Chrysler Stratus Convertible. Manual — part 233

CHARGING SYSTEM

TABLE OF CONTENTS

page

page

DESCRIPTION AND OPERATION

CHARGING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . 1
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

DIAGNOSIS AND TESTING

CURRENT OUTPUT TEST . . . . . . . . . . . . . . . . . . . 1

REMOVAL AND INSTALLATION

2.0L Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SPECIFICATIONS

GENERATOR RATINGS . . . . . . . . . . . . . . . . . . . . . 3
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

DESCRIPTION AND OPERATION

CHARGING SYSTEM

DESCRIPTION

The charging system consists of:
• Generator

• Electronic Voltage Regulator (EVR) circuitry

within the Powertrain Control Module (PCM)

• Ignition switch (refer to the Ignition System for

information)

• Battery (refer to the Battery for information)

• Battery temperature sensor

• Wiring harness and connections (refer to the

Wiring for information)

OPERATION

The charging system is turned on and off with the

ignition switch. When the ignition switch is turned to
the ON position, battery voltage is applied to the
generator rotor through one of the two field termi-
nals to produce a magnetic field. The generator is
driven by the engine through a serpentine belt and
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.

Temperature data, along with data from monitored

line voltage, 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 gen-
erator current output accordingly and to maintain
the proper voltage depending on battery tempera-
ture.

All vehicles are equipped with On-Board Diagnos-

tics (OBD). All OBD-sensed systems, including the
EVR (field control) circuitry, are monitored by the
PCM. Each monitored circuit is assigned a Diagnos-

tic Trouble Code (DTC). The PCM will store a DTC in
electronic memory for any failure it detects.

GENERATOR

DESCRIPTION

The generator is belt-driven by the engine. It is

serviced only as a complete assembly. If the genera-
tor fails for any reason, 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 Y type stator winding connections deliver the

induced AC current to 3 positive and 3 negative
diodes for rectification. From the diodes, rectified DC
current is delivered to the vehicles electrical system
through the generator, battery, and ground terminals.

Noise emitting from the generator may be caused

by:

• Worn, loose or defective bearings

• Loose or defective drive pulley

• Incorrect, worn, damaged or misadjusted drive

belt

• Loose mounting bolts

• Misaligned drive pulley

• Defective stator or diode

• Damaged internal fins

DIAGNOSIS AND TESTING

CURRENT OUTPUT TEST

The current output test will determine if the

charging system can deliver its minimum test cur-
rent (amperage) output. Refer to the Specifications
section at the end of this group for minimum test
current (amperage) requirements.

JX

CHARGING SYSTEM

8C - 1

The first part of this test will determine the com-

bined amperage output of both the generator and the
Electronic Voltage Regulator (EVR) circuitry.

PREPARATION

(1) Determine if any Diagnostic Trouble Codes

(DTC) exist. For repair, refer to the appropriate Pow-
ertrain Diagnostic Procedures manual.

(2) Before starting test, make sure battery is in

good condition and is fully-charged. See the Battery
section for more information.

(3) Check condition of battery cables at battery.

Clean if necessary.

(4) Be sure the generator drive belt is properly

tensioned. Refer to the Cooling System for informa-
tion.

(5) A volt/amp tester equipped with both a battery

load control (carbon pile rheostat) and an inductive-
type pickup clamp (ammeter probe) will be used for
this test. Refer to operating instructions supplied
with tester. When using a tester equipped with an
inductive-type clamp, removal of wiring at the gener-
ator will not be necessary.

(6) Start the engine and allow it to reach operating

temperature.

(7) Shut engine off.
(8) Turn off all electrical accessories and all vehicle

lighting.

(9) Connect the volt/amp tester leads to the bat-

tery post or jump start posts. Be sure the carbon pile
rheostat control is in the OPEN or OFF position
before connecting leads. See Load Test in the Battery
section for more information. Also refer to the oper-
ating instructions supplied with test equipment.

(10) Connect the inductive clamp (ammeter probe).

Refer to the operating instructions supplied with test
equipment.

(11) If volt/amp tester is not equipped with an

engine tachometer, connect a separate tachometer to
the engine.

TEST

(1) Perform the previous test Preparation.
(2) Fully engage the parking brake.
(3) Start engine.
(4) Bring engine speed to 2500 rpm.
(5) With engine speed held at 2500 rpm, slowly

adjust the rheostat control (load) on the tester to
obtain the highest amperage reading. Do not allow
voltage to drop below 12 volts. Record the reading.
This load test must be performed within 15 sec-
onds to prevent damage to test equipment. On
certain brands of test equipment, this load will be
applied automatically. Refer to the operating manual
supplied with test equipment.

(6) The ammeter reading must meet the Minimum

Test Amps specifications as displayed in the Genera-
tor Ratings chart. This can be found in the Specifica-
tions section. A label stating a part reference number
is attached to the generator case. On some engines
this label may be located on the bottom of the case.
Compare this reference number to the Generator
Ratings chart.

(7) Rotate the load control to the OFF position.
(8) Continue holding engine speed at 2500. If EVR

circuitry is OK, amperage should drop below 15–20
amps. With all electrical accessories and vehicle
lighting off, this could take several minutes of engine
operation. If amperage did not drop, refer to the
appropriate Powertrain Diagnostic Procedures man-
ual for testing.

(9) Remove volt/amp tester.
If minimum amperage could not be met, refer to

the appropriate Powertrain Diagnostic Procedures
manual for testing.

REMOVAL AND INSTALLATION

2.0L Generator

REMOVAL

(1) Disconnect the negative battery cable at the

remote terminal, located on the left strut tower.

(2) Remove

the

generator

pivot

bolt.

Located

directly below the generator.

(3) Remove the generator lock nut (Fig. 1).
(4) Loosen

the

(2)

generator

support

bracket

retaining bolts (Fig. 1).

(5) Loosen the accessory drive belt tension bolt

(Fig. 1).

(6) Remove the accessory drive belt from the gen-

erator pulley.

(7) Disconnect the (2) generator electrical connec-

tors

(8) Remove the generator pivot bolt.
(9) Remove the generator from the vehicle.

INSTALLATION

(1) Install the generator in the vehicle.
(2) Install the generator pivot bolt and leave loose

at this time

(3) Install the accessory drive belt. Making sure

the belt is properly seated on all the accessory drive
pulleys

(4) Install the generator lock nut and leave loose

at this time (Fig. 2).

(5) Tighten the accessory drive belt tension bolt to

set the proper belt tension (Fig. 2).

(6) Torque the generator pivot bolt to 54 N·m (40

ft. lbs.).

8C - 2

CHARGING SYSTEM

JX

DIAGNOSIS AND TESTING (Continued)

(7) Torque the generator lock nut to 54 N·m (40 ft.

lbs.).

(8) Connect the generator electrical connectors.

Torque the B+ terminal to 9 N·m (75 in. lbs.).

(9) Connect the negative battery cable.

SPECIFICATIONS

GENERATOR RATINGS

TYPE

ENGINES

MINIMUM TEST AMPS

DENSO

2.0L

100 amps

DENSO

2.5L

100 amps

The Test Specifications are:

1. 2500

6

20 RPMS

2. Voltage Output 12V

6

.3V

3. Field Current 6amps

6

.1amp

Fig. 1 Generator Position & Orientation — Front

1 – GENERATOR LOCK NUT
2 – BELT TENSION BOLT
3 – GENERATOR
4 – GENERATOR SUPPORT BRACKET BOLTS
5 – GENERATOR SUPPORT BRACKET

Fig. 2 Generator Position & Orientation — Front

1 – GENERATOR LOCK NUT
2 – BELT TENSION BOLT
3 – GENERATOR
4 – GENERATOR SUPPORT BRACKET BOLTS
5 – GENERATOR SUPPORT BRACKET

JX

CHARGING SYSTEM

8C - 3

REMOVAL AND INSTALLATION (Continued)

TORQUE

DESCRIPTION

TORQUE

Battery Terminal Nut . . . . . . . . 10 N·m (90 in. lbs.)
Battery Hold Down Clamp Bolt . . . . . . . . . 10 N·m

(90 in. lbs.)

Battery Negative Cable Nut

at Shock Tower . . . . . . . . . . . 10 N·m (90 in. lbs.)

Generator B+ Terminal . . . . . . . 9 N·m (75 in. lbs.)
Generator Mounting Bolt . . . . . 54 N·m (40 ft. lbs.)
Generator Pivot Bolt . . . . . . . . . 54 N·m (40 ft. lbs.)

8C - 4

CHARGING SYSTEM

JX

SPECIFICATIONS (Continued)