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GOOD - RECHARGE
Fully charge battery and
return to service
CHARGE & RETEST
Fully charge battery and
REPLACE BATTERY
BAD-CELL REPLACE
retest battery
Replace the battery and retest complete system Replace the battery and retest complete system
NOTE: The SERVICE CODE is required on every warranty claim submitted for battery replacement.
REMOVAL
(1) Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off. (2) Loosen the battery negative cable terminal
clamp pinch-bolt hex nut.
(3) Disconnect the battery negative cable terminal clamp from the battery negative terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post (Fig. 10).
Fig.10RemovingBatteryCableTerminalClamp
1 - BATTERY 2 - BATTERY TERMINAL PULLER
(4) Loosen the battery positive cable terminal
clamp pinch-bolt hex nut.
(5) Disconnect the battery positive cable terminal clamp from the battery positive terminal post. If nec- essary, use a battery terminal puller to remove the terminal clamp from the battery post (Fig. 10).
(6) Remove the battery hold down retaining bolt.
WARNING: WEAR A SUITABLE PAIR OF RUBBER GLOVES (NOT THE HOUSEHOLD TYPE) WHEN REMOVING A BATTERY BY HAND. SAFETY GLASSES SHOULD ALSO BE WORN. IF THE BAT- TERY IS CRACKED OR LEAKING, THE ELECTRO- LYTE CAN BURN THE SKIN AND EYES.
BATTERY SYSTEM
8F - 14
BATTERY (Continued)(7) Remove the battery from the battery tray.
REMOVAL
DR
INSTALLATION
(1) Clean and inspect the battery. (2) Position the battery onto the battery tray. Ensure that the battery positive and negative termi- nal posts are correctly positioned. The battery cable terminal clamps must reach the correct battery ter- minal post without stretching the cables.
(3) Position the battery hold down and install the
retaining bolt.
CAUTION: Be certain that the battery cable terminal clamps are connected to the correct battery termi- nal posts. Reversed battery polarity may damage electrical components of the vehicle.
(4) Clean the battery cable terminal clamps and
the battery terminal posts.
(5) Reconnect the battery positive cable terminal clamp to the battery positive terminal post. Tighten the terminal clamp pinch-bolt hex nut to 4 N·m (35
in. lbs.).(6) Reconnect the battery negative cable terminal clamp to the battery negative terminal post. Tighten the terminal clamp pinch-bolt hex nut to 4 N·m (35
in. lbs.).(7) Apply a thin coating of petroleum jelly or chas- sis grease to the exposed surfaces of the battery cable terminal clamps and the battery terminal posts.
(8) Obtain a DRB IIIt scan tool and check the PCM for any stored battery disconnect trouble code, if required.
BATTERY HOLDDOWN DESCRIPTION
The battery hold down hardware includes a bolt and a molded plastic hold down bracket which meshes with the battery tray when properly installed. The battery tray and hold down hardware combine to form a very stable and secure battery hold down assembly.
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.
CAUTION: Never operate a vehicle without a battery holddown device properly installed. Damage to the vehicle, components and battery could result.
(1) Loosen and remove the battery hold down
(2) Remove the battery hold down bracket from
retaining bolt.
the battery case.
INSTALLATION
(1) Clean and inspect the battery hold down hard- ware (Refer to 8 - ELECTRICAL/BATTERY SYSTEM - CLEANING).
(2) Position the battery hold down bracket in the battery tray. Be certain that the hold down bracket is properly positioned in the battery tray before tight- ening the hold down hardware.
(3) Install and tighten the battery hold down
retaining bolt.
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 for the location of the proper battery cable wire gauge information.
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 positive cable wire harness or the battery negative cable wire harness, which may include portions of the wiring circuits for the generator and other com- ponents on some models.
Most models feature a stamped brass clamping type female battery terminal crimped onto one end of the battery cable wire and then solder-dipped. A pinch-bolt and hex nut are installed at the open end of the female battery terminal clamp. The battery positive cable also includes a red molded rubber pro- tective cover for the female battery terminal clamp. Large eyelet type terminals are crimped onto the opposite end of the battery cable wire and then sol- der-dipped. The battery positive cable wires have a red insulating jacket to provide visual identification and feature a larger female battery terminal clamp to allow connection to the larger battery positive ter- minal post. The battery negative cable wires have a black insulating jacket and a smaller female battery terminal clamp.
OPERATION
The battery cables connect the battery terminal posts to the vehicle electrical system. These cables
DR BATTERY CABLES (Continued)
also provide a return path for electrical current gen- erated by the charging system for restoring the volt- age 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 ter- minal 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 ends of the battery cable wires opposite the female battery terminal clamps provide secure and reliable connection of the battery to the vehicle elec- trical system.
DIAGNOSIS AND TESTING - BATTERY CABLES A voltage drop test will determine if there is exces- sive resistance in the battery cable terminal connec- tions or the battery cables. If excessive resistance is found in the battery cable connections, the connec- tion point should be disassembled, cleaned of all cor- rosion or then reassembled. Following reassembly, check the voltage drop for the battery cable connection and the battery cable again to confirm repair.
foreign material,
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
WARNING: MODELS EQUIPPED WITH A DIESEL ENGINE HAVE AN AUTOMATIC SHUTDOWN (ASD) RELAY LOCATED IN THE POWER DISTRIBUTION CENTER (PDC). REMOVAL OF THE ASD RELAY MAY NOT PREVENT THE DIESEL ENGINE FROM STARTING. BE CERTAIN TO DISCONNECT THE FUEL SHUTDOWN SOLENOID WIRE HARNESS CONNECTOR TO PREVENT THE ENGINE FROM STARTING. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY.
The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing this test, be certain that the following procedures are accomplished:
BATTERY SYSTEM 8F - 15
† The battery is fully-charged and tested (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY - STANDARD PROCEDURE).
† Fully engage the parking brake. † 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. † Verify that all lamps and accessories are turned off.† To prevent a gasoline engine from starting, remove the Automatic ShutDown (ASD) relay. The ASD relay is located in the Integrated Power Module (IPM), in the engine compartment. See the fuse and relay layout label on 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. 11). 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.
NOTE: If the vehicle is equipped with two 12v bat- teries, step #1 must be performed twice, once for each battery.
Fig.11TestBatteryNegativeConnection
Resistance-Typical
1 - VOLTMETER 2 - BATTERY
(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. 12). Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If connection voltage is detected,
the poor
correct
BATTERY SYSTEM
8F - 16
BATTERY CABLES (Continued)between the battery positive cable terminal clamp and the battery positive terminal post.
NOTE: If the vehicle is equipped with two 12v bat- teries, step #2 must be performed twice, once for each battery.
DR
Fig.13TestBatteryPositiveCableResistance-
Typical
1 - BATTERY 2 - VOLTMETER 3 - STARTER MOTOR
Fig.14TestGroundCircuit
1 - VOLTMETER 2 - BATTERY 3 - ENGINE GROUND
REMOVAL
(1) Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off. (2) Disconnect and isolate the remote battery neg-
ative cable terminal.
(3) Remove the battery from the vehicle. Refer to
the procedure in this group.
(4) One at a time, trace the battery cable retaining pushpins, fasteners and routing clips until the cable is free from the vehicle.
(5) Remove the battery cable from the engine com-
partment.
Fig.12TestBatteryPositiveConnectionResistance
-Typical
1 - VOLTMETER 2 - BATTERY
(3) Connect the voltmeter to measure between the battery positive cable terminal clamp and the starter solenoid B(+) terminal stud (Fig. 13). 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.
NOTE: If the vehicle is equipped with two 12v bat- teries, step #3 must be performed twice, once for each battery.
(4) Connect the voltmeter to measure between the battery negative cable terminal clamp and a good clean ground on the engine block (Fig. 14). 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 eyelet connection to the engine block. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery negative cable.terminal
NOTE: If the vehicle is equipped with two 12v bat- teries, step #4 must be performed twice, once for each battery.
DR BATTERY CABLES (Continued) INSTALLATION
(1) Position the battery cable in the engine com-
partment.
(2) One at a time, install the battery cable retain- ing pushpins, fasteners and routing clips until the cable is installed exactly where it was in the vehicle. Refer to Wiring for illustrations.
(3) Install the battery in the vehicle. Refer to the
procedure in this group.
(4) Connect the battery negative cable terminal.
BATTERY TRAY DESCRIPTION
BATTERY SYSTEM 8F - 17
OPERATION
The battery tray and the battery hold down hard- ware combine to secure and stabilize the battery in the engine compartment, which prevents battery movement during even the most extreme vehicle operation. Unrestrained battery movement during vehicle operation could result in damage to the vehi- cle, the battery, or both.
REMOVAL
LEFT SIDE
(1) Remove the battery from the battery tray (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BAT- TERY - REMOVAL).
(2) Remove the integrated power module (Refer to 8 - ELECTRICAL/POWER DISTRIBUTION/INTEL- LIGENT POWER MODULE - REMOVAL).
(3) Disconnect the wire harness retainers from the
battery tray assembly.
(4) Remove
the anti-lock brake
(if equipped) retaining bolts and support the brake con- troller with mechanics wire. It is not necessary to completely remove the anti-lock brake control unit.
controller
(5) Remove the left front wheelhouse splash shiel- to 23 - BODY/EXTERIOR/LF WHEEL-
d(Refer HOUSE SPLASH SHIELD - REMOVAL).
Fig.15DRBatteryTray
1 - BATTERY TRAY ASSEMBLY 2 - BATTERY TEMPERATURE SENSOR 3 - ANTI-LOCK BRAKE CONTROLLER MOUNTING LOCATION 4 - INTEGRATED POWER MODULE MOUNTING SANCTION
The molded plastic tray battery tray is located in the left front corner of the engine compartment. On this model, the battery tray also provides an anchor point for the anti-lock brake controller, cruise control servo (if equipped) and the integrated power module (Fig. 15). The battery hold down hardware is con- tained within the battery tray. A hole in the bottom of the battery tray is fitted with a battery tempera- ture sensor. Refer to Charging System for more infor- mation on the battery temperature sensor.
Fig.16LowerBatteryTrayRetainingBolts
1 - BATTERY TRAY ASSEMBLY 2 - BATTERY TRAY RETAINING BOLTS 3 - CRUISE CONTROL SERVO
BATTERY SYSTEM
8F - 18
BATTERY TRAY (Continued)DR
(6) Mark the location of
the cruise servo (if equipped) and remove the retaining screws. Position the servo out of the way.
(7) Remove the battery temperature sensor from the battery tray (Refer to 8 - ELECTRICAL/CHARG- ING/BATTERY REMOVAL).
TEMPERATURE
SENSOR
(8) Disconnect the purge solenoid from its mount-
(9) Disconnect the left front fender ground wire. (10) Remove the remaining battery tray retaining
(11) Remove the battery tray from the vehicle.
ing bracket.
bolts (Fig. 16).
RIGHT SIDE
(1) Remove the battery from the battery tray (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BAT- TERY - REMOVAL).
(2) Remove the right
front wheelhouse splash
(3) Disconnect the right front fender ground wire. (4) Remove relay
from grid heater
fasteners
shield.
bracket.
Fig.17RIGHTSIDEBATTERYTRAY
(6) Install the left front wheelhouse splash shield (Refer to 23 - BODY/EXTERIOR/LF WHEELHOUSE SPLASH SHIELD - INSTALLATION).
(7) Install
the
anti-lock brake
controller
(if
equipped).
(8) Connect the wire harness retainers on the bat-
(9) Install the integrated power module (Refer to 8
- ELECTRICAL/POWER DISTRIBUTION/INTELLI- GENT POWER MODULE - INSTALLATION).(10) Install the battery (Refer to 8 - ELECTRI- INSTALLA-
CAL/BATTERY SYSTEM/BATTERY - TION).
(1) Position the battery tray assembly and install
(2) Connect the right front fender ground wire. (3) Install the air box. (4) Install the grid heater relay bracket. (5) Install
front wheelhouse splash
the right
shield.
(6) Install the battery (Refer to 8 - ELECTRICAL/
BATTERY SYSTEM/BATTERY - INSTALLATION).
(5) Remove air box. (6) Remove the remaining battery tray retaining
tery tray assembly.
bolts (Fig. 17).
(7) Remove the battery tray from the vehicle.
INSTALLATION
LEFT SIDE
the retaining bolts.
(1) Position the battery tray assembly and install
RIGHT SIDE
(2) Connect the left front fender ground wire. (3) Install
the purge solenoid on its mounting
the retaining bolts.
bracket.
(4) Install the battery temperature sensor in the battery tray (Refer to 8 - ELECTRICAL/CHARGING/ BATTERY TEMPERATURE SENSOR - INSTALLA- TION).
(5) Install
the cruise servo (if equipped) and
retaining screws.
DR
CHARGING
8F - 19
CHARGING
TABLE OF CONTENTS
page
page
CHARGING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIAGNOSIS AND TESTING - CHARGINGSYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SPECIFICATIONS
GENERATOR RATINGS . . . . . . . . . . . . . . . . . 20
SPECIFICATIONS - TORQUE - GENERATOR/ CHARGING SYSTEM . . . . . . . . . . . . . . . . . . 20
BATTERY TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21GENERATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25VOLTAGE REGULATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27CHARGING DESCRIPTION The charging system consists of: † Generator † Electronic Voltage Regulator
(EVR)
circuitry within the Powertrain Control Module (PCM). Elec- tronic Control Module (ECM) for diesel engines. † Ignition switch † Battery (refer to 8, Battery for information) † Battery temperature sensor † Check Gauges Lamp (if equipped) † Voltmeter (refer to 8, Instrument Panel and † Wiring harness and connections (refer to 8, Wir-
Gauges for information)
ing Diagrams for information)
OPERATION
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. When the ASD relay is on, voltage is supplied to the ASD relay sense circuit at the PCM (ECM Diesel). This voltage is connected through the PCM (ECM Diesel) and sup- plied to one of the generator field terminals (Gen. Source +) at the back of the generator.
The amount of direct current produced by the gen- erator is controlled by the EVR (field control) cir- cuitry contained within the PCM (ECM Diesel). This circuitry is connected in series with the second rotor field terminal and ground.
A battery temperature sensor, located in the bat- tery tray housing, is used to sense battery tempera- ture. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) 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.
All vehicles are equipped with On-Board Diagnos- tics (OBD). All OBD-sensed systems, including EVR (field control) circuitry, are monitored by the PCM (ECM Diesel). Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for certain failures it detects.
The Check Gauges Lamp (if equipped) monitors: charging system voltage, engine coolant tempera- ture and engine oil pressure. If an extreme condition is indicated, the lamp will be illuminated. This is done as reminder to check the three gauges. The sig- nal to activate the lamp is sent via the CCD bus cir- cuits. The lamp is located on the instrument panel. Refer to 8, Instrument Panel and Gauges for addi- tional information.
DIAGNOSIS AND TESTING - CHARGING SYSTEM
the charging system if:
nated with the engine running
The following procedures may be used to diagnose † the check gauges lamp (if equipped) is illumi- † the voltmeter (if equipped) does not register † an undercharged or overcharged battery condi-
properly
tion occurs.
running
caused by:
Remember that an undercharged battery is often † accessories being left on with the engine not
CHARGING
8F - 20
CHARGING (Continued) † a faulty or improperly adjusted switch that allows a lamp to stay on. Refer to Ignition-Off Draw Test in 8, Battery for more information.INSPECTION
The PCM (Powertrain Control Module), or ECM (Diesel) monitors critical input and output circuits of the charging system, making sure they are opera- tional. 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 DRBt scan tool. Per- form the following inspections before attaching the scan tool.
(1) Inspect the battery condition. Refer to 8, Bat-
tery for procedures.
DR
(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.
(5) Inspect generator drive belt condition and ten- sion. Tighten or replace belt as required. Refer to Belt Tension Specifications in 7, Cooling System.
(6)
Inspect automatic belt tensioner (if equipped).
Refer to 7, Cooling System for information.
(7) 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 RATINGS
TYPE DENSO DENSO BOSCH BOSCH DENSO DENSO BOSCH
PART NUMBER
RATED SAE AMPS
56029700AA 56029701AA 56041120AC 56028238AB 56028560AA 56028696AA 56028699AA
136
136
136
136
136
136
136ENGINES 3.7L / 4.7L 5.9L Gas 3.7L / 4.7L 5.9L Gas
8.0L
5.7L Gas/5.9L Diesel 5.7L Gas/5.9L Diesel
SPECIFICATIONS - TORQUE - GENERATOR / CHARGING SYSTEM
DESCRIPTION
Generator Mounting Bolts - 5.7L
Generator Support Bracket
Bolt/Nuts - 5.7L
Generator Mounting Bolts - 8.0L Generator Upper Mounting Bolt -
5.9L Diesel Engine
Generator Upper Mounting Bolt -
5.9L Gas Engine
N·m 41
41
41
41
41
Ft. Lbs.
In. Lbs.
30
30
30
30
30
CHARGING
8F - 21
Ft. Lbs.
In. Lbs.
30
40
40
55
108
DR CHARGING (Continued)
DESCRIPTION
Generator Lower Pivot Bolt / Nut -
5.9L Gas Engine
Generator Vertical Mounting Bolt -
3.7L / 4.7L Engines
Generator (long) Horizontal
Mounting Bolt - 3.7L / 4.7L Engines
Generator (short) Horizontal
Mounting Bolt - 3.7L / 4.7L Engines
Generator B+ Output Cable
Terminal Nut
N·m 41
55
55
74
12
BATTERY TEMPERATURE SENSOR DESCRIPTION
The Battery Temperature Sensor (BTS) is attached
to the battery tray located under the battery.
OPERATION
The BTS is used to determine the battery temper- ature and control battery charging rate. This temper- ature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures.
The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temper- ature increases, resistance in the sensor decreases and the detection voltage at the PCM increases.
The BTS is also used for OBD II diagnostics. Cer- tain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20°F.
REMOVAL
The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (Fig. 1).
(1) Remove battery. Refer to 8, Battery for proce-
dures.
(2) Pry sensor straight up from battery tray mounting hole to gain access to electrical connector (Fig. 1).
(3) Disconnect sensor from engine wire harness
electrical connector.
Fig.1BATTERYTEMPERATURESENSOR
LOCATION
1 - BATTERY TEMP. SENSOR 2 - BATTERY 3 - SENSOR ELEC. CONNECT. 4 - BATTERY TRAY
INSTALLATION
The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray.
(1) Pull electrical connector up through mounting
hole in top of battery tray.
(2) Connect sensor. (3) Snap sensor into battery tray. (4) Install battery. Refer to 8, Battery for proce-
dures.
8F - 22
CHARGING
GENERATOR DESCRIPTION
The generator is belt-driven by the engine using a serpentine type drive belt. It is serviced only as a complete assembly. If the generator fails for any rea- son, the entire assembly must be replaced.
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 stator winding connections deliver the induced alternating current to 3 positive and 3 negative diodes for rectification. From the diodes, rectified direct current is delivered to the vehicle electrical system through the generator battery terminal.
Although the generators appear the same exter- nally, different generators with different output rat- ings are used on this vehicle. Be certain that the replacement generator has the same output rating and part number as the original unit. Refer to Gen- erator Ratings in the Specifications section at the back of this group for amperage ratings and part numbers.
Noise emitting from the generator may be caused by: worn, loose or defective bearings; a loose or defec- tive drive pulley; incorrect, worn, damaged or misad- justed fan drive belt; loose mounting bolts; a misaligned drive pulley or a defective stator or diode.
REMOVAL
3.7L / 4.7L
WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM.
(1) Disconnect negative battery cable at battery. (2) Remove generator drive belt. Refer to 7, Cool-
ing System for procedure.
(3) Unsnap plastic insulator cap from B+ output
terminal (Fig. 2).
(4) Remove B+ terminal mounting nut at rear of generator (Fig. 2). Disconnect terminal from genera- tor.
(5) Disconnect field wire connector at rear of gen-
erator (Fig. 2) by pushing on connector tab.
(6) Remove 1 rear vertical generator mounting bolt
(Fig. 3).
DR
(7) Remove 2 front horizontal generator mounting
bolts (Fig. 3).
(8) Remove generator from vehicle.
Fig.2GENERATORCONNECTORS-3.7L/4.7L
1 - GENERATOR 2 - B+ NUT 3 - PLASTIC INSULATOR CAP 4 - FIELD WIRE CONNECTOR
Fig.3REMOVE/INSTALLGENERATOR-3.7L/4.7L 1 - LOWER BOLTS 2 - REAR BOLT 3 - GENERATOR
DR GENERATOR (Continued)
5.7L
WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM.
CHARGING
8F - 23
(1) Disconnect negative battery cable at battery. (2) Remove generator drive belt. Refer to 7, Cool-
ing System for procedure.
(3) Unsnap plastic insulator cap from B+ output
terminal.
(4) Remove B+ terminal mounting nut at rear of
generator. Disconnect terminal from generator.
(5) Disconnect field wire connector at rear of gen-
erator by pushing on connector tab.
(6) Remove generator support bracket nuts and
bolt (Fig. 4) and remove support bracket.
(7) Remove 2 generator mounting bolts (Fig. 5). (8) Remove generator from vehicle.
Fig.5REMOVE/INSTALLGENERATOR-5.7L
1 - MOUNTING BOLT 2 - GENERATOR 3 - MOUNTING STUD / BOLT
(1) Disconnect both negative battery cables at both
batteries.
terminal.
(2) Remove generator drive belt. Refer to 7, Cool-
ing System for procedure.
(3) Unsnap plastic insulator cap from B+ output
(4) Remove B+ terminal mounting nut at rear of generator (Fig. 7). Disconnect terminal from genera- tor.
(5) Disconnect field wire connector at rear of gen-
erator by pushing on connector tab.
(6) Remove upper mounting bracket bolt (Fig. 6). (7) Remove lower mounting bracket bolt and nut
(Fig. 6).
(8) Remove generator from vehicle.
5.9L Gas
WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM.
(1) Disconnect negative battery cable at battery. (2) Remove generator drive belt. Refer to 7, Cool-
ing System for procedure.
Fig.4GENERATORSUPPORTBRACKET-5.7L
1 - GENERATOR 2 - SUPPORT BRACKET 3 - BRACKET NUTS 4 - BRACKET BOLT
5.9L Diesel
WARNING: DISCONNECT BOTH NEGATIVE CABLES FROM BOTH BATTERIES BEFORE REMOVING BAT- TERY OUTPUT WIRE (B+ WIRE) FROM GENERA- TOR. FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM.
CHARGING
8F - 24
GENERATOR (Continued)DR
(4) Remove B+ terminal mounting nut at rear of generator (Fig. 8). Disconnect terminal from genera- tor.
(5) Disconnect field wire connector at rear of gen-
erator (Fig. 8) by pushing on connector tab.
(6) Remove 1 upper generator mounting bolt (Fig.
(7) Remove 1 lower generator mounting bolt / nut
9).
(Fig. 9).
(8) Remove generator from vehicle.
Fig.65.9LDIESELGENERATOR
1 - GENERATOR 2 - MOUNTING BOLTS
Fig.75.9LDIESELGENER.CONNECTORS
1 - B+ CONNECTOR 2 - GENERATOR 3 - FIELD WIRE CONNECTOR
(3) Unsnap plastic insulator cap from B+ output
terminal (Fig. 8).
Fig.8GENERATORCONNECTORS-5.9LGAS
1 - PLASTIC INSULATOR CAP 2 - FIELD WIRE CONNECTOR 3 - GENERATOR 4 - B+ NUT
8.0L
WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM.
(1) Disconnect negative battery cable at battery. (2) Remove generator drive belt. Refer to 7, Cool-
ing System for procedure.
(3) Unsnap plastic insulator cap from B+ output
terminal.
(4) Remove B+ terminal mounting nut at rear of
generator. Disconnect terminal from generator.
(5) Disconnect field wire connector at rear of gen-
erator by pushing on connector tab.
(6) Remove upper mounting bolt and nut (Fig. 10). (7) Remove lower mounting bolt (Fig. 10).
DR GENERATOR (Continued)
CHARGING
8F - 25
INSTALLATION
3.7L / 4.7L
(1) Position generator to engine and install 2 hor-
izontal bolts and 1 vertical bolt.
(2) Tighten all 3 bolts. Refer to Torque Specifica-
tions.
tor.
(3) Snap field wire connector into rear of genera-
(4) Install B+ terminal eyelet to generator output stud. Tighten mounting nut. Refer to Torque Specifi- cations.
Fig.9REMOVE/INSTALLGENERATOR-5.9LGAS 1 - MOUNTING BOLT 2 - GENERATOR 3 - MOUNTING BRACKET 4 - MOUNTING BOLT/NUT
(8) Remove generator from vehicle.
CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.
CAUTION: When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump may be rotating in the wrong direction if is installed incorrectly, causing the engine to overheat. Refer to belt routing label in engine compartment, or refer to Belt Schematics in 7, Cooling System.
the belt
(5) Install generator drive belt. Refer to 7, Cooling
System for procedure.
(6) Install negative battery cable to battery.
5.7L
(1) Position generator to engine and install 2
mounting bolts.
(2) Tighten bolts. Refer to Torque Specifications. (3) Position support bracket to front of generator and install bolt and nuts. Tighten bolt / nuts. Refer to Torque Specifications.
(4) Snap field wire connector into rear of genera-
tor.
(5) Install B+ terminal eyelet to generator output stud. Tighten mounting nut. Refer to Torque Specifi- cations.
Fig.10REMOVE/INSTALLGENERATOR–8.0L
ENGINE
1 - MOUNTING BOLT 2 - GENERATOR 3 - NUT 4 - MOUNTING BRACKET 5 - MOUNTING BOLT
CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.
CAUTION: When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump may be rotating in the wrong direction if is installed incorrectly, causing the engine to overheat. Refer to belt routing label in engine compartment, or refer to Belt Schematics in 7, Cooling System.
the belt
(6) Install generator drive belt. Refer to 7, Cooling
System for procedure.
CHARGING
8F - 26
GENERATOR (Continued)(7) Install negative battery cable to battery.
5.9L Diesel
(1) Position generator to upper and lower mount- ing brackets and install upper bolt and lower bolt / nut.
(2) Tighten all bolts / nut. Refer to Torque Specifi-
DR
CAUTION: When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump may be rotating in the wrong direction is installed incorrectly, causing the if engine to overheat. Refer to belt routing label in engine compartment, or refer to Belt Schematics in 7, Cooling System.
the belt
(3) Snap field wire connector into rear of genera-
(5) Install generator drive belt. Refer to 7, Cooling
cations.
tor.
System for procedure.
(6) Install negative battery cable to battery.
5.9L Gas
cations.
tor.
(1) Position generator to engine and install upper
bolt and lower bolt / nut.
(2) Tighten all bolts / nut. Refer to Torque Specifi-
(3) Snap field wire connector into rear of genera-
(4) Install B+ terminal eyelet to generator output stud. Tighten mounting nut. Refer to Torque Specifi- cations.
CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.
CAUTION: When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump may be rotating in the wrong direction is installed incorrectly, causing the if engine to overheat. Refer to belt routing label in engine compartment, or refer to Belt Schematics in 7, Cooling System.
the belt
(5) Install generator drive belt. Refer to 7, Cooling
(6) Install negative battery cable to battery.
(4) Install B+ terminal eyelet to generator output stud. Tighten mounting nut. Refer to Torque Specifi- cations.
CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.
CAUTION: When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump may be rotating in the wrong direction if is installed incorrectly, causing the engine to overheat. Refer to belt routing label in engine compartment, or refer to Belt Schematics in 7, Cooling System.
the belt
(5) Install generator drive belt. Refer to 7, Cooling
System for procedure.
(6) Install both negative battery cables to both bat-
teries.
8.0L
cations.
tor.
(1) Position generator to engine and install lower
bolt and upper bolt / nut.
(2) Tighten all bolts / nut. Refer to Torque Specifi-
(3) Snap field wire connector into rear of genera-
System for procedure.
(4) Install B+ terminal eyelet to generator output stud. Tighten mounting nut. Refer to Torque Specifi- cations.
CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.
DR
CHARGING
8F - 27
VOLTAGE REGULATOR DESCRIPTION
The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulat- ing circuit located within the PCM (Powertrain Con- trol Module) (within the ECM for diesel engines). The EVR is not serviced separately. If replacement is nec- essary, the PCM must be replaced.
OPERATION
The amount of direct current produced by the gen- erator 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 battery temperature (refer to Battery Temperature Sensor for more information). It then determines a target charging voltage. If sensed battery voltage is 0.5 volts or lower than the target voltage, the PCM grounds the field winding until sensed battery volt- age is 0.5 volts above target voltage. A circuit in the PCM cycles the ground side of the generator field up to 100 times per second (100Hz), but has the capabil- ity to ground the field control wire 100% of the time (full field) to achieve the target voltage. If the charg- ing rate cannot 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.
8F - 28
STARTING
STARTING
TABLE OF CONTENTS
page
DR
page
STARTING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DIAGNOSIS AND TESTING - STARTINGSYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SPECIFICATIONS
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . 33
SPECIFICATIONS - TORQUE - STARTINGSYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
STARTER MOTOR
DIAGNOSIS AND TESTING - STARTER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37STARTER MOTOR RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DIAGNOSIS AND TESTING - STARTER RELAY . 38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39STARTING DESCRIPTION The starting system consists of: † Starter relay † Starter motor (including an integral starter sole-
noid)
ing system are:
Other components to be considered as part of start- † Battery † Battery cables † Ignition switch and key lock cylinder † Clutch pedal position switch (manual transmis- sion)† Park/neutral position switch (automatic trans- mission) † Wire harnesses and connections. The Battery, Starting, and Charging systems oper- ate in conjunction with one another, and must be tested as a complete system. For correct operation of starting/charging systems, all components used in these 3 systems must perform within specifications. When attempting to diagnose any of these systems, it is important that you keep their interdependency in mind.
The diagnostic procedures used in each of these groups include the most basic conventional diagnostic methods, to the more sophisticated On-Board Diag- nostics (OBD) built into the Powertrain Control Mod- ule (PCM). Use of an induction-type milliampere ammeter, volt/ohmmeter, battery charger, carbon pile rheostat (load tester), and 12-volt test lamp may be required.
Certain starting system components are monitored by the PCM and may produce a Diagnostic Trouble
Code (DTC). Refer to Diagnostic Trouble Codes in Emission Control for a list of codes.
OPERATION
The starting system components form two separate circuits. A high-amperage feed circuit that feeds the starter motor between 150 and 350 amperes (700
amperes - diesel engine), and a low-amperage control circuit that operates on less than 20 amperes. The high-amperage feed circuit components include the battery, the battery cables, the contact disc portion of the starter solenoid, and the starter motor. The low- amperage control circuit components include the igni- tion switch, the clutch pedal position switch (manual transmission), the park/neutral position switch (auto- matic transmission), the starter relay, the electro- magnetic windings of the starter solenoid, and the connecting wire harness components.If the vehicle is equipped with a manual transmis- sion, it has a clutch pedal position switch installed in series between the ignition switch and the coil bat- tery terminal of the starter relay. This normally open switch prevents the starter relay from being ener- gized when the ignition switch is turned to the Start position, unless the clutch pedal is depressed. This feature prevents starter motor operation while the clutch disc and the flywheel are engaged. The starter relay coil ground terminal is always grounded on vehicles with a manual transmission.
If the vehicle is equipped with an automatic trans- mission, battery voltage is supplied through the low- amperage control circuit to the coil battery terminal of the starter relay when the ignition switch is turned to the Start position. The park/neutral posi- tion switch is installed in series between the starter relay coil ground terminal and ground. This normally
DR STARTING (Continued)
open switch prevents the starter relay from being energized and the starter motor from operating unless the automatic transmission gear selector is in the Neutral or Park positions.
When the starter relay coil is energized, the nor- mally open relay contacts close. The relay contacts connect the relay common feed terminal to the relay normally open terminal. The closed relay contacts energize the starter solenoid coil windings.
The energized solenoid pull-in coil pulls in the sole- noid plunger. The solenoid plunger pulls the shift lever in the starter motor. This engages the starter overrunning clutch and pinion gear with the starter ring gear.
As the solenoid plunger reaches the end of
its travel, the solenoid contact disc completes the high- amperage starter feed circuit and energizes the sole- noid plunger hold-in coil. Current now flows between the solenoid battery terminal and the starter motor, energizing the starter.
Once the engine starts, the overrunning clutch pro- tects the starter motor from damage by allowing the
STARTING
8F - 29
starter pinion gear to spin faster than the pinion shaft. When the ignition switch is released to the On position, the starter relay coil is de-energized. This causes the relay contacts to open. When the relay contacts open, the starter solenoid plunger hold-in coil is de-energized.
When the solenoid plunger hold-in coil is de-ener- gized, the solenoid plunger return spring returns the plunger to its relaxed position. This causes the con- tact disc to open the starter feed circuit, and the shift lever to disengage the overrunning clutch and pinion gear from the starter ring gear.
DIAGNOSIS AND TESTING - STARTING SYSTEM
The battery, starting, and charging systems oper- ate in conjunction with one another, and must be tested as a complete system. For correct starting/ charging system operation, all of the components involved in these 3 systems must perform within specifications.
CONDITION
POSSIBLE CAUSE
CORRECTION
Starting System Diagnosis
STARTER FAILS TO OPERATE.
STARTER ENGAGES, FAILS TO TURN ENGINE.
1. Battery discharged or faulty. 2. Starting circuit wiring faulty. 3. Starter relay faulty.
4. Ignition switch faulty.
5. Clutch pedal position switch faulty. 6. Park/Neutral position switch faulty or misadjusted. 7. Starter solenoid faulty.
8. Starter motor faulty.
1. Battery discharged or faulty. 2. Starting circuit wiring faulty. 3. Starter motor faulty.
4. Engine seized.
1. Refer to Battery. Charge or replace battery, if required.
2. Refer to 8, Wiring Diagrams. Test and repair starter feed and/or control circuits, if required. 3. Refer to Starter Relay in Diagnosis and Testing. Replace starter relay if required. 4. Refer to Ignition Switch and Key Lock Cylinder. Replace ignition switch if required. 5. Refer to Clutch Pedal Position Switch.
6. Refer to Park/Neutral Position Switch. Replace park/neutral position switch if required.
7. Refer to Starter Motor. Replace starter motor assembly if required. 8. If all other starting system components and circuits test OK, replace starter motor. 1. Refer to Battery. Charge or replace battery if required.
2. Refer to 8, Wiring Diagrams. Test and repair starter feed and/or control circuits if required. 3. If all other starting system components and circuits test OK, replace starter motor assembly. 4. Refer to Engine Diagnosis in the Diagnosis and Testing section of 9, Engine.
STARTING
8F - 30
STARTING (Continued)DR
CONDITION
POSSIBLE CAUSE
CORRECTION
Starting System Diagnosis
STARTER ENGAGES, SPINS OUT BEFORE ENGINE STARTS.
1. Starter ring gear faulty.
2. Starter motor faulty.
STARTER DOES NOT DISENGAGE.
1. Starter motor improperly installed.
2. Starter relay faulty.
3. Ignition switch faulty.
4. Starter motor faulty.
1. Refer to Starter Motor Removal and Installation. Remove starter motor to inspect starter ring gear. Replace starter ring gear if required. 2. If all other starting system components and circuits test OK, replace starter motor assembly. 1. Refer to Starter Motor Removal and Installation. Tighten starter mounting hardware to correct torque specifications. 2. Refer to Starter Relay Diagnosis and Testing. Replace starter relay if required. 3. Refer to Ignition Switch and Key Lock Cylinder. Replace ignition switch if required. 4. If all other starting system components and circuits test OK, replace starter motor.
INSPECTION
For complete starter wiring circuit diagrams, refer to 8, Wiring Diagrams. Before removing any unit from starting system for repair or diagnosis, perform the following inspections:
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER TO 8, PASSIVE RESTRAINT SYS- TEMS, BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY- MENT AND POSSIBLE PERSONAL INJURY.
tions. Refer to Park/Neutral Position Switch in 21, Transmission. † Starter Relay - Visually inspect starter relay for indications of physical damage and loose or cor- roded wire harness connections. † Starter Motor - Visually inspect starter motor for indications of physical damage and loose or cor- roded wire harness connections. † Starter Solenoid - Visually inspect starter sole- noid for indications of physical damage and loose or corroded wire harness connections. † Wiring - Visually inspect wire harnesses for damage. Repair or replace any faulty wiring, as required. Refer to 8, Wiring Diagrams.
† Battery - Visually inspect battery for indica- tions of physical damage and loose or corroded cable connections. Determine state-of-charge and cranking capacity of battery. Charge or replace battery if required. Refer to Battery in 8, Battery. Note: If equipped with diesel engine, a dual battery sys- tem may be used, and both batteries must be inspected.
† Ignition Switch - Visually inspect
ignition switch for indications of physical damage and loose or corroded wire harness connections. Refer to Igni- tion Switch and Key Lock Cylinder. † Clutch Pedal Position Switch - If equipped with manual transmission, visually inspect clutch pedal position switch for indications of physical dam- age and loose or corroded wire harness connections. Refer to Clutch Pedal Position Switch in 6, Clutch. † Park/Neutral Position Switch - If equipped with automatic transmission, visually inspect park/ neutral position switch for indications of physical damage and loose or corroded wire harness connec-
TESTING
COLD CRANKING TEST
For complete starter wiring circuit diagrams, refer to 8, Wiring Diagrams. The battery must be fully- charged and load-tested before proceeding. Refer to Battery in 8, Battery.
(1) Connect volt-ampere tester to battery terminals (Fig. 1). See instructions provided by manufacturer of volt-ampere tester being used. Note: Certain diesel equipped models use dual batteries. If equipped with dual battery system, tester should be con- nected to battery on left side of vehicle only. Also, tester current reading must be taken from positive battery cable lead that connects to starter motor.
(2) Fully engage parking brake. (3) If equipped with manual transmission, place gearshift selector lever in Neutral position and block clutch pedal in fully depressed position. If equipped
DR STARTING (Continued)
STARTING
8F - 31
FEED CIRCUIT TEST
The starter feed circuit test (voltage drop method) will determine if there is excessive resistance in high-amperage feed circuit. For complete starter wir- ing circuit diagrams, refer 8, Wiring Diagrams.
When performing these tests, it is important to remember that voltage drop is giving an indication of resistance between two points at which voltmeter probes are attached.
Example: When testing resistance of positive bat- tery cable, touch voltmeter leads to positive battery cable clamp and cable connector at starter solenoid. If you probe positive battery terminal post and cable connector at starter solenoid, you are reading com- bined voltage drop in positive battery cable clamp-to- terminal post connection and positive battery cable. The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing tests, following procedures are accom- be certain that plished: † Battery is fully-charged and load-tested. Refer to Battery in 8, Battery. † Fully engage parking brake. † If equipped with manual transmission, place gearshift selector lever in Neutral position and block clutch pedal in fully depressed position. If equipped with automatic transmission, place gearshift selector lever in Park position. † Verify that all lamps and accessories are turned off.† To prevent a gasoline engine from starting, remove Automatic ShutDown (ASD) relay. To prevent a diesel engine from starting, remove Fuel Pump Relay. These relays are located in Power Distribution Center (PDC). Refer to label on PDC cover for relay location.
(1) Connect positive lead of voltmeter to negative battery cable terminal post. Connect negative lead of voltmeter to negative battery cable clamp (Fig. 2). Rotate and hold ignition switch in Start position. Observe voltmeter. If voltage is detected, correct poor contact between cable clamp and terminal post. Note: Certain diesel equipped models use dual batteries. If equipped with dual battery system, procedure must be performed twice, once for each battery.
(2) Connect positive lead of voltmeter to positive battery terminal post. Connect negative lead of volt- meter to battery positive cable clamp (Fig. 3). Rotate and hold ignition switch in Start position. Observe voltmeter. If voltage is detected, correct poor contact between cable clamp and terminal post. Note: Cer- tain diesel equipped models use dual batteries. If equipped with dual battery system, this pro- cedure must be performed twice, once for each battery.
Fig.1VOLTS-AMPSTESTERCONNECTIONS-
TYPICAL
1 - POSITIVE CLAMP 2 - NEGATIVE CLAMP 3 - INDUCTION AMMETER CLAMP
with automatic transmission, place gearshift selector lever in Park position. (4) Verify that all
lamps and accessories are
turned off.
(5) To prevent a gasoline engine from starting, remove Automatic ShutDown (ASD) relay. To prevent a diesel engine from starting, remove Fuel Pump Relay. These relays are located in Power Distribution Center (PDC). Refer to label on PDC cover for relay location.
WARNING: IF EQUIPPED WITH DIESEL ENGINE, ATTEMPT TO START ENGINE A FEW TIMES BEFORE PROCEEDING WITH FOLLOWING STEP.
(6) Rotate and hold ignition switch in Start posi- tion. Note cranking voltage and current (amperage) draw readings shown on volt-ampere tester.
(a) If voltage reads below 9.6 volts, refer to Starter Motor in Diagnosis and Testing. If starter motor is OK, refer to Engine Diagnosis in 9, Engine for further testing of engine. If starter motor is not OK, replace faulty starter motor.
(b) If voltage reads above 9.6 volts and current (amperage) draw reads below specifications, refer to Feed Circuit Test in this section.
(c) If voltage reads 12.5 volts or greater and starter motor does not turn, refer to Control Cir- cuit Testing in this section.
(d) If voltage reads 12.5 volts or greater and starter motor turns very slowly, refer to Feed Cir- cuit Test in this section.
NOTE: A cold engine will increase starter current (amperage) draw reading, and reduce battery volt- age reading.
STARTING
8F - 32
STARTING (Continued)DR
Fig.2TESTBATTERYNEGATIVECONNECTION
RESISTANCE-TYPICAL
1 - VOLTMETER 2 - BATTERY
Fig.4TESTBATTERYPOSITIVECABLE
RESISTANCE-TYPICAL
1 - BATTERY 2 - VOLTMETER 3 - STARTER MOTOR
tery cable attachment on engine block. Repeat test. If reading is still above 0.2 volt, replace faulty negative battery cable. Note: Certain diesel equipped mod- els use dual batteries. If equipped with dual battery system, this procedure must be per- formed twice, once for each battery.
Fig.3TESTBATTERYPOSITIVECONNECTION
RESISTANCE-TYPICAL
1 - VOLTMETER 2 - BATTERY
(3) Connect voltmeter to measure between battery positive terminal post and starter solenoid battery terminal stud (Fig. 4). Rotate and hold ignition switch in Start position. Observe voltmeter. If read- ing is above 0.2 volt, clean and tighten battery cable connection at solenoid. Repeat test. If reading is still above 0.2 volt, replace faulty positive battery cable. Note: Certain diesel equipped models use dual batteries. If equipped with dual battery system, this procedure must be performed on driver side battery only.
(4) Connect voltmeter to measure between nega- tive battery terminal post and a good clean ground on engine block (Fig. 5). Rotate and hold ignition switch in Start position. Observe voltmeter. If read- ing is above 0.2 volt, clean and tighten negative bat-
Fig.5TESTGROUNDCIRCUITRESISTANCE-
TYPICAL
1 - VOLTMETER 2 - BATTERY 3 - ENGINE GROUND
(5) Connect positive lead of voltmeter to starter housing. Connect negative lead of voltmeter to nega- tive battery terminal post (Fig. 6). Rotate and hold ignition switch in Start position. Observe voltmeter. If reading is above 0.2 volt, correct poor starter to engine block ground contact. Note: Certain diesel equipped models use dual batteries. If equipped with dual battery system, this procedure must be performed on driver side battery only.
DR STARTING (Continued)
STARTING
8F - 33
If reading is above 0.2 volt, clean and tighten battery cables at both batteries. Repeat test. If reading is still above 0.2 volt, replace faulty positive battery cable.
If resistance tests detect no feed circuit problems, refer to Starter Motor in the Diagnosis and Testing.
CONTROL CIRCUIT TESTING
Diagnosis and Testing.
The starter control circuit components should be tested in the order in which they are listed, as fol- lows:† Starter Relay - Refer to Starter Relay Diag- nosis and Testing. † Starter Solenoid - Refer to Starter Motor † Ignition Switch - Refer to Ignition Switch † Clutch Pedal Position Switch - If equipped with manual transmission, refer to Clutch Pedal Position Switch in 6, Clutch. † Park/Neutral Position Switch - If equipped with automatic transmission, refer to Park/Neutral Position Switch in 21, Transmission. † Wire harnesses and connections - Refer to 8,
and Key Lock Cylinder
Wiring Diagrams.
Fig.6TESTSTARTERGROUND-TYPICAL
1 - STARTER MOTOR 2 - BATTERY 3 - VOLTMETER
(6) If equipped with dual battery system (certain diesel equipped models), connect positive lead of volt- meter to positive battery cable clamp on battery located on left side of vehicle. Connect negative lead of voltmeter to positive battery terminal post on bat- tery located on right side of vehicle. Rotate and hold ignition switch in Start position. Observe voltmeter.
SPECIFICATIONS
STARTING SYSTEM
Starter Motor and Solenoid
Manufacturer
Denso
Part Number
56028715AD
Engine Application
3.7L / 4.7L / 5.7L / 5.9L
Power Rating
1.4 Kilowatt / 1.9
Horsepower
Denso
56027703AD
8.0L
1.4 Kilowatt / 1.9
Horsepower
Denso 4741012
5.9L Diesel2.7 Kilowatt / 3.6
Horsepower
11 Volts
12 Volts
12 Volts
12 Volts
Gear Reduction
Gear Reduction
Voltage Number of Brushes Drive Type Free Running Test Voltage Free Running Test Amperage Draw Free Running Test Minimum Speed Solenoid Closing Maximum Voltage Required * Cranking Amperage Draw Test * Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw.
125 - 250 Amperes
125 - 250 Amperes
450 - 700 Amperes
200 Amperes
Conventional
73 Amperes
73 Amperes
3601 rpm
3601 rpm
8.0 Volts
7.5 Volts
7.5 Volts
11 Volts
11 Volts
3000
STARTING
8F - 34
STARTING (Continued) SPECIFICATIONS - TORQUE - STARTING SYSTEMDESCRIPTION
Battery Cable Eyelet Nut at
Solenoid (large nut - gas engines)
Battery Cable Eyelet Nut at
Solenoid (large nut - diesel engine)
Starter Solenoid Nut (small nut -
diesel engine)
Starter Mounting Bolts - Gas
Engines
Starter Mounting Nut - Gas Engines
Starter Mounting Bolts - Diesel
N·m 25
14
68
68
43DR
Ft. Lbs.
19
50
50
32In. Lbs.
221
120
55
STARTER MOTOR DIAGNOSIS AND TESTING - STARTER MOTOR Correct starter motor operation can be confirmed by performing the following free running bench test. This test can only be performed with starter motor removed from vehicle. Refer to Specifications for starter motor specifications.
(1) Remove starter motor from vehicle. Refer to
Starter Motor Removal and Installation.
(2) Mount starter motor securely in a soft-jawed bench vise. The vise jaws should be clamped on the mounting flange of starter motor. Never clamp on starter motor by field frame.
(3) Connect a suitable volt-ampere tester and a 12-volt battery to starter motor in series, and set ammeter to 100 ampere scale. See instructions pro- vided by manufacturer of volt-ampere tester being used.
(4) Install jumper wire from solenoid terminal to solenoid battery terminal. The starter motor should operate. If starter motor fails to operate, replace faulty starter motor assembly.
(5) Adjust carbon pile load of tester to obtain free running test voltage. Refer to Specifications for starter motor free running test voltage specifications. (6) Note reading on ammeter and compare reading to free running test maximum amperage draw. Refer to Specifications for starter motor free running test maximum amperage draw specifications.
(7) If ammeter reading exceeds maximum amper- age draw specification, replace faulty starter motor assembly.
STARTER SOLENOID
This test can only be performed with starter motor
removed from vehicle.
(1) Remove starter motor from vehicle. Refer to
Starter Motor Removal and Installation.
(2) Disconnect wire from solenoid field coil termi-
nal.
(3) Check for continuity between solenoid terminal and solenoid field coil terminal with a continuity tester (Fig. 7). There should be continuity. If OK, go to Step 4. If not OK, replace faulty starter motor assembly.
Fig.7CONTINUITYBETWEENSOLENOIDAND
FIELDCOILTERMINALS-TYPICAL
1 - OHMMETER 2 - SOLENOID TERMINAL
