Dodge Neon / Neon SRT-4. Manual — part 82
(13) Unplug the field circuit from the generator
(Fig. 13).
(14) Remove the B+ terminal nut and wire (Fig.
14).
(15) Loosen the accessory drive belt t-bolt (Fig. 9).
(16) Remove the pencil strut (Fig. 15).
(17) Loosen the lower generator pivot bolt (Fig.
16).
(18) Remove the generator belt, refer to the Cool-
ing section for more information.
(19) Remove the generator from the lower mount-
ing bracket and set generator to the side.
Fig. 13 BATTERY CONNECTION ON GENERATOR
Fig. 14 GENERATOR FIELD CONNECTIONS
Fig. 15 Pencil Strut
1 - NUT
2 - PENCIL STRUT
3 - NUT
4 - FLAT WASHER
5 - LOWER TORQUE STRUT
Fig. 16 LOWER PIVOT BOLT
8F - 24
CHARGING
PL/SRT-4
GENERATOR (Continued)
(20) Remove the lower mounting bracket (Fig. 17)
for the generator.
(21) Remove generator through the axle shaft hole
(Fig. 18).
INSTALLATION
INSTALLATION - 2.0L
(1) Install generator (Fig. 6) through wheel well.
(2) Install lower pivot bracket and tighten bolts to
54 N·m (40 ft. lbs.).
(3) Loose install the upper and lower mounting
bolts (Fig. 5).
(4) Connect the generator field circuit wiring con-
nector. Push the RED locking tab to lock.
(5) Install the B+ terminal nut and wire.
(6) Install the generator drive belt.
(7) Lower vehicle.
(8) Tension belt. Refer to the Cooling System sec-
tion for belt tension specification.
(9) Tighten adjustment bolt.
(10) Tighten the jam nut and tighten nut to 54
N·m (40 ft. lbs.).
(11) Raise vehicle and support.
(12) Tighten lower mounting bolt and tighten bolts
to 54 N·m (40 ft. lbs.).
(13) Install splash shield (Fig. 4).
(14) Lower vehicle.
(15) Connect battery cable (Fig. 3).
INSTALLATION - 2.4L SRT-4
(1) Install generator through the axle shaft hole in
wheel well (Fig. 18).
(2) Put generator on upper t-bolt and loosely
install the nut (Fig. 9).
(3) Install the lower mounting bracket (Fig. 17) 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. 16).
(5) Install the B+ terminal nut and wire (Fig. 14)
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. 11).
(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. 11).
(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. 9).
(14) Tighten the lower generator pivot bolt and
tighten bolts to 54 N·m (40 ft. lbs.).
(15) Install the pencil strut (Fig. 15).
(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.
10).
(19) Install the right front wheel.
(20) Lower vehicle.
(21) Tighten nut to the upper adjustment bracket
(Fig. 9) and tighten to 25 N·m (18 ft. lbs.).
Fig. 17 LOWER MOUNTING BRACKET
1 - Axle Shaft Bearing Mount
2 - Lower Generator Mount
Fig. 18 GENERATOR REMOVAL/INSTALLATION
PL/SRT-4
CHARGING
8F - 25
GENERATOR (Continued)
(22) Install the 2 bolts to the heat shield on the
generator (Fig. 8) and tighten bolts to 4.5 N·m (40 in.
lbs.).
(23) Connect the negative battery cable.
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 - 26
CHARGING
PL/SRT-4
GENERATOR (Continued)
STARTING
TABLE OF CONTENTS
page
page
STARTING
. . . . . . . . . . . . . . . . . . . . . . . . . 27
. . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DIAGNOSIS AND TESTING - STARTING
SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . 27
DIAGNOSIS AND TESTING - CONTROL
CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . . . 29
DIAGNOSIS AND TESTING - FEED CIRCUIT
RESISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . 31
DIAGNOSIS AND TESTING - FEED CIRCUIT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
. . . . . . . . . . . . . . . . . . . . . 34
STARTER MOTOR
. . . . . . . . . . . . . . . . . . . . . . . . . 34
. . . . . . . . . . . . . . . . . . . . . . . . 34
. . . . . . . . . . . . . . . . . . . . 34
STARTER MOTOR - 2.0L HIGH OUTPUT
INSTALLATION - 2.0L HIGH OUTPUT
STARTER MOTOR 2.0L 4 SPD AUTO
REMOVAL - 2.0L AUTOMATIC TRANSMISSION
. . . . . . . . . . . . . . . . . . . . . . 37
STARTER MOTOR - 2.4L SRT-4
. . . . . . . . . . . . . . . . . . 37
. . . . . . . . . . . . . . . 38
STARTER MOTOR RELAY
. . . . . . . . . . . . . . . . . . . . . . . . . 39
. . . . . . . . . . . . . . . . . . . . . . . . . . . 39
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
STARTER SOLENOID
. . . . . . . . . . . . . . . . . . . . . . . . . 39
. . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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.
PL/SRT-4
STARTING
8F - 27
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