Dodge Dakota (R1). Manual — part 305
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.
A battery temperature sensor, located in the bat-
tery tray housing, is used to sense battery tempera-
ture. This 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 mag-
netic field. The PCM then compensates and regulates
generator current output accordingly.
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
Diagnostic Trouble Codes in; Powertrain Control
Module; Electronic Control Modules for more DTC
information.
The Check Gauges Lamp (if equipped) monitors:
charging system voltage, engine coolant tempera-
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 CCD bus cir-
cuits. The lamp is located on the instrument panel.
Refer to 8, Instrument Cluster for additional infor-
mation.
DIAGNOSIS AND TESTING - CHARGING
SYSTEM
The following procedures may be used to diagnose
the charging system if:
• the check gauges lamp (if equipped) 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 in 8, Battery for more information.
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
Control Module; Electronic Control Modules 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 DRB
t scan tool. Per-
form the following inspections before attaching the
scan tool.
(1) Inspect the battery condition. Refer to 8, Bat-
tery for procedures.
(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) 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.
(5) Inspect generator drive belt condition and ten-
sion. Tighten or replace belt as required. Refer to
Belt Tension Specifications in 7, Cooling System.
(6)
Inspect automatic belt tensioner (if equipped).
Refer to 7, Cooling System for information.
(7) 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.
8Fa - 2
CHARGING
R1
CHARGING (Continued)
SPECIFICATIONS
SPECIFICATIONS - GENERATOR RATINGS
TYPE
PART NUMBER
RATED SAE AMPS
ENGINES
MINIMUM TEST AMPS
DENSO
56028686AA
117
2.5L
88
DENSO
56028687AA
136
2.5L
95
DENSO
56029913AA
117
3.9L/5.9L
90
DENSO
56030914AA
136
3.9L/5.9L
100
DENSO
56041693AB
136
4.7L
100
DENSO
56028692AA
117
4.7L
90
SPECIFICATIONS - TORQUE- CHARGING SYSTEM
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Generator Mounting Bolt -
3.9L/5.9L Engines
41
30
Generator Pivot Bolt
-3.9L/5.9L Engines
41
30
Generator Mounting Bolt
–2.5L Engine
55
41
Generator Pivot Bolt -
2.5L Engine
55
41
Generator Vertical
Mounting Bolt - 4.7L V-8
Engine
55
40
Generator (long)
Horizontal Mounting Bolt -
4.7L V-8 Engine
55
40
Generator (short)
Horizontal Mounting Bolt -
4.7L V-8 Engine
74
55
Generator B+ Output
Cable Terminal Nut
12
108
SPECIFICATIONS - TORQUE - CHARGING SYSTEM - DIESEL
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
GENERATOR MOUNTING
BOLTS
40
30
B+ TERMINAL ON
GENERATOR
12
108
R1
CHARGING
8Fa - 3
CHARGING (Continued)
BATTERY TEMPERATURE
SENSOR
DESCRIPTION
The Battery Temperature Sensor (BTS) is attached
to the battery tray located under the battery.
OPERATION
The BTS is used to determine the battery temper-
ature and control battery charging rate. This temper-
ature data, along with data from monitored line
voltage, is used by the PCM to vary the battery
charging rate. System voltage will be higher at colder
temperatures and is gradually reduced at warmer
temperatures.
The PCM sends 5 volts to the sensor and is
grounded through the sensor return line. As temper-
ature increases, resistance in the sensor decreases
and the detection voltage at the PCM increases.
The BTS is also used for OBD II diagnostics. Cer-
tain faults and OBD II monitors are either enabled
or disabled, depending upon BTS input (for example,
disable purge and enable Leak Detection Pump
(LDP) and O2 sensor heater tests). Most OBD II
monitors are disabled below 20 degrees F.
REMOVAL
The battery temperature sensor is located under
vehicle battery (Fig. 1) and is attached to a mounting
hole on battery tray.
(1) Remove battery. Refer to 8, Battery for proce-
dures.
(2) Disconnect sensor pigtail harness from engine
wire harness. Sensor pigtail harness is clipped to
vehicle near its electrical connector.
(3) Pry sensor straight up from battery tray
mounting hole.
INSTALLATION
The battery temperature sensor is located under
vehicle battery (Fig. 1) and is attached to a mounting
hole on battery tray.
(1) Feed pigtail harness through hole in top of bat-
tery tray and press sensor into top of battery tray.
(2) Connect pigtail harness.
(3) Install battery. Refer to 8, Battery for proce-
dures.
GENERATOR
DESCRIPTION
The generator is belt-driven by the engine using a
serpentine type drive belt. It is serviced only as a
complete assembly. If the generator fails for any rea-
son, 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 vehicle electrical system
through the generator battery terminal.
Although the generators appear the same exter-
nally, different generators with different output rat-
ings are used on this vehicle. Be certain that the
replacement generator has the same output rating
and part number as the original unit. Refer to Gen-
erator Ratings in the Specifications section at the
back of this group for amperage ratings and part
numbers.
Noise emitting from the generator may be caused
by: worn, loose or defective bearings; a loose or defec-
tive drive pulley; incorrect, worn, damaged or misad-
justed
fan
drive
belt;
loose
mounting
bolts;
a
misaligned drive pulley or a defective stator or diode.
Fig. 1 Battery Temperature Sensor Location
1 - BATTERY TEMPERATURE SENSOR
2 - BATTERY TRAY
8Fa - 4
CHARGING
R1
REMOVAL
WARNING: DISCONNECT NEGATIVE CABLE FROM
BATTERY BEFORE REMOVING BATTERY OUTPUT
WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO
DO SO CAN RESULT IN INJURY OR DAMAGE TO
ELECTRICAL SYSTEM.
(1) Disconnect negative battery cable at battery.
(2) Remove generator drive belt. Refer to Group 7,
Cooling System for procedures.
(3) Unsnap plastic cable protector cover from B+
mounting stud.
(4) 2.5L/3.9L/5.9L
Engines:
Remove
generator
pivot and mounting bolts/nut (Fig. 2) or (Fig. 3). Posi-
tion generator for access to wire connectors.
(5) 4.7L Engine: Remove 3 generator mounting
bolts (Fig. 4). Position generator for access to wire
connectors.
(6) Remove B+ terminal mounting nut at rear of
generator (Fig. 5) or (Fig. 6). Disconnect terminal
from generator.
(7) Disconnect field wire connector at rear of gen-
erator by pushing on connector tab and pulling con-
nector from generator.
(8) Remove generator from vehicle.
REMOVAL - 2.5L DIESEL
(1) Disconnect and isolate negative battery cable.
(2) Remove cap and un-thread nut securing B+
terminal to rear of generator.
(3) Unplug field terminal connector on generator.
Fig. 2 Remove/Install Generator—2.5L
1 - UPPER MOUNTING BRACKET
2 - GENERATOR
3 - UPPER BOLT
4 - LOWER BOLT
5 - SPACER
Fig. 3 Remove/Install Generator—3.9L/5.9L Engines
1 - MOUNTING BOLT
2 - GENERATOR
3 - MOUNTING BRACKET
4 - MOUNTING BOLT/NUT
Fig. 4 Remove/Install Generator—4.7L V-8 Engine
1 - LOWER BOLTS
2 - REAR BOLT
3 - GENERATOR
R1
CHARGING
8Fa - 5
GENERATOR (Continued)
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