NS CHARGING SYSTEM 8C - 1

CHARGING SYSTEM
CONTENTS

page page

DESCRIPTION AND OPERATION ON-BOARD DIAGNOSTIC SYSTEM TEST . . . . . . 4

BATTERY TEMPERATURE SENSOR . . . . . . . . . . 2 REMOVAL AND INSTALLATION
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1 GENERATOR—2.4L ENGINE . . . . . . . . . . . . . . . . 4
ELECTRONIC VOLTAGE REGULATOR . . . . . . . . . 2 GENERATOR—3.0L ENGINE . . . . . . . . . . . . . . . . 5
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 GENERATOR—3.3/3.8 L ENGINE . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING SPECIFICATIONS
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 2 GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CHARGING SYSTEM RESISTANCE TESTS . . . . . 2 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CURRENT OUTPUT TEST . . . . . . . . . . . . . . . . . . 3

DESCRIPTION AND OPERATION the proper voltage depending on battery tempera-

ture.
CHARGING SYSTEM All vehicles are equipped with On-Board Diagnos-
tics (OBD). All OBD-sensed systems, including the
DESCRIPTION EVR (field control) circuitry, are monitored by the
The charging system consists of: PCM. Each monitored circuit is assigned a Diagnos-
• Generator tic Trouble Code (DTC). The PCM will store a DTC in
• Electronic Voltage Regulator (EVR) circuitry electronic memory for any failure it detects.
within the Powertrain Control Module (PCM)
• Ignition switch (refer to the Ignition System for GENERATOR
information)
• Battery (refer to the Battery for information) DESCRIPTION
• Battery temperature sensor The generator is belt-driven by the engine. It is
• Voltmeter (refer to the Instrument Panel and serviced only as a complete assembly. If the genera-
Gauges for information) tor fails for any reason, the entire assembly must be
• Wiring harness and connections (refer to the replaced.
Wiring for information)
OPERATION
OPERATION As the energized rotor begins to rotate within the
The charging system is turned on and off with the generator, the spinning magnetic field induces a cur-
ignition switch. When the ignition switch is turned to rent into the windings of the stator coil. Once the
the ON position, battery voltage is applied to the generator begins producing sufficient current, it also
generator rotor through one of the two field termi- provides the current needed to energize the rotor.
nals to produce a magnetic field. The generator is The Y type stator winding connections deliver the
driven by the engine through a serpentine belt and induced AC current to 3 positive and 3 negative diodes
pulley arrangement. for rectification. From the diodes, rectified DC current is
The amount of DC current produced by the gener- delivered to the vehicles electrical system through the
ator is controlled by the EVR (field control) circuitry, generator, battery, and ground terminals.
contained within the PCM. This circuitry is con- Noise emitting from the generator may be caused by:
nected in series with the second rotor field terminal • Worn, loose or defective bearings
and ground. • Loose or defective drive pulley
Temperature data, along with data from monitored • Incorrect, worn, damaged or misadjusted drive belt
line voltage, is used by the PCM to vary the battery • Loose mounting bolts
charging rate. This is done by cycling the ground • Misaligned drive pulley
path to control the strength of the rotor magnetic • Defective stator or diode
field. The PCM then compensates and regulates gen- • Damaged internal fins
erator current output accordingly and to maintain
8C - 2 CHARGING SYSTEM NS
DESCRIPTION AND OPERATION (Continued)

BATTERY TEMPERATURE SENSOR Remember that an undercharged battery is often

caused by:
OPERATION • Accessories being left on with the engine not
The temperature sensor, in the PCM, is used to running
determine the battery temperature. This temperature • A faulty or improperly adjusted switch that
data, along with data from monitored line voltage, is allows a lamp to stay on. See Ignition-Off Draw Test
used by the PCM to vary the battery charging rate. in the Battery section for more information.
System voltage will be higher at colder temperatures The following procedures may be used to correct a
and is gradually reduced at warmer temperatures. problem diagnosed as a charging system fault.
The battery temperature sensor is also used for
OBD II diagnostics. Certain faults and OBD II mon- INSPECTION
itors are either enabled or disabled depending upon (1) Inspect condition of battery cable terminals,
the battery temperature sensor input (example: dis- battery posts, connections at engine block, starter
able purge and EGR, enable LDP). Most OBD II solenoid and relay. They should be clean and tight.
monitors are disabled below 20°F. Repair as required.
(2) Inspect all fuses in the fuseblock module and
ELECTRONIC VOLTAGE REGULATOR Power Distribution Center (PDC) for tightness in
receptacles. They should be properly installed and
DESCRIPTION tight. Repair or replace as required.
The Electronic Voltage Regulator (EVR) is not a (3) Inspect generator mounting bolts for tightness.
separate component. It is actually a voltage regulat- Replace or tighten bolts if required. Refer to the Gen-
ing circuit located within the Powertrain Control erator Removal/Installation section of this group for
Module (PCM). The EVR is not serviced separately. If torque specifications.
replacement is necessary, the PCM must be replaced. (4) Inspect generator drive belt condition and ten-
sion. Tighten or replace belt as required. Refer to
OPERATION Belt Tension Specifications in the Cooling System.
The amount of DC current produced by the gener- (5) Inspect automatic belt tensioner (if equipped).
ator is controlled by EVR circuitry contained within Refer to the Cooling System for information.
the PCM. This circuitry is connected in series with (6) Inspect connections at generator field, battery
the generators second rotor field terminal and its output, and ground terminals. Also check ground con-
ground. nection at engine. They should all be clean and tight.
Voltage is regulated by cycling the ground path to Repair as required.
control the strength of the rotor magnetic field. The
EVR circuitry monitors system line voltage and bat- CHARGING SYSTEM RESISTANCE TESTS
tery temperature (refer to Battery Temperature Sen- These tests will show the amount of voltage drop
sor for more information). It then compensates and across the generator output wire from the generator
regulates generator current output accordingly. Also output (B+) terminal to the battery positive post.
refer to Charging System Operation for additional They will also show the amount of voltage drop from
information. the ground (-) terminal on the generator or case
ground (Fig. 1) to the battery negative post.
A voltmeter with a 0–18 volt DC scale should be
DIAGNOSIS AND TESTING used for these tests. By repositioning the voltmeter
test leads, the point of high resistance (voltage drop)
CHARGING SYSTEM can easily be found.
When the ignition switch is turned to the ON posi-
tion, battery potential will register on the voltmeter. PREPARATION
During engine cranking a lower voltage will appear (1) Before starting test, make sure battery is in
on the meter. With the engine running, a voltage good condition and is fully-charged. See Group 8A,
reading higher than the first reading (ignition in ON) Battery for more information.
should register. (2) Check condition of battery cables at battery.
The following are possible symptoms of a charging Clean if necessary.
system fault: (3) Start the engine and allow it to reach normal
• The voltmeter does not operate properly operating temperature.
• An undercharged or overcharged battery condi- (4) Shut engine off.
tion occurs. (5) Connect an engine tachometer.
(6) Fully engage the parking brake.
NS CHARGING SYSTEM 8C - 3
DIAGNOSIS AND TESTING (Continued)
nut and then to the wiring connector. If voltage is
now below 0.6 volts, look for dirty, loose or poor
connection at this point. Also check condition of the
generator output wire-to-battery bullet connector.
Refer to Group 8, Wiring for connector location. A
voltage drop test may be performed at each (-
ground) connection in this circuit to locate the
excessive resistance.
(7) Testing (- ground) circuitry:
(a) Touch the positive lead of voltmeter directly
to battery negative POST.
(b) Touch the negative lead of voltmeter to the
generator case. Voltage should be no higher than
0.3 volts. If voltage is higher than 0.3 volts, touch
test lead to generator case and then to the engine
block. If voltage is now below 0.3 volts, look for
Fig. 1 Generator Terminals dirty, loose or poor connection at this point. A volt-
age drop test may be performed at each connection
in this circuit to locate the excessive resistance.
This test can also be performed between the gener-
ator case and the engine. If test voltage is higher
than 0.3 volts, check for corrosion at generator
mounting points or loose generator mounting.

CURRENT OUTPUT TEST

The current output test will determine if the
charging system can deliver its minimum test cur-
rent (amperage) output. Refer to the Specifications
section at the end of this group for minimum test
current (amperage) requirements.
The first part of this test will determine the com-
bined amperage output of both the generator and the
Electronic Voltage Regulator (EVR) circuitry.

PREPARATION
(1) Determine if any Diagnostic Trouble Codes
(DTC) exist. For repair, refer to the appropriate Pow-
ertrain Diagnostic Procedures manual.
(2) Before starting test, make sure battery is in
Fig. 2 Battery Voltage Test—Typical good condition and is fully-charged. See the Battery
section for more information.
TEST (3) Check condition of battery cables at battery.
(1) Start engine. Clean if necessary.
(2) Place heater blower in high position. (4) Be sure the generator drive belt is properly
(3) Turn on headlamps and place in high-beam tensioned. Refer to the Cooling System for informa-
position. tion.
(4) Turn rear window defogger on. (5) A volt/amp tester equipped with both a battery
(5) Bring engine speed up to 2400 rpm and hold. load control (carbon pile rheostat) and an inductive-
(6) Testing (+ positive) circuitry: type pickup clamp (ammeter probe) will be used for
(a) Touch the negative lead of voltmeter directly this test. Refer to operating instructions supplied
to battery positive POST (Fig. 2). with tester. When using a tester equipped with an
(b) Touch the positive lead of voltmeter to the inductive-type clamp, removal of wiring at the gener-
B+ output terminal stud on the generator (not the ator will not be necessary.
terminal mounting nut). Voltage should be no (6) Start the engine and allow it to reach operating
higher than 0.6 volts. If voltage is higher than 0.6 temperature.
volts, touch test lead to terminal mounting stud (7) Shut engine off.
8C - 4 CHARGING SYSTEM NS
DIAGNOSIS AND TESTING (Continued)
(8) Turn off all electrical accessories and all vehicle Trouble Code (DTC) is assigned to each input and
lighting. output circuit monitored by the OBD system. Some
(9) Connect the volt/amp tester leads to the bat- circuits are checked continuously and some are
tery post or jump start posts. Be sure the carbon pile checked only under certain conditions.
rheostat control is in the OPEN or OFF position If the OBD system senses that a monitored circuit
before connecting leads. See Load Test in the Battery is bad, it will put a DTC into electronic memory. The
section for more information. Also refer to the oper- DTC will stay in electronic memory as long as the
ating instructions supplied with test equipment. circuit continues to be bad. The PCM is programmed
(10) Connect the inductive clamp (ammeter probe). to clear the memory after 50 engine starts if the
Refer to the operating instructions supplied with test problem does not occur again.
equipment.
(11) If volt/amp tester is not equipped with an DIAGNOSTIC TROUBLE CODES
engine tachometer, connect a separate tachometer to A DTC description can be read using the DRB scan
the engine. tool. Refer to the appropriate Powertrain Diagnostic
Procedures manual for information.
TEST A DTC does not identify which component in a cir-
(1) Perform the previous test Preparation. cuit is bad. Thus, a DTC should be treated as a
(2) Fully engage the parking brake. symptom, not as the cause for the problem. In some
(3) Start engine. cases, because of the design of the diagnostic test
(4) Bring engine speed to 2500 rpm. procedure, a DTC can be the reason for another DTC
(5) With engine speed held at 2500 rpm, slowly to be set. Therefore, it is important that the test pro-
adjust the rheostat control (load) on the tester to cedures be followed in sequence, to understand what
obtain the highest amperage reading. Do not allow caused a DTC to be set.
voltage to drop below 12 volts. Record the reading.
This load test must be performed within 15 sec- ERASING DIAGNOSTIC TROUBLE CODES
onds to prevent damage to test equipment. On The DRB Scan Tool must be used to erase a DTC.
certain brands of test equipment, this load will be
applied automatically. Refer to the operating manual
supplied with test equipment. REMOVAL AND INSTALLATION
(6) The ammeter reading must meet the Minimum
Test Amps specifications as displayed in the Genera- GENERATOR—2.4L ENGINE
tor Ratings chart. This can be found in the Specifica-
tions section. A label stating a part reference number REMOVAL
is attached to the generator case. On some engines (1) Release hood latch and open hood.
this label may be located on the bottom of the case. (2) Disconnect battery negative cable (Fig. 3).
Compare this reference number to the Generator (3) Remove accessory drive belt, refer to Group 7,
Ratings chart. Cooling System for proper procedures.
(7) Rotate the load control to the OFF position. (4) Disconnect the push-in field wire connector
(8) Continue holding engine speed at 2500. If EVR from back of generator (Fig. 4).
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

Fig. 3 Removal/Installation of Battery Cables
GENERAL INFORMATION
(5) Remove nut holding B+ wire to terminal on
The Powertrain Control Module (PCM) monitors
back of generator.
critical input and output circuits of the charging sys-
(6) Separate B+ wire from generator terminal.
tem, making sure they are operational. A Diagnostic
NS CHARGING SYSTEM 8C - 5
REMOVAL AND INSTALLATION (Continued)
(9) Verify generator charge rate.

GENERATOR—3.0L 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).

Fig. 4 Wire Connectors

(7) Remove nut holding top of generator to adjust-
able T-bolt (Fig. 5).

Fig. 6 Generator–3.0L Engine

(6) Remove bolt holding bottom of generator to
lower pivot bracket (Fig. 4).
(7) Disengage push-in field wire connector from
back of generator.
Fig. 5 Generator–2.4L Engine (8) Remove nut holding B+ wire terminal to back
of generator.
(8) Remove bolt holding bottom generator pivot to
(9) Remove B+ terminal from generator.
lower mount.
(9) Remove generator. INSTALLATION
(1) Place B+ terminal in position on generator.
INSTALLATION (2) Install nut to hold B+ wire terminal to back of
(1) Place generator in position on vehicle.
generator
(2) Install bolt to hold bottom generator pivot to
(3) Connect the push-in field wire connector into
lower mount.
back of generator.
(3) Install nut to hold top of generator to adjust-
(4) Install bolt to hold bottom of generator to lower
able T-bolt.
pivot bracket.
(4) Place B+ wire in position on generator termi-
(5) Install bolt to hold top of generator to mount
nal.
bracket.
(5) Install nut to hold B+ wire to terminal on back
(6) Install accessory drive belt, refer to Group 7,
of generator.
Cooling System for proper procedures.
(6) Connect the push-in field wire connector onto
(7) Install windshield wiper housing, refer to
back of generator.
Group 8K, Windshield Wipers and Washers for
(7) Install accessory drive belt, refer to Group 7,
proper procedures.
Cooling System for proper procedures.
(8) Connect battery negative cable.
(8) Connect battery negative cable.
(9) Verify generator charge rate.
8C - 6 CHARGING SYSTEM NS
REMOVAL AND INSTALLATION (Continued)

GENERATOR—3.3/3.8 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).

Fig. 8 Generator pivot Bolt

Fig. 7 Generator Mounting Bracket

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

SPECIFICATIONS Part number is located on the side of the generator.

GENERATOR TORQUE
DESCRIPTION TORQUE
Type Part Amperage output
Battery Hold Down Bolt . . . . . 14 N·m (125 in. lbs.)
Number
Generator Mounting Bolts . . . . . 54 N·m (40 ft. lbs.)
Nippondenso 90 A 4727220 86 Amp Generator B+ Terminal . . . . . . . . 9 N·m (75 in. lbs.)
HS Starter Mounting Bolts . . . . . . . 54 N·m (40 ft. lbs.)
Nippondenso 120 A 4727325AA 102 Amp Starter Solenoid Battery Nut . . . 10 N·m (90 in. lbs.)
HS