Dodge Viper SRT-10 (ZB). Manual — part 65
(6) Remove the upper mounting bolt (Fig. 6).
(7) Remove the lower mounting bolt and nut (Fig.
6).
(8) Remove generator (Fig. 7).
INSTALLATION
(1) Install generator.
(2) Install the lower mounting bolt and nut (Fig.
6).
(3) Install the upper mounting bolt (Fig. 6).
(4) Tighten the bolts to 55 N·m (41 ft. lbs).
(5) Connect the battery positive cable to the gener-
ator (Fig. 5), and install the B+ stud cap..
(6) Connect the field connector (Fig. 4).
(7) Install the accessory drive belt (Fig. 3), refer to
the Cooling section for more information.
(8) Install air cleaner assembly, refer to the
Engine/air Intake System for more information.
(9) Connect the negative battery cable, tighten the
nut to 14.2 N·m (125 in. lbs.).
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 gener-
ator is controlled by EVR circuitry contained within
the PCM. This circuitry is connected in series with
the generators 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 at the
PDC and battery temperature. It then determines a
target charging voltage. If sensed battery voltage is
lower than the target voltage, the PCM grounds the
field winding until sensed battery voltage is at the
target voltage. A circuit in the PCM cycles the
ground side of the generator field at 250 times per
second (250Hz), but has the capability to feed the
field control wire 100% of the time (full field) to
achieve the target voltage. If the charging rate can-
not be monitored (limp-in), a duty cycle of 20% is
used by the PCM in order to have some generator
output. Also refer to Charging System Operation for
additional information.
Fig. 6 MOUNTING BOLTS
1 - Upper Mounting Bolt
2 - Lower Mounting Bolt
Fig. 7 GENERATOR REMOVAL/INSTALLATION
8F - 18
CHARGING
ZB
GENERATOR (Continued)
STARTING
TABLE OF CONTENTS
page
page
STARTING
. . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIAGNOSIS AND TESTING - STARTING
SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . 19
DIAGNOSIS AND TESTING - CONTROL
CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . . . 21
DIAGNOSIS AND TESTING - FEED CIRCUIT
RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . 23
DIAGNOSIS AND TESTING - CLUTCH
PEDAL POSITION SWITCH . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
STARTER MOTOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . 24
STARTER MOTOR RELAY
. . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
STARTER SOLENOID
. . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
STARTING
DESCRIPTION
The starting system has:
• Ignition switch - Run only
• BCM - Start sense circuit
• Starter relay
• Clutch pedal mounted starter interlock switch
• Wiring harness
• Battery
• Starter motor with an integral solenoid
• Starter Button - In series with the clutch inter-
lock
OPERATION
These components form two separate circuits. A
high amperage circuit that feeds the starter motor up
to 300+ amps, and a control circuit that operates on
less than 25 amps.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - STARTING
SYSTEM TEST
For circuit descriptions and diagrams, refer to the
Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO THE PASSIVE RESTRAINT SYS-
TEMS BEFORE ATTEMPTING STEERING WHEEL,
STEERING
COLUMN,
OR
INSTRUMENT
PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
INSPECTION
Before removing any unit from the starting system
for repair or diagnosis, perform the following inspec-
tions:
• Battery - Visually inspect the battery for indi-
cations of physical damage and loose or corroded
cable connections. Determine the state-of-charge and
cranking capacity of the battery. Charge or replace
the battery, if required. Refer to the Battery section
for more information.
• Ignition Switch - Visually inspect the ignition
switch for indications of physical damage and loose
or corroded wire harness connections.
• Neutral Switch - Visually inspect for indica-
tions of physical damage and loose or corroded wire
harness connections.
• Starter Relay - Visually inspect the starter
relay for indications of physical damage and loose or
corroded wire harness connections.
• Starter Motor - Visually inspect the starter
motor for indications of physical damage and loose or
corroded wire harness connections.
• Starter Solenoid - Visually inspect the starter
solenoid for indications of physical damage and loose
or corroded wire harness connections.
• Wiring - Visually inspect the wire harness for
damage. Repair or replace any faulty wiring, as
required. Check for loose or corroded wire harness
connections at main engine ground and remote jump
post.
• Power Distribution Center (PDC) - Visually
inspect the B+ connections at the PDC for physical
damage and loose or corroded harness connections.
ZB
STARTING
8F - 19
• Starter Button - Visually inspect the starter
button for indications of physical damage and loose
or corroded wire harness connections.
STARTING SYSTEM DIAGNOSIS
CONDITION
POSSIBLE CAUSE
CORRECTION
STARTER FAILS
TO ENGAGE.
1. BATTERY DIS-
CHARGED OR FAULTY.
1. REFER TO THE BATTERY SECTION FOR MORE INFOR-
MATION. CHARGE OR REPLACE BATTERY, IF REQUIRED.
2. STARTING CIRCUIT
WIRING FAULTY.
2. REFER TO FEED CIRCUIT RESISTANCE TEST AND FEED
CIRCUIT TEST IN THIS SECTION.
3. STARTER RELAY
FAULTY.
3. REFER TO RELAY TEST, IN THIS SECTION. REPLACE
RELAY, IF NECESSARY.
4. IGNITION SWITCH
FAULTY.
4. REFER TO IGNITION SWITCH TEST, IN THE STEERING
SECTION OR 8 WIRING DIAGRAMS. REPLACE SWITCH, IF
NECESSARY.
5. CLUTCH INTER-
LOCK SWITCH
5. REFER TO CLUTCH PEDAL POSITION SWITCH TEST, IN
THE CLUTCH. SECTION. REPLACE SWITCH, IF NECESSARY.
6. STARTER SOLENOID
FAULTY.
6. REFER TO SOLENOID TEST, IN THIS SECTION. REPLACE
STARTER ASSEMBLY, IF NECESSARY.
7. STARTER ASSEM-
BLY FAULTY.
7. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
8. FAULTY TEETH ON
RING GEAR.
8. ROTATE FLYWHEEL 360°, AND INSPECT TEETH AND
RING GEAR REPLACED IF DAMAGED.
9. PCM DOUBLE
START OVERRIDE
OUTPUT FAILURE.
9. REFER TO PCM DIAGNOSTIC. CHECK FOR CONTINUITY
BETWEEN PCM AND TERMINAL 85. REPAIR OPEN CIRCUIT
AS REQUIRED. IF OK, PCM MAY BE DEFECTIVE.
10. STARTER BUTTON
10. INSPECT AND TEST, IF BAD REPLACE STARTER BUT-
TON.
STARTER
ENGAGES,
FAILS TO TURN
ENGINE.
1. BATTERY DIS-
CHARGED OR FAULTY.
1. REFER TO THE BATTERY SECTION FOR MORE INFOR-
MATION. CHARGE OR REPLACE BATTERY AS NECESSARY.
2. STARTING CIRCUIT
WIRING FAULTY.
2. REFER TO THE FEED CIRCUIT RESISTANCE TEST AND
THE FEED CIRCUIT TEST IN THIS SECTION. REPAIR AS
NECESSARY.
3. STARTER ASSEM-
BLY FAULTY.
3. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
4. ENGINE SEIZED.
4. REFER TO THE ENGINE SECTION, FOR DIAGNOSTIC
AND SERVICE PROCEDURES.
5. LOOSE CONNEC-
TION AT BATTERY,
PDC, STARTER, OR
ENGINE GROUND.
5. INSPECT FOR LOOSE CONNECTIONS.
6. FAULTY TEETH ON
RING GEAR.
6. ROTATE FLYWHEEL 360°, AND INSPECT TEETH AND
RING GEAR REPLACED IF DAMAGED.
8F - 20
STARTING
ZB
STARTING (Continued)
CONDITION
POSSIBLE CAUSE
CORRECTION
STARTER
ENGAGES,
SPINS OUT
BEFORE
ENGINE
STARTS.
1. BROKEN TEETH ON
STARTER RING GEAR.
1. REMOVE STARTER. INSPECT RING GEAR AND REPLACE
IF NECESSARY.
2. STARTER ASSEM-
BLY FAULTY.
2. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
STARTER DOES
NOT DISEN-
GAGE.
1. STARTER IMPROP-
ERLY INSTALLED.
1. INSTALL STARTER. TIGHTEN STARTER MOUNTING
HARDWARE TO CORRECT TORQUE SPECIFICATIONS.
2. STARTER RELAY
FAULTY.
2. REFER TO RELAY TEST, IN THIS SECTION. REPLACE
RELAY, IF NECESSARY.
3. IGNITION SWITCH
FAULTY.
3. REFER TO IGNITION SWITCH TEST, IN THE STEERING
SECTION. REPLACE SWITCH, IF NECESSARY.
4. STARTER ASSEM-
BLY FAULTY.
4. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
5. FAULTY TEETH ON
RING GEAR.
5. ROTATE FLYWHEEL 360°, AND INSPECT TEETH AND
RING GEAR REPLACED IF DAMAGED.
6. STARTER BUTTON
6. INSPECT AND TEST, IF BAD REPLACE STARTER BUT-
TON.
DIAGNOSIS AND TESTING - CONTROL
CIRCUIT TEST
The starter control circuit has:
• Starter motor with integral solenoid
• Starter relay
• Body Control Module (BCM)
• Ignition switch
• Battery
• All related wiring and connections
• Powertrain Control Module (PCM)
• Starter Button
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
• To disable ignition and fuel systems, disconnect
the Automatic Shutdown Relay (ASD). The ASD relay
is located in the Power Distribution Center (PDC).
Refer to the PDC cover for the proper relay location.
STARTER SOLENOID
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN THE PARK POSITION WITH THE
PARKING BRAKE APPLIED.
(1) Verify battery condition. Battery must be in
good condition with a full charge before performing
any starter tests. Refer to Battery Tests.
(2) Perform Starter Solenoid test BEFORE per-
forming the starter relay test.
(3) Perform a visual inspection of the starter/
starter solenoid for corrosion, loose connections or
faulty wiring.
(4) Locate and remove the starter relay from the
Power Distribution Center (PDC). Refer to the PDC
label for relay identification and location.
(5) Connect a remote starter switch or a jumper
wire between the remote battery positive post and
terminal 87 of the starter relay connector.
(a) If engine cranks, starter/starter solenoid is
good. Go to the Starter Relay Test.
(b) If engine does not crank or solenoid chatters,
check wiring and connectors from starter relay to
starter solenoid for loose or corroded connections.
Particularly at starter terminals.
(c) Repeat test. If engine still fails to crank prop-
erly, trouble is within starter or starter mounted
solenoid, and replace starter. Inspect the ring gear
teeth.
STARTER RELAY
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN NEUTRAL POSITION WITH THE
PARKING BRAKE APPLIED.
ZB
STARTING
8F - 21
STARTING (Continued)
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