Dodge Dakota (R1). Manual — part 301
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
8F - 26
CHARGING
AN
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.
INSTALLATION
(1) Position generator to engine and snap field
wire connector into rear of generator.
(2) Install B+ terminal to generator mounting
stud. Tighten mounting nut to 12 N·m (108 in. lbs.)
torque.
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
AN
CHARGING
8F - 27
GENERATOR (Continued)
(3) Install
generator
mounting
fasteners
and
tighten as follows:
• Generator mounting bolt 3.9L/5.9L engines—41
N·m (30 ft. lbs.) torque.
• Generator pivot bolt/nut 3.9L/5.9L engines—41
N·m (30 ft. lbs.) torque.
• Generator mounting bolt 2.5L engine—55 N·m
(41 ft. lbs.) torque.
• Generator pivot bolt 2.5L engine—55 N·m (41 ft.
lbs.) torque.
• Vertical mounting bolt 4.7L engine—55 N·m (40
ft. lbs.)
• Long horizontal mounting bolt 4.7L engine—55
N·m (40 ft. lbs.)
• Short horizontal mounting bolt 4.7L engine—74
N·m (55 ft. lbs.)
CAUTION: Never force a belt over a pulley rim
using a screwdriver. The synthetic fiber of the belt
can be damaged.
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. The
water pump will be rotating in the wrong direction if
the belt is installed incorrectly, causing the engine
to overheat. Refer to belt routing label in engine
compartment, or refer to Belt Schematics in 7, Cool-
ing System.
(4) Install generator drive belt. Refer to 7, Cooling
System for procedure.
(5) Snap cable protector cover to B+ mounting stud.
(6) Install negative battery cable to battery.
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 generator
is controlled by EVR circuitry contained within the
PCM. This circuitry is connected in series with the gen-
erators second rotor field terminal and its ground.
Voltage is regulated by cycling the ground path to
control the strength of the rotor magnetic field. The
EVR circuitry monitors system line voltage (B+) and
battery temperature (refer to Battery Temperature
Sensor for more information). It then determines a
target charging voltage. If sensed battery voltage is
0.5 volts or lower than the target voltage, the PCM
grounds the field winding until sensed battery volt-
age is 0.5 volts above target voltage. A circuit in the
PCM cycles the ground side of the generator field up
to 100 times per second (100Hz), but has the capabil-
ity to ground the field control wire 100% of the time
(full field) to achieve the target voltage. If the charg-
ing rate cannot be monitored (limp-in), a duty cycle
of 25% is used by the PCM in order to have some
generator output. Also refer to Charging System
Operation for additional information.
Fig. 5 Generator Connectors—Typical Bosch
1 - FIELD WIRE CONNECTOR
2 - FIELD WIRES
3 - B+ (OUTPUT TERMINAL)
Fig. 6 Generator Connectors—Typical Denso
1 - FIELD WIRES
2 - B+ (OUTPUT TERMINAL)
3 - FIELD WIRE CONNECTOR
8F - 28
CHARGING
AN
GENERATOR (Continued)
STARTING
TABLE OF CONTENTS
page
page
STARTING
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . 30
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 34
STARTER MOTOR
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . 35
STARTER MOTOR RELAY
STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . 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.
Certain starting system components are monitored
by the PCM and may produce a Diagnostic Trouble
Code (DTC). Refer to Diagnostic Trouble Codes for
additional information and a list of codes.
OPERATION
The starting system components form two separate
circuits. A high-amperage feed circuit that feeds the
starter motor between 150 and 350 amperes (700
amperes - diesel engine), and a low-amperage control
circuit that operates on less than 20 amperes. The
high-amperage feed circuit components include the
battery, the battery cables, the contact disc portion of
the starter solenoid, and the starter motor. The low-
amperage control circuit components include the igni-
tion switch, the clutch pedal position switch (manual
transmission), the park/neutral position switch (auto-
matic transmission), the starter relay, the electro-
magnetic windings of the starter solenoid, and the
connecting wire harness components.
If the vehicle is equipped with a manual transmis-
sion, it has a clutch pedal position switch installed in
series between the ignition switch and the coil bat-
tery terminal of the starter relay. This normally open
switch prevents the starter relay from being ener-
gized when the ignition switch is turned to the
momentary Start position, unless the clutch pedal is
depressed. This feature prevents starter motor oper-
ation while the clutch disc and the flywheel are
engaged. The starter relay coil ground terminal is
always grounded on vehicles with a manual trans-
mission.
If the vehicle is equipped with an automatic trans-
mission, battery voltage is supplied through the low-
amperage control circuit to the coil battery terminal
of the starter relay when the ignition switch is
turned to the momentary Start position. The park/
neutral position switch is installed in series between
the starter relay coil ground terminal and ground.
This normally open switch prevents the starter relay
from being energized and the starter motor from
AN
STARTING
8F - 29
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