Dodge Sprinter. Manual — part 44
VOLTAGE REGULATOR
DESCRIPTION
The electronic voltage regulator (1) (Fig. 15) is
attached to the rear of the generator. The regulator
may be serviced separately from the generator.
REMOVAL
CAUTION: DISCONNECT NEGATIVE CABLE FROM
BATTERY BEFORE REMOVING BATTERY OUTPUT
WIRE FROM GENERATOR. FAILURE TO DO SO
CAN RESULT IN INJURY.
(1) Disconnect and isolate negative battery cable.
(2) Raise and support vehicle.
(3) Remove bolt (2) (Fig. 16) at turbocharger brace
(1) (Fig. 16).
(4) Loosen bolt (1) (Fig. 17) at brace (2) (Fig. 17).
Swivel the race (2) to the side.
(5) Remove + terminal nuts (3) and (4) (Fig. 17).
(6) Remove wires (5) and (6) (Fig. 17).
Fig. 14 DECOUPLER INSTALLATION (Litens)
Fig. 15 VOLTAGE REGULATOR
1 - Carbon Brushes
2 - Voltage Regulator
Fig. 16 BRACE BOLT
1 - Turbocharger Brace
2 - Brace Bolt
Fig. 17 REAR OF GENERATOR
1 - Brace Bolt
2 - Brace
3 - Nut
4 - Nut
5 - Wire
6 - Wire
8F - 24
CHARGING SYSTEM
VA
(7) Remove plastic cover (1) (Fig. 18) by removing
screw (2) and nuts (3) and (4).
(8) Remove screws (1), (3), and (4) (Fig. 19).
(9) Remove voltage regulator (2) (Fig. 19). To pre-
vent damage to the carbon brushes, slowly pull
the voltage regulator straight out from genera-
tor without slanting or tipping.
(10) Check condition of commutator rings (1) (Fig.
20). If rings are worn, replace generator assembly.
(11) Check condition of carbon brushes (1) (Fig.
21). If brushes are worn, replace generator assembly.
Fig. 18 PLASTIC COVER
1 - Plastic Cover
2 - Screw
3 - Nut
4 - Nut
Fig. 19 MOUNTING BOLTS
1 - Screw
2 - Voltage Regulator
3 - Screw
4 - Screw
Fig. 20 COMMUTATOR RINGS
1 - Commutator Rings
Fig. 21 VOLTAGE REGULATOR
1 - Carbon Brushes
2 - Voltage Regulator
VA
CHARGING SYSTEM
8F - 25
INSTALLATION
(1) Check condition of carbon brushes (1) (Fig. 22).
If brushes are worn, replace generator assembly.
(2) Check condition of commutator rings (1) (Fig.
23). If rings are worn, replace generator assembly.
(3) Position voltage regulator (2) (Fig. 24) to rear
of generator. To prevent damage to the carbon
brushes (1) (Fig. 22), slowly install the voltage
regulator straight into the generator without
slanting or tipping.
(4) Install screws (1), (3), and (4) (Fig. 24).
(5) Install plastic cover (1) (Fig. 25), screw (2) and
nuts (3) and (4).
Fig. 22 VOLTAGE REGULATOR
1 - Carbon Brushes
2 - Voltage Regulator
Fig. 23 COMMUTATOR RINGS
1 - Commutator Rings
Fig. 24 MOUNTING BOLTS
1 - Screw
2 - Voltage Regulator
3 - Screw
4 - Screw
Fig. 25 PLASTIC COVER
1 - Plastic Cover
2 - Screw
3 - Nut
4 - Nut
8F - 26
CHARGING SYSTEM
VA
(6) Position wire eyelets (5) and (6) (Fig. 26) to
generator studs.
(7) Install + terminal nuts (3) and (4) (Fig. 26).
Tighten + nut (4) to 18 N·m (159 in. lbs.). Tighten +
nut (3) to 5 N·m (44 in. lbs.).
(8) Install turbocharger brace bolt (1) (Fig. 26) at
brace (2) (Fig. 26). Tighten bolt (1) to 20 N·m (15 ft.
lbs.).
(9) Install bolt (2) (Fig. 27) at turbocharger brace
(1) (Fig. 27). Tighten bolt (2) to 30 N·m (22 ft. lbs.).
(10) Lower vehicle.
(11) Connect negative battery cable.
(12) Check charging system for proper operation.
Fig. 26 REAR OF GENERATOR
1 - Brace Bolt
2 - Brace
3 - Nut
4 - Nut
5 - Wire
6 - Wire
Fig. 27 BRACE BOLT
1 - Turbocharger Brace
2 - Brace Bolt
VA
CHARGING SYSTEM
8F - 27
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