Dodge Neon / Neon SRT-4. Manual — part 80
(2) One at a time, install the battery cable retain-
ing pushpins, fasteners and routing clips until the
cables are installed exactly where they were in the
vehicle.
(3) Install the battery in the vehicle. Refer to the
procedure in this group.
(4) Connect the remote battery negative cable ter-
minal.
BATTERY TRAY
DESCRIPTION
The battery is placed in a plastic tray located in
the left front side of the vehicle, next to the left strut
tower. Refer to Battery Hold down for more informa-
tion on hold down hardware.
OPERATION
The battery tray provides a secure mounting loca-
tion and supports the battery. On some vehicles, the
battery tray also provides the anchor point/s for the
battery holddown hardware. The battery tray and
the battery holddown hardware combine to secure
and stabilize the battery in the engine compartment,
which prevents battery movement during vehicle
operation. Unrestrained battery movement during
vehicle operation could result in damage to the vehi-
cle, the battery, or both.
REMOVAL
(1) Remove the battery from the vehicle. Refer to
the procedure in this section.
(2) Remove two nuts to the rear and two bolts to
the front of the battery tray (Fig. 13).
(3) Remove the tray retaining bolt under the cen-
ter of the tray.
(4) Slide battery tray out form under the air
cleaner assembly. Do not remove the air cleaner
assembly.
(5) Remove battery tray from vehicle.
INSTALLATION
(1) Slide battery tray in under the air cleaner
assembly.
(2) Install two nuts at the rear and two bolts at
the front of the battery tray.
(3) Install the bolt located under the tray.
(4) Install the battery in the vehicle. Refer to the
procedure in this section.
THERMAL GUARD
DESCRIPTION
A flexible plastic bubble-wrap style thermal guard
wraps around the battery case to enclose the sides of
the battery. The thermal guard consists of a heavy
black plastic outer skin and two lighter plies of plas-
tic that have been formed into a sheet with hundreds
of small air pockets entrapped between them.
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 between the plastic plies of
the thermal guard create 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
(1) Open hood.
(2) Disconnect and isolate the battery negative
cable then the positive cable.
(3) Carefully lift the thermal guard off over the
battery (Fig. 14) taking care not to rip it.
(4) Remove the thermal guard from vehicle.
Fig. 13 Battery Tray Removal
1 - BATTERY TRAY
2 - LEFT STRUT TOWER
3 - PDC
4 - MOUNTING HOLES/SLOTS
5 - COOLANT RESERVOIR
8F - 16
BATTERY SYSTEM
PL/SRT-4
BATTERY CABLES (Continued)
INSTALLATION
(1) Carefully install the thermal guard over the
battery taking care not to rip it.
(2) Connect the battery negative and positive
cables.
Fig. 14 Battery Thermal Guard
1 - BATTERY THERMAL GUARD
2 - BATTERY
PL/SRT-4
BATTERY SYSTEM
8F - 17
THERMAL GUARD (Continued)
CHARGING
TABLE OF CONTENTS
page
page
CHARGING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . . . . 20
BATTERY TEMPERATURE SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . . . . . . . . . . . . 21
GENERATOR
. . . . . . . . . . . . . . . . . . . . . . . . . 21
. . . . . . . . . . . . . . . . . . . . . . . . . . . 21
. . . . . . . . . . . . . . . . . . . . . . 21
. . . . . . . . . . . . . . . . . 22
. . . . . . . . . . . . . . . . . . 25
VOLTAGE REGULATOR
. . . . . . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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)
• Battery Temperature Sensor (2.0L)
• Inlet Air Temperature (calculated battery tem-
perature) (1.6L)
• 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 predicted using the battery
temperature sensors input for the 2.0L engines. For
the 1.6L engines battery temperature is calculated
using these inputs: Inlet Air Temperature 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-
TROL
MODULES/POWERTRAIN
CONTROL
MODULE - DESCRIPTION) section for more DTC
information.
The Check Gauges Lamp (if equipped) monitors:
charging system voltage, engine coolant tempera-
8F - 18
CHARGING
PL/SRT-4
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 scan tool.
Refer to the appropriate Powertrain Diagnostic Pro-
cedures 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 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
Diagnostic manual 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 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.
PL/SRT-4
CHARGING
8F - 19
CHARGING (Continued)
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