.
All en­

gines
use
serpentine drive. The amount
of DC
current produced
by the
gener­
ator
is
controlled
by the
Powertrain Control Module (PCM).
All vehicles
are
equipped with
On
Board Diagnos­
tics (OBD).
All OBD
sensing systems
are
monitored
by
the PCM. The PCM
will store
in
electronic mem­ ory
any
detectable failure within
the
monitored cir­

cuits.
Refer
to
USING ON-BOARD DIAGNOSTIC SYSTEM
in
this group
for
more information.

OPERATIONAL CHECK
WITH
VOLTMETER
When
the
ignition switch
is
turned
to the RUN po­

sition, battery potential will register
on the
voltme­
ter. During engine cranking
a
lower voltage will appear
on the
meter. With
the
engine running,
a

voltage reading higher than
the
first reading (igni­
tion
in RUN)
should register.

DIAGNOSTIC PROCEDURES
If
the
indicator does
not
operate properly,
or if an

undercharged
or
overcharged battery condition
oc­

curs,
the
following procedures
may be
used
to
diag­
nose
the
charging system. Remember that
an
undercharged battery
is
often
caused
by:
• accessories being left
on
overnight
•
or by a
defective switch which allows
a
bulb, such
as a
trunk
or
glove
box

light,
to
stay
on
(refer
to
Ignition
Off
Draw).
WISUAL
INSPECTION

• Inspect condition
of
battery cable terminals, bat­
tery posts, connections
at
engine block, starter motor solenoid
and
relay. They should
be
clean
and
tight.
Repair
as
required.
• Inspect
all
fuses
in the
fuse block
for
tightness
in

receptacles. They should
be
properly installed
and

tight. Repair
or
replace
as
required.
• Inspect generator mounting bolts
for
tightness.
Re­

place
or
torque bolt
as
required (refer
to
Torque Specifications).
• Inspect generator drive belt condition
and
tension.
Tension
or
replace belt
as
required. Refer
to
Belt
Tension Specifications. • Inspect connection
at
generator
B+
output.
It

should
be
clean
and
tight. Repair
as
required.

GENERATOR
OUTPUT
WIRE RESISTANCE TEST
(FIG.
1)
Generator output wire resistance test will show
amount
of
voltage drop across generator output wire
between generator
BAT
terminal
and
battery posi­ tive post.

PREPARATION
(1) Before starting test make sure vehicle
has a

fully charged battery. Test
and
procedures
on how to
check
for a
fully charged battery
are
shown
in
Bat­
tery section
of
this Group.
(2) Turn
OFF
ignition switch.
(3)
Disconnect negative cable from battery.

(4)
Disconnect generator output wire from genera­
tor output Battery terminal. (5) Connect
a 0-150
ampere scale
D.C.
ammeter
in

series between generator
BAT
terminal
and
discon­
nected generator output wire. Connect Positive lead
to generator
BAT
terminal
and
Negative lead
to
dis­ connected generator output wire. (6) Connect Positive lead
of a
test voltmeter
(Range
0-18
volts minimum)
to
disconnected genera­
tor output wire. Connect negative lead
of
test voltme­
ter
to
battery positive cable
at
positive post. (7) Connect
one end of a
Jumper Wire
to
ground
and with other
end
probe green
K20
lead wire
at

back
of
generator
(Fig. 1).
(This will generate
a
fault
code).

CAUTION:
Do not
connect blue
A142
lead
of
wiring
to ground. Refer
to
Group
8W
-
Wiring Diagrams
for
more information.

(8) Connect
an
engine tachometer
and
connect neg­
ative cable
to
battery.
(9) Connect
a
variable carbon pile rheostat
be­

tween battery terminals.
Be
sure carbon pile
is in
"Open"
or "Off
position before connecting leads.
See

Battery Section, Load Testing
for
instructions.

TEST
(1) Start engine. Immediately after starting,
re­

duce engine speed
to
idle.