1996 CHRYSLER VOYAGER charging

OVERCHARGE TEST
8C - 6 CHARGING SYSTEMNS
DIAGNOSIS AND TESTING (Continued)

TEST
(1) Perform the previous test Preparation.
(2) Fully engage the parking brake.
(3) Start engine.
(4) Bring engine speed to 2500 rpm.
(5) With engine speed held at 2500 rpm, slowly
adjust the rheostat control (load) on the tester to
obtain the highest amperage reading. Do not allow
voltage to drop below 12 volts. Record the reading.
This load test must be performed within 15 sec-
onds to prevent damage to test equipment.On
certain brands of test equipment, this load will be
applied automatically. Refer to the operating manual
supplied with test equipment.
(6) The ammeter reading must meet the Minimum
Test Amps specifications as displayed in the Genera-tor Ratings chart. This can be found in the Specifica-
tions section at the end of this group. A label stating
a part reference number is attached to the generator
case. On some engines this label may be located on
the bottom of the case. Compare this reference num-
ber to the Generator Ratings chart.
(7) Rotate the load control to the OFF position.
(8) Continue holding engine speed at 2500. If EVR
circuitry is OK, amperage should drop below 15±20
amps. With all electrical accessories and vehicle
lighting off, this could take several minutes of engine
operation. If amperage did not drop, refer to the
appropriate Powertrain Diagnostic Procedures man-
ual for testing.
(9) Remove volt/amp tester.
If minimum amperage could not be met, refer to
the appropriate Powertrain Diagnostic Procedures
manual for testing.
ON-BOARD DIAGNOSTIC SYSTEM TEST
GENERAL INFORMATION
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 OBD system. Some
circuits are checked continuously and some are
checked only under certain conditions.
If the OBD system senses that a monitored circuit
is bad, it will put a DTC into electronic memory. The
DTC will stay in electronic memory as long as the
circuit continues to be bad. The PCM is programmed
to clear the memory after 50 engine starts if the
problem does not occur again.
DIAGNOSTIC TROUBLE CODES
Refer to Group 25, On Board Diagnostic for more
information. A DTC description can be read using the
DRB scan tool. Refer to the appropriate Powertrain
Diagnostic Procedures manual for information.
A DTC does not identify which component in a cir-
cuit is bad. Thus, a DTC should be treated as a
symptom, not as the cause for the problem. In some
cases, because of the design of the diagnostic test
procedure, a DTC can be the reason for another DTC
to be set. Therefore, it is important that the test pro-
cedures be followed in sequence, to understand what
caused a DTC to be set.
ERASING DIAGNOSTIC TROUBLE CODES
The DRB Scan Tool must be used to erase a DTC.
Fig. 1 Generator Terminals
Fig. 2 Battery Voltage TestÐTypical
NSCHARGING SYSTEM 8C - 7
DIAGNOSIS AND TESTING (Continued)

VOLTAGE DROP TEST
8C - 8 CHARGING SYSTEMNS

REMOVAL AND INSTALLATION
GENERATORÐ2.4L ENGINE
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect battery negative cable (Fig. 3).
(3) Remove accessory drive belt, refer to Group 7,
Cooling System for proper procedures.
(4) Disconnect the push-in field wire connector
from back of generator (Fig. 4).
(5) Remove nut holding B+ wire to terminal on
back of generator.
(6) Separate B+ wire from generator terminal.
(7) Remove nut holding top of generator to adjust-
able T-bolt (Fig. 5).
(8) Remove bolt holding bottom generator pivot to
lower mount.
(9) Remove generator.
INSTALLATION
(1) Place generator in position on vehicle.
(2) Install bolt to hold bottom generator pivot to
lower mount.(3) Install nut to hold top of generator to adjust-
able T-bolt.
(4) Place B+ wire in position on generator termi-
nal.
(5) Install nut to hold B+ wire to terminal on back
of generator.
(6) Connect the push-in field wire connector onto
back of generator.
(7) Install accessory drive belt, refer to Group 7,
Cooling System for proper procedures.
(8) Connect battery negative cable.
(9) Verify generator charge rate.
GENERATORÐ3.0L ENGINE
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect battery negative cable (Fig. 3).
(3) Remove windshield wiper housing, refer to
Group 8K, Windshield Wipers and Washers for
proper procedures.
(4) Remove accessory drive belt, refer to Group 7,
Cooling System for proper procedures.
(5) Remove bolt holding top of generator to mount
bracket (Fig. 6).
(6) Remove bolt holding bottom of generator to
lower pivot bracket (Fig. 4).
(7) Disengage push-in field wire connector from
back of generator.
(8) Remove nut holding B+ wire terminal to back
of generator.
(9) Remove B+ terminal from generator.
INSTALLATION
(1) Place B+ terminal in position on generator.
(2) Install nut to hold B+ wire terminal to back of
generator
(3) Connect the push-in field wire connector into
back of generator.
Fig. 3 Removal/Installation of Battery Cables
Fig. 4 Wire Connectors
Fig. 5 Generator±2.4L Engine
NSCHARGING SYSTEM 8C - 9

(4) Install bolt to hold bottom of generator to lower
pivot bracket.
(5) Install bolt to hold top of generator to mount
bracket.
(6) Install accessory drive belt, refer to Group 7,
Cooling System for proper procedures.
(7) Install windshield wiper housing, refer to
Group 8K, Windshield Wipers and Washers for
proper procedures.
(8) Connect battery negative cable.
(9) Verify generator charge rate.
GENERATORÐ3.3/3.8 L ENGINE
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect battery negative cable (Fig. 3).
(3) Remove windshield wiper housing, refer to
Group 8K, Windshield Wipers and Washers for
proper procedures.
(4) Remove accessory drive belt, refer to Group 7,
Cooling System for proper procedures.
(5) Remove bolt holding top of generator mount
bracket to engine air intake plenum (Fig. 7).
(6) Remove bolts holding outside of generator
mount bracket to generator mount plate.
(7) Remove bolt holding top of generator to mount
bracket.
(8) Remove generator mount bracket from vehicle.
(9) Rotate generator toward rear dash panel.
(10) Disconnect the push-in field wire connector
from back of generator (Fig. 6).
(11) Remove nut holding B+ wire terminal to back
of generator.
(12) Separate B+ terminal from generator.
(13) Remove bolt holding bottom of generator to
lower pivot bracket (Fig. 8).
(14) Remove generator from vehicle (Fig. 9).
INSTALLATION
(1) Place generator in position on vehicle.
Fig. 6 Generator±3.0L EngineFig. 7 Generator Mounting Bracket
Fig. 8 Generator pivot Bolt
Fig. 9 Generator±3.3/3.8 L Engine
8C - 10 CHARGING SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

(2) Install bolt to hold bottom of generator to lower
pivot bracket.
(3) Place B+ terminal in position on generator.
(4) Install nut to hold B+ wire terminal to back of
generator.
(5) Connect the push-in field wire connector into
back of generator.
(6) Rotate generator forward away from dash
panel.
(7) Place generator mount bracket in position on
vehicle.
(8) Install bolt to hold top of generator to mount
bracket.
(9) Install bolts to hold outside of generator mount
bracket to generator mount plate.
(10) Install bolt to hold top of generator mount
bracket to engine air intake plenum.
(11) Install accessory drive belt, refer to Group 7,
Cooling System for proper procedures.
(12) Install windshield wiper housing, refer to
Group 8K, Windshield Wipers and Washers for
proper procedures.
(13) Connect battery negative cable.
(14) Verify generator charge rate.SPECIFICATIONS
GENERATOR
Part number is located on the side of the generator.
TORQUE
DESCRIPTION TORQUE
Battery Hold Down Bolt.......14N´m(125 in. lbs.)
Generator Mounting Bolts......54N´m(40ft.lbs.)
Generator B+ Terminal.........9N´m(75in.lbs.)
Starter Mounting Bolts.........54N´m(40ft.lbs.)
Starter Solenoid Battery Nut. . . .10 N´m (90 in. lbs.)
TypePart Num-
berAmperage out-
put
Nippondenso 90 A
HS4727220 86 Amp
Nippondenso 120 A
HS4727221 98 Amp
NSCHARGING SYSTEM 8C - 11
REMOVAL AND INSTALLATION (Continued)

Refer to Group 25, for further information and use-
age of the DRB scan tool and a more complete list of
Diagnostic Trouble Code.
SPEED CONTROL SLOWS DOWN BY ITSELF
Test vehicle speed sensor, refer to group 8E. If sen-
sor fails replace sensor, if it passes perform the fol-
lowing test:
(1) Perform the speed control switch test on the
DECEL switch, if it fails replace switch.
(2) If the switch passes, conduct the vacuum sup-
ply test.
(3) If it passes, conduct the servo vacuum test. If it
fails replace servo.
(4) If continuity, replace the PCM.
SPEED CONTROL ELECTRICAL TEST
Electronic speed control systems may be tested
using two different methods. One involves use of a
DRB. If this test method is desired, refer to the Pow-
ertrain Diagnostic Test Procedures for charging and
speed control system manual.The other test method uses a volt/ohm meter. The
volt/ohm meter method is described in the following
tests.
If any information is needed concerning wiring,
refer to Group 8W, Wiring Diagrams (Fig. 2).
CAUTION: When test probing for voltage or conti-
nuity at electrical connectors, care must be taken
not to damage connector, terminals, or seals. If
these components are damaged, intermittent or
complete system failure may occur.
When electrical connections are removed, corrosion
should be removed from electrical terminals and a
light coating of Mopar Multi-Purpose Grease, or
equivalent, applied. Inspect connectors for damage
terminals.
A poor connection can cause a complete or inter-
mittent malfunction and is also the only connection
in the circuit, that can not be tested. For this reason,
a loose connection may be misdiagnosed as a compo-
nent malfunction.
SPEED CONTROL DIAGNOSTIC TROUBLE CODES
Hex Code DRB Scan Tool Display Description of Diagnostic Trouble
Code
23 No Vehicle Speed Sensor Signal No vehicle distance (speed) sensor
signal detected during road load
conditions.
OF Speed Control Solenoid Circuits An open or shorted condition
detected in the Speed Control
vacuum or vent solenoid circuits.
56 MUX S/C Switch High Speed Control switch input above
the maximum acceptable voltage.
57 MUX S/C Switch Low Speed Control switch input below
the minimum acceptable voltage.
52 S/C Power Relay Or 12V Driver
CircuitMalfunction detected with power
feed to speed control servo solnoids.
Check Engine Lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
8H - 4 VEHICLE SPEED CONTROL SYSTEMNS
DIAGNOSIS AND TESTING (Continued)

ning light functions (for Canadian vehicles), and has
been designed with internal relays to take advantage
of low current switching requirements in the vehicle.
It is plugged into the junction block at positions
three and four (Fig. 1), where all wiring associated
with its operation is terminated. The junction block
is adjacent to and left of the steering column of the
vehicle. For diagnostic information refer to Group 8J,
Turn Signal and Flashers.
On vehicles built for use in the United States, only
position four is used. Vehicles built for use in Canada
utilize both positions three and four.
To gain access to the device, remove the lower
steering column cover and knee blocker. Refer to
Group 8E, Instrument Panel and Gauges.SYSTEM FUNCTION
The combination-flasher/DRL may be operated in
its hazard warning mode either with or without the
ignition circuit being active. However, in order to
operate in the turn signal mode or the DRL mode,
the ignition circuit must be completed to the module.
While the combination-flasher portion is idle, there
is no current drawn through the module. The device
does not become active in the turn signal or hazard
warning modes until a signal ground circuit is sup-
plied to either of the turn signal inputs or the hazard
warning input. With the ignition OFF, there is no
current drawn through the module.
While the ignition is ON, the front turn signal fil-
aments are illuminated steadily thus providing the
DRL function. The DRL function may be inhibited by
applying a signal ground input from either the park
brake circuit or the headlamp relay activation circuit.
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
When a vehicle experiences problems with the
headlamp system, verify the condition of the battery
connections, charging system, headlamp bulbs, wire
connectors, relay, high beam dimmer switch and
headlamp switch. Refer to Group 8W, Wiring Dia-
grams, for component locations and circuit informa-
tion.
Fig. 1 Junction Block Terminal PINS
8L - 2 LAMPSNS
GENERAL INFORMATION (Continued)