Dodge Neon / Neon SRT-4. Manual — part 81

SPECIFICATIONS

TORQUE

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Battery Terminal Nut

9

6.6

75

Battery Hold Down Clamp

Bolt

9

6.6

75

Generator Mounting Bolt

54

40

Generator Pivot Bolt

54

40

Pivot Bracket Bolts

54

40

GENERATOR RATINGS

TYPE

PART NUMBER

RATED SAE AMPS

ENGINES

MINIMUM TEST

AMPS

Mitsubishi

4794222AC

85 AMPS

2.0L

75 AMPS

BATTERY TEMPERATURE
SENSOR

DESCRIPTION

The Battery Temperature sensor is mounting in

the side of the battery thermal guard (Fig. 1).

OPERATION

The PCM uses the temperature of the battery area

to control the charge system voltage. This tempera-
ture, along with data from monitored line voltage, is

used by the PCM to vary the battery charging rate.
The system voltage is higher at cold temperatures
and is gradually reduced as temperature around the
battery increases.

For vehicles with 1.6L engine, there is no physical

battery temp sensor in place to detect battery temp.
Rather, an algorithm buit in PCM is employed to pre-
dict battery temp using inlet air temp, vehicle speed,
and coolant temp, among other signals. The PCM
maintains the optimal output of the generator by
monitoring battery voltage and controlling it to a
range of 13.5 - 14.7 volts based on battery tempera-
ture. The system target voltage is 13.5 – 14.7 volts.
However the actual voltage go below this during
heavy electrical loads and generator speeds. Also the
actual voltage can be lower than the target voltage
between the battery and the battery voltage sense
circuit, approximately 0.2 — 0.3 volts.

The battery temperature sensor is also used for

OBD II diagnostics. Certain faults and OBD II mon-
itors are either enabled or disabled depending upon
the battery temperature sensor input (example: dis-
able purge and EGR, enable LDP). Most OBD II
monitors are disabled below 20°F.

REMOVAL

(1) Open hood.
(2) Disconnect and isolate the battery negative

cable then the positive cable.

(3) Disconnect the Battery Temperature Sensor

electrical connector.

(4) Carefully lift the thermal guard off over the

battery.

(5) Remove the thermal guard from vehicle.

Fig. 1 BATTERY TEMPERATURE SENSOR

1 - Battery Thermal Guard
2 - Battery Temperature Sensor

8F - 20

CHARGING

PL/SRT-4

CHARGING (Continued)

(6) Unsnap the Battery Temperature Sensor and

remove the sensor (Fig. 2).

INSTALLATION

(1) Install the Battery Temperature Sensor to the

thermal guard (Fig. 2).

(2) Carefully install the thermal guard over the

battery.

(3) Connect the Battery Temperature Sensor elec-

trical connector.

(4) Connect the battery positive cable then the

negative cable.

(5) Close hood.

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. The generator produces DC voltage.

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.

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

REMOVAL

REMOVAL - 2.0L

(1) Disconnect battery negative cable (Fig. 3).

(2) Loosen the jam nut and adjustment bolt.
(3) Raise vehicle and support.
(4) Remove accessary drive splash shield (Fig. 4).

Fig. 2 BATTERY TEMPERATURE SENSOR

CONNECTION

Fig. 3 Battery Cable

Fig. 4 Splash Shield and Belt

PL/SRT-4

CHARGING

8F - 21

BATTERY TEMPERATURE SENSOR (Continued)

(5) Loosen the lower mounting bolt.
(6) Remove the generator drive belt.
(7) Disconnect the generator field circuit wiring

connector. Push the RED locking tab to release.

(8) Remove the B+ terminal nut and wire.
(9) Remove the upper and lower mounting bolt

(Fig. 5) and move generator off of pivot bracket.

(10) Remove pivot bracket.

(11) Remove Generator (Fig. 6) through wheel

well.

REMOVAL - 2.4L SRT-4

The generator is located above the oil filter and

axle shaft (Fig. 7).

(1) Disconnect the negative battery cable.
(2) Remove the 2 bolts (Fig. 8) from the top of the

heat shield on the generator.

Fig. 5 Lower Mounting Bolt

Fig. 6 Generator

Fig. 7 GENERATOR LOCATION - 2.4L TURBO

1 - Oil Filter
2 - Generator
3 - Axle Shaft

Fig. 8 GENERATOR HEAT SHIELD

8F - 22

CHARGING

PL/SRT-4

GENERATOR (Continued)

(3) Remove nut from the upper T-bolt adjustment

bracket (Fig. 9).

(4) Raise vehicle and support.
(5) Remove the right front wheel.
(6) Remove the accessory drive splash shield (Fig.

10).

(7) Remove the axle retaining nut.
(8) Remove the lower control arm from the steer-

ing knuckle (Fig. 11).

(9) Remove the 2 bolts for the axle shaft bearing

support.

(10) Remove the axle shaft assembly (Fig. 11). Put

a container under the transmission to catch the
transmission fluid from the transmission.

(11) Remove the lower heat shield bolt (Fig. 12).

(12) Remove the generator heat shield.

Fig. 9 Generator T-Bolt and Upper Pivot Bolt

Fig. 10 Accessory Drive Splash Shield

1 - ACCESSORY DRIVE BELT SPLASH SHIELD

Fig. 11 AXLE SHAFT

1 - Axle Shaft
2 - Lower Control Arm
3 - Steering Knuckle

Fig. 12 LOWER HEAT SHIELD MOUNTING

PL/SRT-4

CHARGING

8F - 23

GENERATOR (Continued)