The document describes the components and operation of a vehicle's charging system, which includes the generator, electronic voltage regulator, battery, and other parts. It provides details on how the generator is controlled to regulate voltage and discusses diagnostic procedures if issues arise, such as an illuminated check gauge light or improper voltage readings. Specifications for the generator, torque values, and removal/installation procedures are also included.
The document describes the components and operation of a vehicle's charging system, which includes the generator, electronic voltage regulator, battery, and other parts. It provides details on how the generator is controlled to regulate voltage and discusses diagnostic procedures if issues arise, such as an illuminated check gauge light or improper voltage readings. Specifications for the generator, torque values, and removal/installation procedures are also included.
The document describes the components and operation of a vehicle's charging system, which includes the generator, electronic voltage regulator, battery, and other parts. It provides details on how the generator is controlled to regulate voltage and discusses diagnostic procedures if issues arise, such as an illuminated check gauge light or improper voltage readings. Specifications for the generator, torque values, and removal/installation procedures are also included.
The document describes the components and operation of a vehicle's charging system, which includes the generator, electronic voltage regulator, battery, and other parts. It provides details on how the generator is controlled to regulate voltage and discusses diagnostic procedures if issues arise, such as an illuminated check gauge light or improper voltage readings. Specifications for the generator, torque values, and removal/installation procedures are also included.
Generator Electronic Voltage Regulator (EVR) circuitry within the Powertrain Control Module (PCM). Ignition switch Battery. For information, refer to BATTERY . Battery temperature sensor Check Gauges Lamp (if equipped) Voltmeter. For information, refer to appropriate Electrical Diagnostic article. Wiring harness and connections. For information, refer to appropriate wiring information.
OPERATION OPERATION
Fig. 1: Identifying Charging System Components
Courtesy of CHRYSLER GROUP, LLC
1 - PCM 2 - TIPM 3 - Battery 4 - Generator 5 - Feed Back Circuit B+ 6 - Control Circuit 7 - Battery Sense
The charging system is turned on and off with the Powertrain Control Module (PCM) and ignition switch with engine running. The field circuit will not be energized until engine is running and ignition switch on. This voltage is connected through the PCM and supplied to one of the generator field terminals (Gen. Source B+) at the back of the generator. The generator is internally grounded. The generator regulates the field using pin-1 of the field connector (high side driver).
The generator is driven by the engine through a serpentine belt and pulley, or a decoupler pulley arrangement.
The PCM receives a voltage input from the generator (5) and also a battery voltage input (7) from the Totally Integrated Power Module (TIPM), it then compares the voltages to the desired voltage programed in the Electronic Voltage Regulator (EVR) software, and, if there is a difference it sends a signal to the generator EVR circuit to increase or decrease output. It uses a Pulse Width Modulation (PWM) to send signals to the generator circuitry to control the amount of output from the generator. The amount of DC current produced by the generator is controlled by the EVR circuitry contained within the generator.
All vehicles are equipped with On-Board Diagnostics (OBD). All OBD-sensed systems, including EVR circuitry, are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for certain failures it detects.
The Check Gauges Lamp (if equipped) monitors: charging system voltage, engine coolant temperature and engine oil pressure. If an extreme condition is indicated, the lamp will be illuminated. This is done as reminder to check the three gauges. The lamp is located on the instrument panel.
Voltage is monitored at the B+ terminal stud to insure it is connected. If the B+ cable is loose, the PCM will shut down generator field. Because of this new feature, pin-2 of the field connector is internally connected to the B+ terminal.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - CHARGING SYSTEM
The following procedures may be used to diagnose the charging system if:
the check gauges lamp (if equipped) is illuminated with the engine running the voltmeter (if equipped) does not register properly an undercharged or overcharged battery condition occurs.
Remember that an undercharged battery is often caused by:
accessories being left on with the engine not running
a faulty or improperly adjusted switch that allows a lamp to stay on for Ignition-Off Draw Test. Refer to IGNITION-OFF DRAW TEST .
INSPECTION
The PCM (Powertrain Control Module) monitors the critical input and output circuits of the charging system, making sure they are operational. A Diagnostic Trouble Code (DTC) is assigned to each input and output circuit monitored by the On-Board Diagnostic (OBD) system. Some charging system circuits are checked continuously, and some are checked only under certain conditions.
For Diagnostic Trouble Codes, refer to appropriate diagnostic information.
To perform a complete test of the charging system, use a diagnostic scan tool. Perform the following inspections before attaching the scan tool.
1. Inspect the battery condition. Refer to INSPECTION .
2. Inspect the condition of battery cable terminals, battery posts, connections at engine block, starter solenoid and relays. They should be clean and tight. Repair as required. 3. Inspect all the fuses in the Totally Integrated Power Module (TIPM) for tightness in there receptacles. They should be properly installed and tight. Repair or replace as required. 4. Inspect the generator mounting bolts for tightness. Replace or tighten the bolts if required. For torque specifications, refer to SPECIFICATIONS. 5. Inspect the generator drive belt condition and tension. Tighten or replace the belt as required. Refer to BELT, SERPENTINE . 6. Inspect the automatic belt tensioner (when equipped). 7. Inspect the generator electrical connections at generator field, battery output, and ground terminal (if equipped). Also check the generator ground wire connection at the engine (if equipped). They should all be clean and tight. Repair as required.
SPECIFICATIONS GENERATOR RATINGS
TYPE RATED SAE AMPS ENGINES
DENSO 160 3.7L / 4.7L / 5.7L
TORQUE SPECIFICATIONS - GENERATOR / CHARGING SYSTEM
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 reason, the entire assembly must be replaced.
OPERATION
OPERATION
As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current 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 stator winding connections deliver the induced alternating current to 3 or 6 positive and 3 or 6 negative diodes for rectification. From the diodes, rectified direct current is delivered to the vehicle electrical system through the generator battery terminal.
Although the generators appear the same externally, different generators with different output ratings are used on this vehicle. Be certain that the replacement generator has the same output rating and part number as the original unit. For amperage ratings, refer to GENERATOR RATINGS.
Noise emitting from the generator may be caused by: worn, loose or defective bearings; a loose or defective drive pulley; incorrect, worn, damaged or misadjusted fan drive belt; loose mounting bolts; a misaligned drive pulley or a defective stator or diode.
REMOVAL
3.7L / 4.7L Fig. 2: Generator, Nut, Cap & Connectors Courtesy of CHRYSLER GROUP, LLC
1 - GENERATOR 2 - B+ NUT 3 - PLASTIC INSULATOR CAP 4 - FIELD WIRE CONNECTOR
WARNING: Disconnect the negative cable from the battery before removing the battery output wire (B+ wire) from the generator. Failure to do so can result in injury or damage to the electrical system.
1. Disconnect the negative battery cable.
2. Remove the generator drive belt. Refer to BELT, SERPENTINE, REMOVAL . 3. Unsnap the plastic insulator cap from the B+ output terminal (3). Refer to Fig. 2. 4. Remove the B+ terminal mounting nut at the rear of generator (2). Refer to Fig. 2. Disconnect the terminal from the generator. 5. Disconnect the field wire connector at the rear of the generator (4) by pushing on the connector tab. Refer to Fig. 2. Fig. 3: Generator & Bolts Courtesy of CHRYSLER GROUP, LLC
1 - LOWER BOLTS 2 - REAR BOLT 3 - GENERATOR
6. Remove the one rear vertical generator mounting bolt (2). Refer to Fig. 3. 7. Remove the two front horizontal generator mounting bolts (1). Refer to Fig. 3. 8. Remove the generator from vehicle.
5.7L Fig. 4: Generator Support Bracket, Nuts & Bolt Courtesy of CHRYSLER GROUP, LLC
WARNING: Disconnect the negative cable from the battery before removing the battery output wire (B+ wire) from the generator. Failure to do so can result in injury or damage to the electrical system.
1. Disconnect the negative battery cable.
2. Remove the generator drive belt. Refer to BELT, SERPENTINE, REMOVAL . 3. Unsnap the plastic insulator cap from the B+ output terminal. 4. Remove the B+ terminal mounting nut at the rear of the generator. Disconnect the terminal from the generator. 5. Disconnect the field wire connector at the rear of generator by pushing on the connector tab. 6. Remove the generator support bracket nuts (3) and bolt (4) and remove the support bracket. Refer to Fig. 4. Fig. 5: Generator, Mounting Stud & Bolt Courtesy of CHRYSLER GROUP, LLC
7. Remove the two generator mounting bolts (1) and (3). Refer to Fig. 5. 8. Remove the generator from the vehicle.
DIESEL Fig. 6: Diesel Generator & Mounting Bolts Courtesy of CHRYSLER GROUP, LLC
1 - GENERATOR 2 - MOUNTING BOLTS
WARNING: Disconnect both negative cables from both batteries before removing battery output wire (B+ wire) from generator. Failure to do so can result in injury or damage to electrical system.
1. Disconnect both negative battery cables at both batteries.
2. Remove generator drive belt. Refer to BELT, SERPENTINE, REMOVAL . 3. Remove upper mounting bracket bolt (2). Refer to Fig. 6. 4. Remove lower mounting bracket bolt and nut (2). Refer to Fig. 6. 5. Remove generator from engine. Fig. 7: Diesel Generator Connectors Courtesy of CHRYSLER GROUP, LLC
6. Unsnap plastic insulator cap (1) from B+ output terminal.
7. Remove B+ terminal mounting nut at rear of generator. Disconnect terminal from generator. 8. Disconnect field wire connector (3) at rear of generator by pushing on connector tab.
INSTALLATION
3.7L / 4.7L
1. Position the generator to the engine and install the two horizontal bolts and the one vertical bolt. Tighten all three bolts to 55 N.m (40 ft. lbs.). 2. Snap the field wire connector into the rear of the generator. 3. Install the B+ terminal eyelet to the generator output stud. Tighten to 12 N.m (8.8 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 may 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 INSTALLATION . 4. Install the accessory drive belt. Refer to BELT, SERPENTINE, INSTALLATION . 5. Connect the negative battery cable.
5.7L
1. Position the generator to the engine and install the two mounting bolts. Tighten to 41 N.m (30 ft. lbs.). 2. Position the support bracket to the front of the generator and install the bolt and nuts. Tighten to 41 N.m (30 ft. lbs.). 3. Snap the field wire connector into the rear of the generator. 4. Install the B+ terminal eyelet to the generator output stud. Tighten mounting nut to 12 N.m (8.8 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 may 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, SERPENTINE, INSTALLATION .
5. Install the generator drive belt. Refer to BELT, SERPENTINE, INSTALLATION .
6. Connect the negative battery cable.
DIESEL
1. Position generator to upper and lower mounting brackets and install upper bolt and lower bolt / nut. 2. Tighten all bolts/nut to 30 ft. lbs. (41 N.m). 3. Snap field wire connector into rear of generator. 4. Install B+ terminal eyelet to generator output stud. Tighten mounting nut. Refer to TORQUE SPECIFICATIONS - GENERATOR / CHARGING SYSTEM.
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 may 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, SERPENTINE, INSTALLATION .
6. Install both negative battery cables to both batteries. REGULATOR, VOLTAGE DESCRIPTION
DESCRIPTION
The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit located within the PCM (Powertrain Control Module). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced.
OPERATION
OPERATION
The amount of direct current produced by the generator 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 battery positive path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line voltage (B+) and battery temperature (refer to appropriate Electrical Diagnostic article). 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 voltage is 0.5 volts above target voltage. A circuit in the PCM cycles the battery positive (high side) of the generator field up to 400 times per second (400Hz), but has the capability to ground the field control wire 100% of the time (full field) to achieve the target voltage. If the charging rate cannot be monitored (limp-in), a duty cycle of 25% is used by the PCM in order to have some generator output. For additional information, refer to OPERATION.
