1993 DODGE TRUCK Service Repair Manual

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

•

Fig.
3
Remove
or Install
Starter
Motor
STARTER
MOTOR REMOVAL AND INSTALLATION

DIESEL
(1) Disconnect negative cable from battery.
(2) Remove battery cable by pulling rubber boot up
and removing nut (Fig. 1). (3) Remove solenoid wire from solenoid.
(4) Remove starter motor mounting bolts (Figs. 1
and 2).

INSTALLATION
(1) Install starter motor. Tighten bolts to 68 N»m
(50 ft. lbs.). (2) Attach solenoid wire. Tighten solenoid nut to 6
N»m (55 in. lbs.). (3) Attach battery cable to starter motor. Tighten
cable nut to 10 N*m (90 in. lbs.). (4) Connect negative cable to battery.
BATTERY/STARTER/GENERATOR SERVICE
8B - 5

Fig.
2
Remove
Or Install
Starter
Motor
Mounting
Bolt

8B
- 6
BATTERY/STARTER/GENERATOR
SERVICE

•
GENERATOR SERVICE
CONTENTS
page

GENERATOR
REPLACEMENT-
DIESEL
ENGINE
8

GENERAL
INFORMATION
6

GENERAL
INFORMATION This section will cover generator removal
and in­

stallation.
The
generator
is not
serviceable. Informa­
tion covering on-vehicle testing
can be
found
in
Group
8A -
Battery/Starting/Charging/System Diag­
nostics. The standard equipment generator
on the D and W

bodies
is the 75 amp
generator.
The
Ramcharger
is
equipped with
the 90 amp
generator. When
a
vehicle
is equipped with
a
heavy duty package
or
diesel
en­

gine,
a 120 amp
generator
is
used.

GENERATOR
REPLACEMENT
-3.9L/5.2L/5.9L-LDC

GAS
ENGINE
Drive belts
on
these engines
are
equipped with
a

spring loaded automatic belt tensioner
(Fig. 1).
This
belt tensioner
is
used
on all
belt configurations.
For
more information, refer
to
Group
7 -
Cooling, Belt
Removal/Installation.

REMOVAL
(1) Disconnect negative cable from battery.
(2) Attach
a
socket/wrench
to
pulley mounting bolt
of automatic tensioner
(Fig. 1).

(3) Rotate tensioner assembly clockwise
(as
viewed
from front) until tension
has
been relieved from belt. (4) Remove belt from idler pulley first.
(5) Remove belt from vehicle.

(6)
Remove lower generator mounting bolt
and nut

(Fig.
2).

(7) Remove upper generator mounting bolt
and re­

move generator.
(8) Remove
B+
terminal
nut, 2
field terminal

nuts,
ground,
and
harness hold down nuts
(Fig. 3).

Remove wire connectors.

INSTALLATION
(1) Install harness
to
generator. Tighten nuts
as

follows:
• Ground terminal,
B+
terminal
and
Wire Harness Hold Down
7-10 N*m
(60-90
in.
lbs.).
• Field terminals
2.5-3 N-m
(20-30
in.
lbs.). (2) Install generator. Tighten both bolts
to 41 N»m

(30
ft.
lbs.).
page

GENERATOR
REPLACEMENT—3.9L/5.2L/
5.9L-LDC
GAS
ENGINE
6

GENERATOR
REPLACEMENT—5.9L
HDC-GAS
ENGINE
7
Fig.
1 Automatic Belt Tensioner—Belt
Removal/

Installation

Fig.
2
Generator
Mounting
Bolts

•

Fig.
3
Remove
or install
Wire
Connector
Assembly
CAUTION:
When
installing
serpentine
accessory

drive
belt,
the
belt
MUST
be
routed
correctly.
If not,
the engine may overheat due to the
water
pump ro­

tating
in the wrong
direction.
Refer to Group 7 -
Cooling
System
for
correct
engine
belt
routing.
The

correct
belt
with
the
correct
length
must be
used

(3) Position drive belt over all pulleys except the
idler pulley. This pulley is located between the gen­
erator and A/C compressor.
(4) Attach a socket/wrench to pulley mounting bolt
of the automatic tensioner (Fig. 1).

(5)
Rotate socket/wrench clockwise. Place belt over
idler pulley. Let tensioner rotate back into place. Re­
move wrench. Be sure belt is properly seated on all
pulleys.
(6) Check belt indexing marks. Refer to Group 7 -
Cooling, Automatic Belt Tensioner.
(7) Connect negative cable to battery.

GENERATOR
REPLACEMENT—5.9L
HDC-GAS

ENGINE
Drive belts on these engines are equipped with a
spring loaded automatic belt tensioner (Fig. 4). This
belt tensioner is used on all belt configurations. For more information, refer to Group 7 - Cooling, Belt
Removal/Installation.

REMOVAL
(1) Disconnect negative cable from battery.
(2) Attach a socket/wrench to pulley mounting bolt
of automatic tensioner (Fig. 4). The threads on this
bolt are left hand.
BATTERY/STARTER/GENERATOR
SERVICE
8B - 7

Fig.
4 Automatic Belt Tensioner—5.9L
HDC-Gas
Engine
(3) Rotate tensioner assembly counterclockwise (as
viewed from front) until tension has been relieved
from belt.
(4) Remove belt from idler pulley first.
(5) Remove belt from vehicle.
(6) Remove lower generator mounting bolt and nut
(Fig. 5).

Fig.
5 Generator
Mounting
Bolts

(7) Remove upper generator mounting bolt and re­
move generator.
(8) Remove B+ terminal nut, 2 field terminal

nuts,
ground, and harness hold down nuts (Fig. 6).
Remove wire connectors.

8B
- 8
BATTERY/STARTER/GENERATOR
SERVICE

•

Fig.
6
Remove
or Install
Wire
Connector
Assembly
INSTALLATION

(1) Install harness to generator. Tighten nuts as
follows:
• Ground terminal, B+ terminal and Wire Harness
Hold Down 7-10 Nun (60-90 in. lbs.).
• Field terminals 2.5-3 Nun (20-30 in. lbs.).
(2) Install generator. Tighten both bolts to 41 Nun
(30 ft. lbs.).

CAUTION:
When
installing
the
serpentine
accessory

drive
belt,
the
belt
MUST
be
routed
correctly.
If not,

the
engine
may
overheat
due to the
water
pump
ro­

tating
in the
wrong
direction.
Refer
to
Group
7 -
Cooling
System
for
correct
engine
belt
routing.
The

correct
belt
with
the
correct
length
must
be
used

(3) Position drive belt over all pulleys except wa­
ter pump pulley.
(4) Attach a 3/8 inch rachet to tensioner.
(5) Rotate ratchet and belt tensioner counterclock­

wise.
Place belt over water pump pulley. Let ten­ sioner rotate back into place. Remove ratchet. Be
sure belt is properly seated on all pulleys.
(6) Connect negative cable to battery.
GENERATOR
REPLACEMENT—DIESEL
ENGINE

(1) Remove negative cable from battery.
(2) Remove generator drive belt. See Group 7 -
Cooling System, for instructions. (3) Remove B+ terminal nut, 2 field terminal

nuts,
ground, and harness hold down nuts (Fig. 6).
Remove wire connectors. (4) Remove upper mounting bolt and nut (Fig. 7). (5) Remove lower mounting bolt.
(6) Remove generator from the vehicle.
(7) To install generator, first tighten lower mount­
ing bolt to 43 Nun (32 ft. lbs.). Tighten upper bolt to
24 Nun (18 ft. lbs.).
Fig.
7
Remove
or Install Generator
Mounting
Bolts

•
BATTERY/STARTER/GENERATOR
SERVICE
8B - 9

Load

Test

(Amps)
cold

Cranking
Rating
@ 0°F
Reserve
Capacity
300 Amp 600 Amp 120 Minutes
405 Amp 810 Amp 133 Minutes
535 Amp 1075 Amp
170 Minutes

CRANKING
RATING
is the
current
a
battery
can
deliver
for 30
seconds
anej
maintain
a
terminal
voltage
of 7.2
volts
or
greater
at
specified
temperature.

RESERVE
CAPACITY RATING
is the
length
of
time
a
battery
can
deliver
25
amps and maintain
a
minimum
terminal
voltage
of
10.5 volts
at
27 °C (80
°F).

J938A-25

GAS ENGINE DIESEL ENGINE

Manufacturer
Nippondenso

Engine
Application 5.9L, 5.2L
&
3.9L
Part Number and
53005984

Power Rating
1.4
Kw
Voltage
12

No.
of
Fields 4

No.
of
Poles. 4

Brushes
4
Drive Reduction
Gear
Train

Free
Running Test Voltage 11
Amperage Draw 73 Amps
Minimum Speed
rpm
3601
rpm

Solenoid
Closing Voltage 7.5 Volts
Cranking Amperage Draw Test
. . .
125-200
Amps*

*
Engine
should be up to operating
temperature.
Extremely heavy oil
or
tight engine
will
increase
starter
amperage draw.
J938B-14
REDUCTION
GEAR
STARTER

Manufacturer
Nippondenso

Engine
Application 5.9L
Part Number
and
Power Rating
4428221

3
kw

Voltage
12

No.
of
Fields
4

No.
of
Poles 4

Brushes
4
Drive Conventional
Gear Train

Free
Running Test Voltage
Amperage Draw
Minimum Speed
rpm
11
220 Amps Max.
4200
rpm Min.

Solenoid
Closing Voltage 8 Volts
Cranking Amperage Draw Test
. .
450-550
Amps*

*
Engine
should
be up to
operating
temperature.
Extremely heavy oil or tight engine
will
increase
starter
amperage draw.
J918B-21

GENERATOR SPECIFICATIONS
TYPE

PHUT
HUMSIR
PULLEY
GROOVES

ENGINE
RATING

NIPPONDENSO
53008646
7
ALL GASOLINE 75 AMPS

NIPPONDENSO
53008647
7
ALL GASOLINE 90 AMPS

NIPPONDENSO
53008651
7
ALL GASOLINE
120
AMPS

NIPPONDENSO
5234374
8
DIESEL
120 AMPS
J938B-28
SPECIFICATIONS

BATTERY SPECIFICATIONS

•

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