Chrysler PT Cruiser. Manual — part 484
INSTALLATION
INSTALLATION - 2.0/2.4L
(1) Install generator (Fig. 12) and loose assemble
the bolt and nut (Fig. 10).
(2) Install and tension the generator belt, refer to
the Cooling section for more information.
(3) Tighten the lower pivot bolt to 54 N·m (40 ft.
lbs.)
(4) Install axle shaft, refer to the Axle section
(5) Install lower control arm to steering knuckle,
refer to the Supension section.
(6) Install the lower ball joint nut and tighten,
refer to the Supension section.
(7) Install the axle retaining nut and tighten, refer
to the Axle section.
(8) Install the pencil strut (Fig. 9), refer to the
body section.
(9) Install the B+ terminal nut and wire and
tighten (Fig. 11) to 11.3 N·m (100 ins. lbs.).
(10) Plug in the field circuit to the generator
(11) Install the accessory drive splash shield (Fig.
8).
(12) Install the right front wheel, refer to the
Wheels and Tire section.
(13) Lower vehicle.
(14) Tighten the T-bolt locknut (Fig. 7) and tighten
to 54 N·m (40 ft. lbs.)
(15) Connect the negative battery cable.
(16) Install the air cleaner lid and connect the
inlet air temperature sensor and makeup hose.
(17) Check the transmission fluid.
INSTALLATION - 2.4L TURBO
(1) Install generator through the axle shaft hole in
wheel well (Fig. 22).
(2) Put generator on upper t-bolt and loosen install
the nut (Fig. 15).
(3) Install the lower mounting bracket (Fig. 21) for
the generator to the block and tighten bolts to 54
N·m (40 ft. lbs.).
(4) Loose install the lower pivot bolt for the gener-
ator (Fig. 19).
(5) Install the B+ terminal nut and wire (Fig. 17)
and tighten nut to 11.3 N·m (100 in. lbs.).
(6) Plug in the field circuit to the generator.
(7) Install the axle shaft assembly (Fig. 20).
(8) Install the 2 bolts for the axle shaft bearing
support and tighten bolts to 54.2 N·m (40 ft. lbs).
(9) Install the axle shaft into the steering knuckle
(Fig. 20).
(10) Install the lower control arm to the steering
knuckle and install the bolt and tighten bolts to 94.9
N·m (70 ft. lbs.).
(11) Install the axle retaining nut and tighten nut
to 244 N·m (180 ft. lbs.).
(12) Install and tension the generator belt, refer to
the Cooling section for more information.
(13) Tighten the accessory drive belt t-bolt and
tighten nut to 54 N·m (40 ft. lbs.) (Fig. 15).
(14) Tighten the lower generator pivot bolt and
tighten bolts to 54 N·m (40 ft. lbs.).
(15) Install the pencil strut (Fig. 18).
(16) Install the generator heat shield.
(17) Install the lower heat shield bolt and tighten
bolt to 54.2 N·m (40 ft. lbs.).
(18) Install the accessory drive splash shield (Fig.
16).
Fig. 28 IDLER PULLEY BRACKET
Fig. 29 GENERATOR LOCATION
1 - Generator
2 - Eletrical Connertors
3 - Idler Pulley and Bracket
8F - 34
CHARGING
PT
GENERATOR (Continued)
(19) Install the right front wheel.
(20) Lower vehicle.
(21) Tighten nut to the upper adjustment bracket
(Fig. 15) and tighten to 25 N·m (18 ft. lbs.).
(22) Install the 2 bolts to the heat shield on the
generator (Fig. 14) and tighten bolts to 4.5 N·m (40
in. lbs.).
(23) Connect the negative battery cable.
INSTALLATION - 1.6L
(1) Install the 2 lower and 1 upper mounting bolts
into the generator (Fig. 30).
(2) Install the generator to the vehicle (Fig. 27).
(3) Hand start the bolts.
(4) Install the upper inboard mounting bolts and
hand start the bolt.
(5) Raise vehicle and support.
(6) Tighten the outboard generator mounting bolt.
Torque to 28 N·m (250 in. lbs.).
(7) Install the accessory drive belt, refer to the
cooling section for more information.
(8) Install the right splash shield.
(9) Lower vehicle.
(10) Tighten the lower inboard generator mounting
bolt. Torque to 28 N·m (250 in. lbs.).
(11) Tighten the upper 2 mounting bolts. Torque to
28 N·m (250 in. lbs.).
(12) Install the power steering reservoir to the
support bracket (Fig. 24).
(13) Connect the electrical connectors to the gener-
ator (Fig. 23).
(14) Install the lower intake manifold, refer to the
engine section for more information.
(15) Install the fuel rail.
(16) Install the 2 bolts to the fuel rail at the lower
manifold.
(17) Install the fuel line to the fuel rail.
(18) Install the wiring harness to the fuel rail
brackets.
(19) Connect the electrical connectors to the fuel
injectors.
(20) Connect the negative battery cable.
(21) Install air cleaner assembly cover.
INSTALLATION - 2.2 DIESEL
NOTE: The orientation of the generator (Fig. 31), it
will fit onto the bracket backwards. If this occurs
damage to the generator will happen.
(1) Install the 2 upper bolts and the 2 lower bolts
into the generator.
(2) Install generator as assembly (Fig. 31) MAKE
SURE OF ORIENTATION OF GENERATOR.
(3) Install the accessory drive idler pulley and
bracket to the 2 lower mounting bolts for the gener-
ator (Fig. 28).
(4) Tighten generator mounting bolts to 28 N·m
(38 ft. lbs.)
(5) Connect the wiring connectors to the back of
the generator (Fig. 29).
(6) Connect the battery cable to the generator.
(7) Install the A/C line to the compressor.
(8) Install the radiator, condenser, and inner cooler
assembly
(9) Connect the electrical connector to the radiator
fan.
(10) Install the upper radiator hose.
(11) Connect the A/C line to the condenser.
(12) Raise vehicle and support.
(13) Install the accessory drive belt, refer to the
Cooling section for more information.
(14) Install the splash shield.
Fig. 30 GENERATOR BOLTS
Fig. 31 GENERATOR ORIENTATION
PT
CHARGING
8F - 35
GENERATOR (Continued)
(15) Install the right front tire.
(16) Install the lower radiator hose and the 2
inner cooler hoses.
(17) Install the underbody plate (skid plate), refer
to the Body section for more information.
(18) Lower vehicle.
(19) Install ambient temperature sensor.
(20) Install the upper radiator crossmember.
(21) Install the hood seal, refer to the Body section
for more information.
(22) Install the front grill, refer to the Body section
for more information.
(23) Connect the negative battery cable.
(24) Fill radiator, refer to the Cooling section for
more information.
(25) Install A/C refrigerant. Refer to the Air Con-
ditioning section for more information.
VOLTAGE REGULATOR
DESCRIPTION
The Electronic Voltage Regulator (EVR) is not a
separate component. It is actually a voltage regulat-
ing circuit located within the Powertrain Control
Module (PCM). The EVR is not serviced separately. If
replacement is necessary, the PCM must be replaced.
OPERATION
The amount of DC current produced by the gener-
ator is controlled by EVR circuitry contained within
the PCM. This circuitry is connected in series with
the generators second rotor field terminal and its
ground.
Voltage is regulated within the PCM on the NGC
vehicles, to control the strength of the rotor magnetic
field. The EVR circuitry monitors system line voltage
at the PDC and calculated battery temperature or
inlet air temperature sensor (refer to Inlet Air Tem-
perature Sensor, if equipped, for more information ).
It then determines a target charging voltage. If
sensed battery voltage is lower than the target volt-
age, the PCM feeds the field winding until sensed
battery voltage is at the target voltage. A circuit in
the PCM cycles the feed side of the generator field at
250 times per second (250Hz), but has the capability
to feed the field control wire 100% of the time (full
field) to achieve the target voltage. If the charging
rate cannot be monitored (limp-in), a duty cycle of
20% is used by the PCM in order to have some gen-
erator output. Also refer to Charging System Opera-
tion for additional information.
8F - 36
CHARGING
PT
GENERATOR (Continued)
STARTING
TABLE OF CONTENTS
page
page
STARTING
. . . . . . . . . . . . . . . . . . . . . . . . . 37
. . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DIAGNOSIS AND TESTING - STARTING
SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . 37
DIAGNOSIS AND TESTING - CONTROL
CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . . . 39
DIAGNOSIS AND TESTING - FEED CIRCUIT
RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . 41
DIAGNOSIS AND TESTING - FEED CIRCUIT
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
STARTER MOTOR
. . . . . . . . . . . . . . . . . . . . . . 43
. . . . . . . . . . . . . . . . 43
. . . . . . . . . . . . . . . . . . . 44
. . . . . . . . . . . . . . . . 45
. . . . . . . . . . . . . . . . . . 47
. . . . . . . . . . . . . . . . 47
INSTALLATION - STARTER 2.4L TURBO
STARTING
DESCRIPTION
The starting system consists of:
• Starter relay
• Starter motor (including an integral starter sole-
noid)
Other components to be considered as part of start-
ing system are:
• 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.
OPERATION
These components form two separate circuits. A
high amperage circuit that feeds the starter motor up
to 300+ amps, and a control circuit that operates on
less than 20 amps.
The PCM controls a double start over-ride safety
that does not allow the starter to be engaged if the
engine is already running.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - STARTING
SYSTEM TEST
For circuit descriptions and diagrams, refer to the
Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO THE PASSIVE RESTRAINT SYS-
TEMS BEFORE ATTEMPTING STEERING WHEEL,
STEERING
COLUMN,
OR
INSTRUMENT
PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
INSPECTION
Before removing any unit from the starting system
for repair or diagnosis, perform the following inspec-
tions:
• Battery - Visually inspect the battery for indi-
cations of physical damage and loose or corroded
cable connections. Determine the state-of-charge and
PT
STARTING
8F - 37
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