Chrysler PT Cruiser. Manual — part 481
REMOVAL - DIESEL ENGINE
(1) Remove the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - REMOVAL).
(2) Remove the passengers front seat (Refer to 23 -
BODY/SEATS/SEAT - REMOVAL).
(3) Remove the battery tray retaining bolt.
(4) Remove the battery tray from the vehicle.
INSTALLATION
INSTALLATION - GASOLINE ENGINE
(1) Place battery tray into place in the engine com-
partment.
(2) Install the bolts retaining the battery tray.
(3) Install the battery (Refer to 8 - ELECTRICAL/
BATTERY SYSTEM/BATTERY - INSTALLATION).
(4) Close hood.
INSTALLATION - DIESEL ENGINE
(1) Place battery tray into place in the passenger
compartment.
(2) Install the battery tray retaining bolt.
(3) Install the front passenger seat (Refer to 23 -
BODY/SEATS/SEAT - INSTALLATION).
(4) Install the battery (Refer to 8 - ELECTRICAL/
BATTERY SYSTEM/BATTERY - INSTALLATION).
(5) Install and connect the vent tube assembly.
THERMAL GUARD
DESCRIPTION
On gasoline engine equipped vehicles, a flexible
thermal guard wraps around the battery case to
enclose the sides of the battery (Fig. 27). The thermal
guard consists of a plastic cloth outer skin with a
polyester based insulator fiber.
OPERATION
The thermal guard protects the battery from
engine compartment temperature extremes. The tem-
perature of the battery can affect battery perfor-
mance. The air trapped in the thermal guard creates
a dead air space, which helps to insulate the sides of
the battery case from the air temperature found in
the surrounding engine compartment.
REMOVAL
WARNING:
TO PROTECT THE HANDS FROM BATTERY ACID, A
SUITABLE
PAIR
OF
HEAVY
DUTY
RUBBER
GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD
BE WORN WHEN REMOVING OR SERVICING A
BATTERY. SAFETY GLASSES ALSO SHOULD BE
WORN.
Fig. 27 Battery Thermal Guard
1 - THERMAL GUARD
2 - BATTERY
8F - 22
BATTERY SYSTEM
PT
BATTERY TRAY (Continued)
(1) Make sure ignition switch is in OFF position
and all accessories are OFF.
(2) Open hood.
(3) Remove air cleaner housing (Refer to 9 -
ENGINE/AIR
INTAKE
SYSTEM/AIR
CLEANER
HOUSING - REMOVAL).
(4) Disconnect and isolate the battery negative
cable.
(5) Disconnect the battery positive cable.
(6) Loosen bolt and retainer that holds the battery
down to the tray.
(7) Lift battery out of battery tray and remove
from vehicle.
(8) Carefully lift the thermal guard off over the
battery taking care not to tear it.
(9) Remove the thermal guard from battery.
INSTALLATION
When replacing battery, the thermal guard MUST
be transferred to the new battery.
(1) Slip the battery thermal guard over the battery
being careful not to tear it.
(2) Install battery in vehicle.
(3) Install battery hold down clamp, making sure
that it is properly positioned on battery.
(4) Connect battery cable clamps to battery posts.
Install battery positive cable first.
(5) Tighten clamp nuts securely.
(6) Install the air cleaner housing (Refer to 9 -
ENGINE/AIR
INTAKE
SYSTEM/AIR
CLEANER
HOUSING - INSTALLATION).
BATTERY TRAY SUPPORT
BRACKET
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the air cleaner housing.
(3) Remove the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - REMOVAL).
(4) Remove the battery tray and battery tempera-
ture sensor.
(5) Raise the vehicle on a hoist.
(6) Working under the vehicle, remove two of the
battery tray support bracket retaining bolts.
(7) Lower the vehicle on the hoist.
(8) Remove the remaining two battery tray sup-
port bracket retaining bolts and remove the bracket
from the vehicle.
INSTALLATION
(1) Position the battery tray support bracket and
install the two battery tray support bracket retaining
bolts.
(2) Raise the vehicle on the hoist.
(3) Working under the vehicle, install the two bat-
tery tray support bracket retaining bolts.
(4) Lower the vehicle on a hoist.
(5) Install the battery tray and battery tempera-
ture sensor (if equipped).
(6) Install the battery (Refer to 8 - ELECTRICAL/
BATTERY SYSTEM/BATTERY - INSTALLATION).
(7) Install the air cleaner housing.
(8) Connect the negative battery cable.
PT
BATTERY SYSTEM
8F - 23
THERMAL GUARD (Continued)
CHARGING
TABLE OF CONTENTS
page
page
CHARGING
DIAGNOSIS AND TESTING - ON-BOARD
. . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . 26
BATTERY TEMPERATURE SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL - 2.0, 2.4, and 2.4L TURBO
INSTALLATION - 2.0, 2.4, and 2.4L TURBO
GENERATOR
. . . . . . . . . . . . . . . . . . . . . . . . . 28
. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
. . . . . . . . . . . . . . . . . . . 28
. . . . . . . . . . . . . . . . 30
. . . . . . . . . . . . . . . . . . . . . . 32
. . . . . . . . . . . . . . . . 33
. . . . . . . . . . . . . . . . 34
. . . . . . . . . . . . . . . . . . 35
VOLTAGE REGULATOR
. . . . . . . . . . . . . . . . . . . . . . . . . 36
. . . . . . . . . . . . . . . . . . . . . . . . . . . 36
CHARGING
DESCRIPTION - CHARGING SYSTEM
The charging system consists of:
• Generator
• Decoupler Pulley (If equipped)
• Electronic Voltage Regulator (EVR) circuitry
within the Powertrain Control Module (PCM)
• Ignition switch (refer to the Ignition System sec-
tion for information)
• Battery (refer to the Battery section for informa-
tion)
• Inlet Air Temperature (calculated battery tem-
perature 1.6L)
• Battery Temperature Sensor (2.0L, 2.4L, and
2.4L turbo)
• Voltmeter (refer to the Instrument Cluster sec-
tion for information if equipped)
• Wiring harness and connections (refer to the
Wiring section for information)
• Accessory drive belt (refer to the Cooling section
for more information)
OPERATION - CHARGING SYSTEM
The charging system is turned on and off with the
ignition switch. The system is on when the engine is
running and the ASD relay is energized. The ASD
relay is energized when the PCM grounds the ASD
control circuit. This voltage is connected through the
PCM or IPM (intelligent power module) and supplied
to one of the generator field terminals (Gen. Source
+) at the back of the generator.
The generator is driven by the engine through a
serpentine
belt
and
pulley
or
decoupler
pulley
arrangement.
The amount of DC current produced by the gener-
ator is controlled by the EVR (field control) circuitry
contained within the PCM. This circuitry is con-
nected in series with the second rotor field terminal
and ground.
Battery temperature is detected using a stand
alone sensor for vehicles having 2.0, 2.4, and 2.4L
Turbo engines. For 1.6L engines vehicles battery
temperature is predicted using the values of 4 exist-
ing sensors inputs. These inputs are Inlet Air Sensor,
Coolant Sensor, Vehicle Speed Sensor, and Fan State
(on/off). The charging lamp will come on if either the
inlet air temperature, coolant temperature, or vehicle
speed sensor fail. If one of these sensors fail the
charging system will default to 13.5 Volts. This tem-
perature data, along with data from monitored line
voltage (ASD voltage sense circuit), is used by the
PCM to vary the battery charging rate. This is done
by cycling the ground path to control the strength of
the rotor magnetic field. The PCM then compensates
and regulates generator current output accordingly
to maintain system voltage at the targeted system
voltage based on battery temperature.
All vehicles are equipped with On-Board Diagnos-
tics (OBD). All OBD-sensed systems, including EVR
(field control) circuitry, are monitored by the PCM.
Each monitored circuit is assigned a Diagnostic Trou-
ble Code (DTC). The PCM will store a DTC in elec-
tronic memory for certain failures it detects. Refer to
On-Board Diagnostics in the Electronic Control Mod-
ules(Refer to 8 - ELECTRICAL/ELECTRONIC CON-
8F - 24
CHARGING
PT
TROL
MODULES/POWERTRAIN
CONTROL
MODULE - DESCRIPTION) section for more DTC
information.
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 PCI bus cir-
cuits. The lamp is located on the instrument panel.
Refer to the Instrument Cluster section for additional
information.
DIAGNOSIS AND TESTING - ON-BOARD
DIAGNOSTIC SYSTEM
The Powertrain Control Module (PCM) monitors
critical input and output circuits of the charging sys-
tem, making sure they are operational. A Diagnostic
Trouble Code (DTC) is assigned to each input and
output circuit monitored by the OBD system. Some
circuits are checked continuously and some are
checked only under certain conditions.
If the OBD system senses that a monitored circuit
is bad, it will put a DTC into electronic memory. The
DTC will stay in electronic memory as long as the
circuit continues to be bad. The PCM is programmed
to clear the memory after 40 good trip if the problem
does not occur again.
DIAGNOSTIC TROUBLE CODES
A DTC description can be read using the DRBIII
t
scan tool. Refer to the appropriate Powertrain Diag-
nostic Procedures manual for information.
A DTC does not identify which component in a cir-
cuit is bad. Thus, a DTC should be treated as a
symptom, not as the cause for the problem. In some
cases, because of the design of the diagnostic test
procedure, a DTC can be the reason for another DTC
to be set. Therefore, it is important that the test pro-
cedures be followed in sequence, to understand what
caused a DTC to be set.
ERASING DIAGNOSTIC TROUBLE CODES
The DRBIII
t Scan Tool must be used to erase a
DTC.
The following procedures may be used to diagnose
the charging system if:
• the check gauges lamp or battery lamp is illumi-
nated with the engine running
• the voltmeter (if equipped) does not register
properly
• an undercharged or overcharged battery condi-
tion occurs.
Remember that an undercharged battery is often
caused by:
• accessories being left on with the engine not
running
• a faulty or improperly adjusted switch that
allows a lamp to stay on. Refer to Ignition-Off Draw
Test (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/
BATTERY - STANDARD PROCEDURE)
• loose generator belt.
INSPECTION
The Powertrain Control Module (PCM) monitors
critical input and output circuits of the charging sys-
tem, making sure they are operational. A Diagnostic
Trouble Code (DTC) is assigned to each input and
output circuit monitored by the On-Board Diagnostic
(OBD) system. Some charging system circuits are
checked continuously, and some are checked only
under certain conditions.
Refer to Diagnostic Trouble Codes in; Powertrain
Control Module; Electronic Control Modules for more
DTC information. This will include a complete list of
DTC’s including DTC’s for the charging system.
To perform a complete test of the charging system,
refer to the appropriate Powertrain Diagnostic Proce-
dures service manual and the DRBIII
t scan tool.
Perform the following inspections before attaching
the scan tool.
(1) Inspect the battery condition. Refer to the Bat-
tery section (Refer to 8 - ELECTRICAL/BATTERY
SYSTEM - DIAGNOSIS AND TESTING) for proce-
dures.
(2) Inspect condition of battery cable terminals,
battery posts, connections at engine block, starter
solenoid and relay. They should be clean and tight.
Repair as required.
(3) Inspect all fuses in both the fuseblock and Power
Distribution Center (PDC) or IPM (if equipped) for
tightness in receptacles. They should be properly
installed and tight. Repair or replace as required.
(4) Inspect generator mounting bolts for tightness.
Replace or tighten bolts if required. Refer to the Gen-
erator Removal/Installation section of this group for
torque specifications (Refer to 8 - ELECTRICAL/
CHARGING - SPECIFICATIONS).
(5) Inspect generator drive belt condition and ten-
sion. Tighten or replace belt as required. Refer to
Belt Tension Specifications(Refer to 7 - COOLING/
ACCESSORY DRIVE - SPECIFICATIONS).
(6) Inspect decoupler pulley (if equipped). Ensure
decoupler pulley is driving the alternator rotor.
(7) Inspect automatic belt tensioner (if equipped).
Refer to the Cooling System for more information.
(8) Inspect generator electrical connections at gen-
erator field, battery output, and ground terminal (if
equipped). Also check generator ground wire connec-
tion at engine (if equipped). They should all be clean
and tight. Repair as required.
PT
CHARGING
8F - 25
CHARGING (Continued)
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст