1993 DODGE TRUCK ignition
[x] Cancel search: ignitionPage 334 of 1502
•
ELECTRICAL
8A - 13 GENERATOR TEST PROCEDURES ON
VEHICLE
INDEX
page
Current
Output
Test
......................
14
Diagnostic Procedures
13
General
Information
13
Generator
Output
Wire Resistance Test
.......
13
page
How
to
Use
Malfunction
Indicator
(Check Engine) Lamp
for
Fault
Codes
17
Operational Check
with
Voltmeter
............
13
Using
On-Board Diagnostic System
15
GENERAL
INFORMATION
The generator
is
belt-driven
by the
engine.
All en
gines
use
serpentine drive. The amount
of DC
current produced
by the
gener
ator
is
controlled
by the
Powertrain Control Module (PCM).
All vehicles
are
equipped with
On
Board Diagnos
tics (OBD).
All OBD
sensing systems
are
monitored
by
the PCM. The PCM
will store
in
electronic mem ory
any
detectable failure within
the
monitored cir
cuits.
Refer
to
USING ON-BOARD DIAGNOSTIC SYSTEM
in
this group
for
more information.
OPERATIONAL CHECK
WITH
VOLTMETER
When
the
ignition switch
is
turned
to the RUN po
sition, battery potential will register
on the
voltme
ter. During engine cranking
a
lower voltage will appear
on the
meter. With
the
engine running,
a
voltage reading higher than
the
first reading (igni
tion
in RUN)
should register.
DIAGNOSTIC PROCEDURES
If
the
indicator does
not
operate properly,
or if an
undercharged
or
overcharged battery condition
oc
curs,
the
following procedures
may be
used
to
diag
nose
the
charging system. Remember that
an
undercharged battery
is
often
caused
by:
• accessories being left
on
overnight
•
or by a
defective switch which allows
a
bulb, such
as a
trunk
or
glove
box
light,
to
stay
on
(refer
to
Ignition
Off
Draw).
WISUAL
INSPECTION
• Inspect condition
of
battery cable terminals, bat
tery posts, connections
at
engine block, starter motor solenoid
and
relay. They should
be
clean
and
tight.
Repair
as
required.
• Inspect
all
fuses
in the
fuse block
for
tightness
in
receptacles. They should
be
properly installed
and
tight. Repair
or
replace
as
required.
• Inspect generator mounting bolts
for
tightness.
Re
place
or
torque bolt
as
required (refer
to
Torque Specifications).
• Inspect generator drive belt condition
and
tension.
Tension
or
replace belt
as
required. Refer
to
Belt
Tension Specifications. • Inspect connection
at
generator
B+
output.
It
should
be
clean
and
tight. Repair
as
required.
GENERATOR
OUTPUT
WIRE RESISTANCE TEST
(FIG.
1)
Generator output wire resistance test will show
amount
of
voltage drop across generator output wire
between generator
BAT
terminal
and
battery posi tive post.
PREPARATION
(1) Before starting test make sure vehicle
has a
fully charged battery. Test
and
procedures
on how to
check
for a
fully charged battery
are
shown
in
Bat
tery section
of
this Group.
(2) Turn
OFF
ignition switch.
(3)
Disconnect negative cable from battery.
(4)
Disconnect generator output wire from genera
tor output Battery terminal. (5) Connect
a 0-150
ampere scale
D.C.
ammeter
in
series between generator
BAT
terminal
and
discon
nected generator output wire. Connect Positive lead
to generator
BAT
terminal
and
Negative lead
to
dis connected generator output wire. (6) Connect Positive lead
of a
test voltmeter
(Range
0-18
volts minimum)
to
disconnected genera
tor output wire. Connect negative lead
of
test voltme
ter
to
battery positive cable
at
positive post. (7) Connect
one end of a
Jumper Wire
to
ground
and with other
end
probe green
K20
lead wire
at
back
of
generator
(Fig. 1).
(This will generate
a
fault
code).
CAUTION:
Do not
connect blue
A142
lead
of
wiring
to ground. Refer
to
Group
8W
-
Wiring Diagrams
for
more information.
(8) Connect
an
engine tachometer
and
connect neg
ative cable
to
battery.
(9) Connect
a
variable carbon pile rheostat
be
tween battery terminals.
Be
sure carbon pile
is in
"Open"
or "Off
position before connecting leads.
See
Battery Section, Load Testing
for
instructions.
TEST
(1) Start engine. Immediately after starting,
re
duce engine speed
to
idle.
Page 335 of 1502
8A
- 14
ELECTRICAL
CASE
GROUND
FIELD
TERMINALS
142-DG/OR
BATTERY
VOLTAGE
ALTERNATOR
CASE
GROUND
GROUND ALTERNATOR
BATTERY
TERMINAL
ENGINE
CONTROLLER TO ENGINE
CONTROLLER TERMINAL
51
LESS
THAN
"BATTERY VOLTAGE
m^mm i
A21 DB-
20
AMP FUSE
A14
RD
AUTO
SHUTDOWN
RELAY
IGNITION
SWITCH
POWER
DISTRIBUTION
CENTER
JUMPER WIRE TO GROUND TEST
AMMETER TEST
VOLTMETER
2
i
DISCONNEaED
ALTERNATOR
OUTPUT
WIRE
ACC
OFF
J938A-17
CARBON
PILE
RHEOSTAT
Fig.
1 Generator Output
Wire
Resistance
Test
(Typical)
(2) Adjust engine speed and carbon pile to main
tain 20 amperes flowing in circuit. Observe voltmeter
reading. Voltmeter reading should not exceed 0.5
volts.
RESULTS
If a higher voltage drop is indicated, inspect, clean
and tighten all connections between generator BAT
terminal and battery Positive post. A voltage drop
test may be performed at each connection to locate
connection with excessive resistance. If resistance
tested satisfactorily, reduce engine speed, turn off carbon pile and turn off ignition switch.
(1) Disconnect negative cable from battery.
(2) Remove test ammeter, voltmeter, carbon pile,
and tachometer. (3) Remove "Jumper Wire".
(4) Connect generator output wire to generator
BAT terminal post. Tighten to 5 to 6 Nnn (45 to 75
in.
lbs.). (5) Connect negative cable to battery.
(6) Use DRB II Scan Tool to erase diagnostic trou
ble code.
CURRENT
OUTPUT
TEST
Current output test determines whether or not gen
erator is capable of delivering its rated current out
put.
PREPARATION
(1) Before starting any tests make sure vehicle has
a fully charged battery. Test and procedures on how
to check for a fully charged battery are shown in
Battery section of this Group,
(2) Disconnect negative cable from battery.
(3) Disconnect generator output wire at the gener
ator battery terminal.
(4) Connect a 0-150 ampere scale D.C. ammeter in
series between generator BAT terminal and discon
nected generator output wire (Fig. 2). Connect posi
tive lead to generator BAT terminal and negative
lead to disconnected generator output wire.
(5) Connect positive lead of a test voltmeter (range
0-18 volts minimum) to generator BAT terminal.
(6) Connect negative lead of test voltmeter to a
good ground.
(7) Connect an engine tachometer and connect neg
ative cable to battery.
(8) Connect a variable carbon pile rheostat be
tween battery terminals. Be sure carbon pile is in Open or Off position before connecting leads. See
Battery section, Load Testing for instructions.
(9) Connect one end of a Jumper Wire to ground
and with other and probe green K20 lead wire at
back of generator (Fig. 2). (This will generate a fault
code).
Page 336 of 1502
•
ELECTRICAL
8A - 15 a
CASE
GROUND
CAPACITOR
ALTERNATOR ~L FIELD
TERMINALS
A
142-DG/OR BATTERY
VOLTAGE K20-DG
—!
GROUND
CASE
GROUND
til
ALTERNATOR BATTERY
TERMINAL ENGINE
CONTROLLER TO ENGINE
CONTROLLER TERMINAL
51
LESS
THAN
BATTERY VOLTAGE A21
DB-
.....
IGNITION SWITCH
20 AMP FUSE
AUTO
AH ^
SHUTDOWN POWER
RELAY
DISTRIBUTION
\
CENTER TEST
AMMETER JUMPER WIRE
TO GROUND
TEST
VOLTMETER
GO
5—n
DISCONNECTED
ALTERNATOR OUTPUT WIRE GROUND
ACC
Bl
OFF
RUN OFF
START*T
|ACC
CARBON
PILE RHEOSTAT
J938A-18
Fig.
2 Generator Current Output Test—Typical
CAUTION:
Do not
connect
blue
A142
lead
of
wiring
to ground.
Refer
to
Group
8W -
Wiring
Diagrams
for
more
information.
TEST
(1) Start engine. Immediately after starting reduce
engine speed to idle. (2) Adjust carbon pile and engine speed in incre
ments until a speed of 1250 rpm and voltmeter read
ing of 15 volts is obtained.
CAUTION:
Do not
allow
voltage
meter
to
read
above
16 volts.
(3) The ammeter reading must be within limits
shown in generator specifications in back of this
group for that size of generator being tested.
RESULTS
(1) If reading is less than specified and generator
output wire resistance is not excessive, the generator
should be replaced. Refer to Group 8B - Generator
Service for information.
(2) After current output test is completed reduce
engine speed, turn off carbon pile and turn off igni
tion switch.
(3) Disconnect negative cable from battery. (4) Remove test ammeter, voltmeter, tachometer
and carbon pile. (5) Remove Jumper Wire (Fig. 2).
(6) Connect generator output wire to generator
BAT terminal post. Tighten nut to 5-6 Nnn (45-75 in.
lbs.).
(7) Connect negative cable to battery.
(8) Use DRB II Scan Tool to erase diagnostic trou
ble code.
USING
ON-BOARD
DIAGNOSTIC
SYSTEM
OPERATION
OF
ON-BOARD
DIAGNOSTIC
SYSTEM
The Powertrain Control Module monitors critical
input and output circuits of the charging system
making sure they are okay. Some are checked contin
uously and some are only checked under certain con
ditions.
If the OBD system senses that one of the critical
circuits is bad, it will consider this a real problem
and put a DTC into memory. Each input and output
circuit monitored by the OBD system has its own
DTC.
The DTC will stay in memory as long as the
circuit continues to be bad. If the problem does not
occur again after the code is put into memory, the
Powertrain Control Module will clear the memory af
ter 50 to 100 engine starts.
Page 337 of 1502
8A
- 16
ELECTRICAL
CHARGING
SYSTEM DIAGNOSTICS
IMPROPER
CHARGING
CHECK
BATTERY CONDITION
SEE
BATTERY
SECTION
FOR
DETAILS
CORRODED
BATTERY CABLES OR TERMINALS
DRIVE BELTS
LOOSE
LOOSE
OR
CORRODED
WIRING
CONNECTIONS
AT
GENERATOR
LOOSE
OR
CORRODED
WIRING
CONNECTIONS
AT
TERMINAL BLOCK
LOOSE
CHASSIS
TO
BATTERY GROUND
CABLE
LOOSE
GENERATOR
GROUND WIRE
LOOSE
OR
CORRODED
WIRING
CONNECTIONS
AT
BULKHEAD
DISCONNECT
CHECK
FOR
APPROXIMATELY
12 VOLTS
AT
FIELD
INPUT
BRUSH
TERMINAL
WIHT
IGNITION
SWITCH
"ON"
UNS'
OR
CHAF rEADY
LOW
K3ING
TEST
GENERATOR
OUTPUT
WIRE
RESISTANCE
CHARGING
RESISTANCE
TOO
HIGH
CORRODED
OR
SHORTED CABLES OR
HIGH
RESISTANCE
ACROSS
FUSIBLE LINK
RESISTANCE
O.K.
TEST
GENERATOR CURRENT
OUTPUT
CURRENT
OUTPUT
O.K.
REFER
TO
USING ON-BOARD DIAGNOSTIC SYSTEM
o
CHAR
/ER
.GING
GROUNDED
GENERATOR FIELD WIRE, FIELD
TERMINAL,
OR
CONNECTIONS
1 NO
1
ALTERf
ISY
MATOR
WORN
OR
FRAYED
DRIVE BELT
REFER
TO
USING ON-BOARD DIAGNOSTIC SYSTEM GENERATOR
MOUNTING
LOOSE
FAULTY
GENERATOR
FAULTY
GENERATOR •FOR MORE INFORMATION REFER
TO
THE POWERTRAIN DIAGNOSTIC PROCEDURES
MANUAL COVERING
THE
VEHICLE INVOLVED
*SEE
GROUP
8W,
WIRING DIAGRAMS
FOR
CIRCUIT
AND
COMPONENT INFORMATION
FAULTY
GENERATOR
J938A-V0
Page 338 of 1502
•
ELECTRICAL
8A - 17
DIAGNOSTIC
TROUBLE
CODES
Diagnostic trouble codes are 2 digit numbers
flashed on Malfunction Indicator lamp (Check En
gine) that identify which circuit is bad. In most cases
they do not identify which component in a circuit is
bad. A DTC description can be read using the DRB II scan tool. Refer to Group 14 - Fuel Systems for more
information. Therefore, a DTC is only a result, not
necessarily the reason for the problem. However, in
some cases, as a result of the design of the driveabil- ity test procedure, a DTC can be the reason for the
problem. It is important that the test procedure be followed in order to understand what the DTC of the
on-board diagnostic system are trying to tell.
HOW
TO
USE
MALFUNCTION
INDICATOR
(CHECK
ENGINE)
LAMP
FOR
FAULT
CODES
To activate this function cycle the ignition switch
on-off-on-off-on within 5 seconds and any DTC stored
in the Powertrain Control Module will be displayed.
The Check Engine lamp will display a DTC by flash ing on and off. There is a short pause between
flashes and a longer pause between digits. All codes
displayed are two digit numbers with a four second
pause between codes. An example of a code is as follows:
(1) Lamp on for 2 seconds, then turns off.
(2) Lamp flashes 4 times pauses and then flashes
1.
(3) Lamp pauses for 4 seconds, flashes 4 times,
pauses and then flashes 7 times.
The two codes are 41 and 47. Any number of codes
can be displayed (maximum of 8 faults can be stored) as long as they are in memory. The lamp will flash
until all of them (including 55) are displayed (55 =
End of test).
CHARGING
SYSTEM
FAULT
CODES
See Generator Fault Code Chart for fault codes
which apply to the charging system. Refer to the
Powertrain Diagnostic Procedures Manual to diag
nose an On-Board Diagnostic System, Fault Code.
GENERATOR
DIAGNOSTIC
TROUBLE
CODE
(DTC)
DTC
Type
Malfunction
Indicator
Lamp
Circuit
When
Monitored
By
the
Logic
Module
When
Put Into
Memory
Actuator
Test
Sensor
Read
Test
41 Fault
Yes
Generator Field
Control
(Charging
System)
All the
time
when
the ignition switch
is
on.
An
open or shorted condition in
the generator
field
control circuit.
Yes
None
46 Fault
Yes
Charging
System
Voltage
All the
time
when the
engine
is
running.
If the
battery
sense
voltage is
more than 1 volt
above
the
desired
control voltage for
more than 20
seconds.
None
Yes
47 Fault
Yes
Charging
System
Voltage
Engine
rpm
above
1,500 rpm Battery voltage
1
volt
less
than set point during engine
operation and no
change
in
voltage
during
internal
PCM
test performed on generator field.
None
Yes
J938A-20
Page 342 of 1502
• BATTERY/STARTER/GENERATOR
SERVICE
8B - 1
CONTENTS
page page
BATTERY
SERVICE
PROCEDURES
1 SPECIFICATIONS 9
GENERATOR
SERVICE
6 STARTER
SERVICE
PROCEDURES
4
BATTERY SERVICE PROCEDURES
GENERAL
INFORMATION This section will cover the Battery service, re
moval, and installation procedures only. For diagnos
tic procedures, see Group 8A - Battery/Starting/ Charging Systems Diagnostics. The Maintenance Free Battery (Fig. 1) does not
have removable battery cell caps. Water can not be added to this battery. The battery is sealed, except
for small vent holes in the top. The chemical compo sition inside of the battery produces an extremely
small amount of gases at normal charging voltages.
The battery is equipped with a test indicator (Fig. 1)
that display colored balls to indicate battery
state-of-
charge. Green Indicator = Full charge
Black Indicator = Discharged
Yellow Indicator = Battery replacement required Fig. 1 Maintenance Free Battery
BATTERY
VISUAL INSPECTION AND
SERVICE
(1) Make sure ignition switch is on OFF position
and all battery feed accessories are OFF. (2) Disconnect and remove battery cables at bat
tery. Remove NEGATIVE cable first.
WARNING: WEAR
A
SUITABLE PAIR
OF
RUBBER
GLOVES
(NOT THE
HOUSEHOLD TYPE) WHEN
RE
MOVING
A
BATTERY
BY
HAND. SAFETY
GLASSES
SHOULD ALSO
BE
WORN.
IF THE
BATTERY
IS
CRACKED
OR
LEAKING
THE
ELECTROLYTE
CAN
BURN
THE
SKIN
AND
EYES.
(3) Remove battery hold down (Fig. 2) and remove
battery from vehicle. Fig. 2 Battery
Holddown
BATTERY/STARTER/GENERATOR
SERVICE
Page 345 of 1502
8B
- 4
BATTERY/STARTER/GENERATOR SERVICE
•
STARTER SERVICE PROCEDURES
GENERAL INFORMATION
This section will cover the Starter removal and in
stallation. For diagnostic procedures, see Group 8A -
Battery/Starting/Charging Systems Diagnostics.
STARTING
SYSTEM DESCRIPTION
The starter system circuits consist of:
• a battery
• engine starter motor and solenoid
• starter relay
• ignition switch
© park/neutral position switch (automatic transmis sion)
• clutch interlock switch (manual transmission-die-
sel)
• connecting wires and battery cables. Turning the ignition switch to the start position,
causes the starter relay points to close allowing cur
rent to energize solenoid windings. This causes sole
noid plunger and clutch shift lever to move engaging
clutch pinion gear into ring gear. At the same time
the solenoid contacts close causing starter motor to
crank. As soon as engine starts running clutch pin ion gear overruns to protect starter armature from
damage due to excessive speed. Once the engine starts running, the ignition key switch should be im
mediately returned to the run position to prevent ex
cessive starter motor damage.
WARNING:
ALWAYS DISCONNECT NEGATIVE
CA
BLE FROM
BATTERY
BEFORE SERVICING
THE
STARTER.
STARTER
MOTOR REMOVAL AND INSTALLATION EXCEPT DIESEL
(1) Disconnect negative cable from battery.
(2) Remove wire terminal connector from starter
motor (Fig. 1). (3) Remove mounting bolt and nut securing starter
to bellhousing (Fig. 2).
(.4) Move starter forward to clear lower mounting
stud and starter gear housing nose. This allows
starter to come down past the exhaust pipe (Fig. 3). To install, reverse removal procedures.
Fig.
2
Remove
or Install
Starter
Mounting
Bolt
and
Nut
Page 352 of 1502
•
IGNITION
SYSTEMS
8D
- 1
CONTENTS
page page
COMPONENT IDENTIFICATION/SYSTEM DIAGNOSTICS/SERVICE PROCEDURES
7
OPERATION
1
IGNITION SWITCH
25
COMPONENT REMOVAL/INSTALLATION
..... 18
SPECIFICATIONS
28
COMPONENT
IDENTIFICATION/SYSTEM OPERATION
INDEX
page
Automatic
Shut Down (ASD) Relay
1
Camshaft Position Sensor
2
Crankshaft Position Sensor
2
Distributors
3
Engine Coolant
Temperature
Sensor
...........
4
General
Information
1
page
Ignition
Coil
3
Intake
Manifold Charge
Air
Temperature
Sensor
. . 4
Manifold Absolute Pressure (MAP) Sensor
4
Powertrain
Control
Module (PCM)
. 5
Throttle
Position Sensor
5
GENERAL
INFORMATION
Throughout this group, references
are
made
to
par
ticular vehicle models
by
alphabetical designation
or
by
the
particular vehicle nameplate.
A
chart showing a breakdown
of
alphabetical designations
is
included
in
the
Introduction group
at the
beginning
of
this
manual. 5.9L
gas
powered engines will
be
referred
to as ei
ther: LDC (Light Duty Cycle),
or
HDC (Heavy Duty Cycle). This section
of the
group, Component Identifica
tion/System Operation, will discuss ignition system operation
and
will identify ignition system compo
nents.
For diagnostic procedures
and
adjustments, refer
to
the Diagnostics/Service Procedures section
of
this
group.
For removal
and
installation
of
ignition system
components, refer
to the
Component Removal/Instal
lation section
of
this group. For other useful information, refer
to
On-Board
Di
agnostics
in the
General Diagnosis sections
of
Group
14,
Fuel System
in
this manual. For operation
of the DRB II
Diagnostic Scan Tool,
refer
to the
appropriate Powertrain Diagnostic Proce
dures service manual.
An Ignition specifications section
is
included
at the
end
of
this group.
A
general Maintenance Schedule (mileage intervals)
for
ignition related items
can be
found
in
Group
0,
Lubrication and Maintenance. This
schedule
can
also
be
found
in the
Owners Manual.
IGNITION
SYSTEMS
The ignition systems used
on all
engines
are
basi
cally identical. Similarities
and
differences between
the systems will
be
discussed.
A sequential multi-port fuel injection system
is
used
on all gas
powered engines.
The ignition system
is
controlled
by the
powertrain
control module (PCM)
on all
engines.
The
PCM
was
formerly referred
to as the
SBEC
or
engine control ler.
The ignition system consists
of:
• Spark Plugs
• Ignition Coil
• Secondary Ignition Cables
• Ignition distributor. Contains rotor
and
camshaft
position sensor • Powertrain Control Module (PCM)
• Crankshaft Position Sensor
AUTOMATIC SHUT DOWN (ASD) RELAY
The automatic shut down (ASD) relay
is
located
in
the engine compartment (Fig.
1). As one of its
func
tions,
the ASD
relay will supply battery voltage
to
the ignition coil.
The
ground circuit
for the
ASD
re
lay
is
controlled
by the
powertrain control module (PCM).
The PCM
regulates
ASD
relay operation
by
switching
the
ground circuit on-and-off.
IGNITION
SYSTEMS