Dodge Dakota (R1). Manual — part 300
BATTERY TRAY
DESCRIPTION
The battery is mounted in a molded plastic tray
(Fig. 25) located in the left front corner of the engine
compartment. The battery tray is secured on the
inboard side with screws to a stamped steel battery
tray support located on the left side of the radiator,
on the outboard side with screws to the front exten-
sion of the left front wheelhouse inner panel and at
the front to the front closure panel on the left side of
the radiator yoke. The battery tray support is
secured at the front with screws to the left side of
the radiator yoke, and at the rear with a screw to the
front extension of the left front wheelhouse inner
panel.
A hole in the bottom of the battery tray is fitted
with a battery temperature sensor. Refer to Battery
Temperature Sensor in the index of this service
manual for the location of more information on the
battery temperature sensor. The battery tray also
includes two stanchions that are molded into the rear
of the tray, which support the forward end of the
Power Distribution Center (PDC). Refer to Power
Distribution Center in the index of this service
manual for the location of more information on the
PDC mounting.
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 battery tray.
Refer to Battery in the index of this service manual
for the location of the proper battery removal proce-
dures.
(2) Remove the Power Distribution Center (PDC)
from the stanchions on the rear of the battery tray.
Refer to Power Distribution Center in the index of
this service manual for the location of the proper
PDC removal procedures.
(3) Remove the two screws that secure the inboard
side of the battery tray to the battery tray support
(Fig. 26).
(4) Remove the two screws that secure the out-
board side of the battery tray to the front extension
of the left front wheelhouse inner panel.
(5) Remove the one screw that secures the front of
the battery tray to the front closure panel on the left
side of the radiator yoke.
(6) Remove the battery temperature sensor from
the battery tray. Refer to Battery Temperature
Sensor in the index of this service manual for the
location of the proper battery temperature sensor
removal procedures.
(7) Remove the battery tray from the battery tray
support and the front extension of the left front
wheelhouse inner panel.
(8) Remove the one screw that secures the rear of
the battery tray support to the front extension of the
left front wheelhouse inner panel.
(9) Remove the two screws that secure the front of
the battery tray support to the left side of the radia-
tor yoke.
(10) Remove the battery tray support from the left
front wheelhouse inner panel and the left side of the
radiator yoke.
Fig. 25 Battery Tray
1 - SCREW
2 - SENSOR
3 - YOKE
4 - SCREW
5 - SUPPORT
6 - SCREW
7 - WHEELHOUSE INNER PANEL
8 - TRAY
9 - SCREW
8F - 22
BATTERY SYSTEM
AN
INSTALLATION
(1) Clean and inspect the battery tray. Refer to
Battery in the index of this service manual for the
location of the proper battery tray cleaning and
inspection procedures.
(2) Position the battery tray support onto the left
front wheelhouse inner panel and the left side of the
radiator yoke.
(3) Install and tighten the two screws that secure
the battery tray support to the left side of the radia-
tor yoke. Tighten the screws to 11.3 N·m (100 in.
lbs.).
(4) Install and tighten the one screw that secures
the rear of the battery tray support to the front
extension of the left front wheelhouse inner panel.
Tighten the screw to 11.3 N·m (100 in. lbs.).
(5) Install the battery temperature sensor onto the
battery tray. Refer to Battery Temperature Sensor
in the index of this service manual for the location of
the proper battery temperature sensor installation
procedures.
(6) Position the battery tray onto the battery tray
support and the front extension of the left front
wheelhouse inner panel. Be certain that the battery
temperature sensor wiring is properly routed.
(7) Install and tighten the two screws (rear screw
first) that secure the outboard side of the battery
tray to the front extension of the left front wheel-
house inner panel. Tighten the screws to 12.4 N·m
(110 in. lbs.).
(8) Install and tighten the two screws that secure
the inboard side of the battery tray to the battery
tray support. Tighten the screws to 12.4 N·m (110 in.
lbs.).
(9) Install and tighten the one screw that secures
the front of the battery tray to the front closure
panel on the left side of the radiator yoke. Tighten
the screw to 12.4 N·m (110 in. lbs.).
(10) Install the Power Distribution Center (PDC)
onto the stanchions on the rear of the battery tray.
Refer to Power Distribution Center in the index of
this service manual for the location of the proper
PDC installation procedures.
(11) Install the battery onto the battery tray. Refer
to Battery in the index of this service manual for
the location of the proper battery installation proce-
dures.
Fig. 26 Battery Tray Remove/Install
1 - SCREW
2 - SENSOR
3 - YOKE
4 - SCREW
5 - SUPPORT
6 - SCREW
7 - WHEELHOUSE INNER PANEL
8 - TRAY
9 - SCREW
AN
BATTERY SYSTEM
8F - 23
BATTERY TRAY (Continued)
CHARGING
TABLE OF CONTENTS
page
page
CHARGING
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . 24
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 25
BATTERY TEMPERATURE SENSOR
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
GENERATOR
VOLTAGE REGULATOR
CHARGING
DESCRIPTION
The charging system consists of:
• Generator
• Electronic Voltage Regulator (EVR) circuitry
within the Powertrain Control Module (PCM)
• Ignition switch (refer to 8, Ignition System for
information)
• Battery (refer to 8, Battery for information)
• Battery temperature sensor
• Generator Lamp (if equipped)
• Check Gauges Lamp (if equipped)
• Voltmeter (refer to 8, Instrument Panel and
Gauges for information)
• Wiring harness and connections (refer to 8, Wir-
ing for information)
OPERATION
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. When the
ASD relay is on, voltage is supplied to the ASD relay
sense circuit at the PCM. This voltage is connected
through the PCM and supplied to one of the genera-
tor field terminals (Gen. Source +) at the back of the
generator.
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 Panel and Gauges for addi-
tional information.
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
8F - 24
CHARGING
AN
• 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.
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
AN
CHARGING
8F - 25
CHARGING (Continued)
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