ZJ CHARGING SYSTEM 8C - 1

CHARGING SYSTEM
CONTENTS

page page

GENERAL INFORMATION CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 2

OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 CURRENT OUTPUT TEST . . . . . . . . . . . . . . . . . . 5
DESCRIPTION AND OPERATION ON-BOARD DIAGNOSTIC SYSTEM TEST . . . . . . 6
BATTERY TEMPERATURE SENSOR . . . . . . . . . . 2 REMOVAL AND INSTALLATION
CHARGING SYSTEM OPERATION . . . . . . . . . . . 1 BATTERY TEMPERATURE SENSOR . . . . . . . . . . 8
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
VOLTAGE REGULATOR . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS
DIAGNOSIS AND TESTING GENERATOR RATINGS . . . . . . . . . . . . . . . . . . . . 8
BATTERY TEMPERATURE SENSOR . . . . . . . . . . 6 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . 8
CHARGING SYSTEM RESISTANCE TESTS . . . . . 3

GENERAL INFORMATION • Electronic Voltage Regulator (EVR) circuitry

within the Powertrain Control Module (PCM)
OVERVIEW • Ignition switch (refer to Group 8D, Ignition Sys-
The battery, starting, and charging systems oper- tem for information)
ate with one another, and must be tested as a com- • Battery (refer to Group 8A, Battery for informa-
plete system. In order for the vehicle to start and tion)
charge properly, all of the components involved in • Battery temperature sensor
these systems must perform within specifications. • Voltmeter (refer to Group 8E, Instrument Panel
Group 8A covers the battery, Group 8B covers the start- and Gauges for information)
ing system, and Group 8C covers the charging system. • Wiring harness and connections (refer to Group
Refer to Group 8W - Wiring Diagrams for complete circuit 8W, Wiring for information)
descriptions and diagrams. We have separated these sys- The charging system is turned on and off with the
tems to make it easier to locate the information you are ignition switch. When the ignition switch is turned to
seeking within this Service Manual. However, when the ON position, battery voltage is applied to the
attempting to diagnose any of these systems, it is impor- generator rotor through one of the two field termi-
tant that you keep their interdependency in mind. nals to produce a magnetic field. The generator is
The diagnostic procedures used in these groups driven by the engine through a serpentine belt and
include the most basic conventional diagnostic meth- pulley arrangement.
ods to the more sophisticated On-Board Diagnostics The amount of DC current produced by the gener-
(OBD) built into the Powertrain Control Module ator is controlled by the EVR (field control) circuitry,
(PCM). Use of a induction milliampere ammeter, volt/ contained within the PCM. This circuitry is con-
ohmmeter, battery charger, carbon pile rheostat (load nected in series with the second rotor field terminal
tester), and 12-volt test lamp may be required. and ground.
All OBD-sensed systems are monitored by the A battery temperature sensor located in the bat-
PCM. Each monitored circuit is assigned a Diagnos- tery tray housing, is used to sense battery tempera-
tic Trouble Code (DTC). The PCM will store a DTC in ture. This temperature data, along with data from
electronic memory for any failure it detects. See the monitored line voltage, is used by the PCM to vary
On-Board Diagnostics Test in Group 8C - Charging the battery charging rate. This is done by cycling the
System for more information. ground path to control the strength of the rotor mag-
netic field. The PCM then compensates and regulates
generator current output accordingly.
DESCRIPTION AND OPERATION All vehicles are equipped with On-Board Diagnos-
tics (OBD). All OBD-sensed systems, including the
CHARGING SYSTEM OPERATION 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
8C - 2 CHARGING SYSTEM ZJ
DESCRIPTION AND OPERATION (Continued)
electronic memory for any failure it detects. See On-
Board Diagnostic System Test in this group for more
information.

GENERATOR
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 rea-
son, the entire assembly must be replaced.
As the energized rotor begins to rotate within the
generator, the spinning magnetic field induces a cur-
rent 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 Y type stator winding connections deliver the
induced AC current to 3 positive and 3 negative
diodes for rectification. From the diodes, rectified DC Fig. 1 Battery Temperature Sensor
current is delivered to the vehicle electrical system Voltage is regulated by cycling the ground path to
through the generator battery and ground terminals. control the strength of the rotor magnetic field. The
Although the generators appear the same exter- EVR circuitry monitors system line voltage and bat-
nally, different generators with different output rat- tery temperature (refer to Battery Temperature Sen-
ings are used on this vehicle. This will depend upon sor for more information). It then compensates and
engine size and optional equipment. Be certain that regulates generator current output accordingly. Also
the replacement generator has the same output rat- see Charging System Operation for additional infor-
ing as the original unit. See Generator Ratings in the mation.
Specifications section at the back of this group for
amperage ratings.
Noise emitting from the generator may be caused DIAGNOSIS AND TESTING
by: worn, loose or defective bearings; a loose or defec-
tive drive pulley; incorrect, worn, damaged or misad- CHARGING SYSTEM
justed fan drive belt; loose mounting bolts; a When the ignition switch is turned to the ON posi-
misaligned drive pulley or a defective stator or diode. tion, battery potential will register on the voltmeter.
During engine cranking a lower voltage will appear
BATTERY TEMPERATURE SENSOR on the meter. With the engine running, a voltage
The battery temperature sensor is used to deter- reading higher than the first reading (ignition in ON)
mine the battery temperature and control battery should register.
charging rate. This temperature data, along with The following procedures may be used to diagnose
data from monitored line voltage, is used by the PCM the charging system if:
to vary the battery charging rate. System voltage will • the voltmeter does not operate properly
be higher at colder temperatures and is gradually • an undercharged or overcharged battery condi-
reduced at warmer temperatures. tion occurs.
The sensor is located under the vehicle battery, Remember that an undercharged battery is often
and is attached to the battery tray (Fig. 1). caused by:
• accessories being left on with the engine not
VOLTAGE REGULATOR running
The Electronic Voltage Regulator (EVR) is not a • a faulty or improperly adjusted switch that
separate component. It is actually a voltage regulat- allows a lamp to stay on. See Ignition-Off Draw Test
ing circuit located within the Powertrain Control in Group 8A, Battery for more information.
Module (PCM). The EVR is not serviced separately. If
replacement is necessary, the PCM must be replaced. INSPECTION
Operation: The amount of DC current produced (1) Inspect condition of battery cable terminals,
by the generator is controlled by EVR circuitry con- battery posts, connections at engine block, starter
tained within the PCM. This circuitry is connected in solenoid and relay. They should be clean and tight.
series with the generators second rotor field terminal Repair as required.
and its ground. (2) Inspect all fuses in the fuseblock module and
Power Distribution Center (PDC) for tightness in
ZJ CHARGING SYSTEM 8C - 3
DIAGNOSIS AND TESTING (Continued)
receptacles. They should be properly installed and PREPARATION
tight. Repair or replace as required. (1) Before starting test, make sure battery is in
(3) Inspect the electrolyte level in the battery. good condition and is fully-charged. See Group 8A,
Replace battery if electrolyte level is low. Battery for more information.
(4) Inspect generator mounting bolts for tightness. (2) Check condition of battery cables at battery.
Replace or tighten bolts if required. Refer to the Gen- Clean if necessary.
erator Removal/Installation section of this group for (3) Start the engine and allow it to reach normal
torque specifications. operating temperature.
(5) Inspect generator drive belt condition and ten- (4) Shut engine off.
sion. Tighten or replace belt as required. Refer to (5) Connect an engine tachometer.
Belt Tension Specifications in Group 7, Cooling Sys- (6) Fully engage the parking brake.
tem.
(6) Inspect automatic belt tensioner (if equipped). TEST
Refer to Group 7, Cooling System for information. (1) Start engine.
(7) Inspect connections at generator field, battery (2) Place heater blower in high position.
output, and ground terminals. Also check ground con- (3) Turn on headlamps and place in high-beam
nection at engine. They should all be clean and tight. position.
Repair as required. (4) Turn vehicle interior lamps on.
(5) Start engine. Bring engine speed up to 2400
CHARGING SYSTEM RESISTANCE TESTS rpm and hold.
These tests will show the amount of voltage drop (6) Testing (+) circuitry:
across the generator output wire, from the generator (a) Touch the negative lead of voltmeter directly
output (B+) terminal (Fig. 2) to the battery positive to battery positive post.
post. They will also show the amount of voltage drop (b) Touch the positive lead of voltmeter to the B+
from the ground (-) terminal on the generator (Fig. 2) output terminal stud on the generator (not the termi-
to the battery negative post. nal mounting nut). Voltage should be no higher than
0.6 volts. If voltage is higher than 0.6 volts, touch test
lead to terminal mounting stud 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 per-
formed at each (+) connection in this circuit to locate
the excessive resistance.
(7) Testing (-) circuitry:
(a) Touch the negative lead of voltmeter directly
to battery negative post.
(b) Touch the positive lead of voltmeter to the
ground terminal stud on the generator case (not the
terminal mounting nut). Voltage should be no higher
than 0.3 volts. If voltage is higher than 0.3 volts,
touch test lead to terminal mounting stud nut and
then to the wiring connector. If voltage is now below
0.3 volts, look for dirty, loose or poor connection at
this point. A voltage drop test may be performed at
each (-) connection in this circuit to locate the exces-
sive resistance. This test can also be performed
between the generator case and the engine. If test
Fig. 2 Generator Terminals voltage is higher than 0.3 volts, check for corrosion at
A voltmeter with a 0–18 volt DC scale should be generator mounting points or loose generator mount-
used for these tests. By repositioning the voltmeter ing.
test leads, the point of high resistance (voltage drop)
can easily be found.
8C - 4 CHARGING SYSTEM ZJ
DIAGNOSIS AND TESTING (Continued)

Charging System Test

ZJ CHARGING SYSTEM 8C - 5
DIAGNOSIS AND TESTING (Continued)
CURRENT OUTPUT TEST TEST 1
The current output test will determine if the (1) Perform the previous test Preparation.
charging system can deliver its minimum test cur- (2) Fully engage the parking brake.
rent (amperage) output. Refer to the Specifications (3) Start engine.
section at the end of this group for minimum test (4) Bring engine speed to 2500 rpm.
current (amperage) requirements. (5) With engine speed held at 2500 rpm, slowly
The first part of this test (Test 1) will determine adjust the rheostat control (load) on the tester to
the combined amperage output of both the generator obtain the highest amperage reading. Do not allow
and the Electronic Voltage Regulator (EVR) circuitry. voltage to drop below 12 volts. Record the reading.
The second part of this test (Test 2) will determine This load test must be performed within 15 sec-
only generator amperage and will not include anal- onds to prevent damage to test equipment. On
ysis of EVR circuitry. EVR circuitry is located within certain brands of test equipment, this load will be
the Powertrain Control Module (PCM). To test volt- applied automatically. Refer to the operating manual
age regulator circuitry, refer to the appropriate Pow- supplied with test equipment.
ertrain Diagnostic Procedures service manual. (6) The ammeter reading must meet the Minimum
Test Amps specifications as displayed in the Genera-
PREPARATION tor Ratings chart. This can be found in the Specifica-
(1) Determine if any Diagnostic Trouble Codes tions section at the end of this group. A label stating
(DTC’s) exist. To determine a DTC, refer to On-Board a part reference number is attached to the generator
Diagnostics in this group. For repair, refer to the appro- case. On some engines this label may be located on
priate Powertrain Diagnostic Procedures manual. the bottom of the case. Compare this reference num-
(2) Before starting test, make sure battery is in ber to the Generator Ratings chart.
good condition and is fully-charged. See Group 8A, (7) Rotate the load control to the OFF position.
Battery for more information. (8) Continue holding engine speed at 2500. If EVR
(3) Check condition of battery cables at battery. circuitry is OK, amperage should drop below 15–20
Clean if necessary. amps. With all electrical accessories and vehicle
(4) Perform the previous Output Wire Resistance lighting off, this could take several minutes of engine
Test (voltage drop test). This will ensure clean and operation. If amperage did not drop, refer to the
tight generator/battery electrical connections. appropriate Powertrain Diagnostic Procedures man-
(5) Be sure the generator drive belt is properly ual for testing.
tensioned. Refer to Group 7, Cooling System for (9) Remove volt/amp tester.
information. If minimum amperage could not be met, proceed to
(6) A volt/amp tester equipped with both a battery Test 2. This test will determine if the generator is
load control (carbon pile rheostat) and an inductive- faulty, or if EVR circuitry is defective.
type pickup clamp (ammeter probe) will be used for
this test. Refer to operating instructions supplied TEST 2
with tester. When using a tester equipped with an (1) Perform the previous test preparation.
inductive-type clamp, removal of wiring at the gener- (2) Fully engage the parking brake.
ator will not be necessary. (3) Connect one end of a jumper wire to a good
(7) Start the engine and allow it to reach operating ground. Connect the other end of jumper wire to the
temperature. (-) field control circuit terminal. This terminal is
(8) Shut engine off. located on the back of the generator (Fig. 2). Con-
(9) Turn off all electrical accessories and all vehicle necting the jumper wire will remove the voltage reg-
lighting. ulator circuitry from the test. It will also generate a
(10) Connect the volt/amp tester leads to the bat- Diagnostic Trouble Code (DTC).
tery. Be sure the carbon pile rheostat control is in the
OPEN or OFF position before connecting leads. See CAUTION: Do not connect the jumper wire to the
Load Test in Group 8A, Battery for more information. (+) ASD Relay output terminal (Fig. 2). Damage to
Also refer to the operating instructions supplied with electrical system components may result. The (-)
test equipment. field control circuit terminal is located farther away
(11) Connect the inductive clamp (ammeter probe). from the B+ output terminal than the (+) ASD Relay
Refer to the operating instructions supplied with test terminal (Fig. 2).
equipment.
(4) Start engine. Immediately after starting,
(12) If volt/amp tester is not equipped with an engine
reduce engine speed to idle. This will prevent any
tachometer, connect a separate tachometer to the
electrical accessory damage from high voltage.
engine.
8C - 6 CHARGING SYSTEM ZJ
DIAGNOSIS AND TESTING (Continued)
(5) Adjust carbon pile rheostat (load) and engine ON-BOARD DIAGNOSTIC SYSTEM TEST
speed in slow increments until a speed of 1250 rpm,
and a voltmeter reading of 15 volts is obtained. GENERAL INFORMATION
Immediately record ammeter reading. Do not apply The Powertrain Control Module (PCM) monitors
load to system longer than 15 seconds as damage to critical input and output circuits of the charging sys-
test equipment may result. tem, making sure they are operational. A Diagnostic
Trouble Code (DTC) is assigned to each input and
CAUTION: When adjusting rheostat load, do not allow output circuit monitored by the OBD system. Some
voltage to rise above 16 volts. Damage to the battery circuits are checked continuously and some are
and electrical system components may result. checked only under certain conditions.
If the OBD system senses that a monitored circuit
(6) The ammeter reading must meet the Minimum is bad, it will put a DTC into electronic memory. The
Test Amps specifications as displayed in the Genera- DTC will stay in electronic memory as long as the
tor Ratings chart. This can be found in the Specifica- circuit continues to be bad. The PCM is programmed
tions section at the end of this group. A label stating to clear the memory after 50 engine starts if the
a part reference number is attached to the generator problem does not occur again.
case. On some engines this label may be located on
the bottom of the case. Compare this reference num- DIAGNOSTIC TROUBLE CODES
ber to the Generator Rating chart. Diagnostic Trouble Codes (DTC) are two-digit num-
(7) Remove volt/amp tester. bers flashed on the malfunction indicator (Check
(8) Remove jumper wire. Engine) lamp that identify which circuit is bad. Refer
(9) Use the DRB scan tool to erase the DTC. Refer to Group 25, On Board Diagnostic for more informa-
to the DRB screen for procedures. tion. A DTC description can also be read using the
DRB scan tool. Refer to the appropriate Powertrain
RESULTS Diagnostic Procedures manual for information.
• If amp reading meets specifications in Test 2, A DTC does not identify which component in a cir-
generator is OK. cuit is bad. Thus, a DTC should be treated as a
• If amp reading is less than specified in Test 2, symptom, not as the cause for the problem. In some
and wire resistance (voltage drop) tests were OK, the cases, because of the design of the diagnostic test
generator should be replaced. Refer to Removal and procedure, a DTC can be the reason for another DTC
Installation in this group for procedures. to be set. Therefore, it is important that the test pro-
• If Test 2 results were OK, but Test 1 results cedures be followed in sequence, to understand what
were not, the problem is in EVR circuitry. Refer to caused a DTC to be set.
appropriate Powertrain Diagnostic Procedures man- See the Generator Diagnostic Trouble Code chart (Fig.
ual for diagnosis. 3) for DTC’s which apply to the charging system. Refer to
the Powertrain Diagnostic Procedures manual to diag-
BATTERY TEMPERATURE SENSOR nose an on-board diagnostic system trouble code.
To perform a complete test of this sensor and its
circuitry, refer to the appropriate Powertrain Diag- RETRIEVING DIAGNOSTIC TROUBLE CODES
nostic Procedures manual. To test the sensor only, To start this function, cycle the ignition switch ON-
refer to the following: OFF-ON-OFF-ON within 5 seconds. This will cause
(1) The sensor is located under the battery and is any DTC stored in the PCM memory to be displayed.
attached to the battery tray (Fig. 1). A two-wire pig- The malfunction indicator (Check Engine) lamp will
tail harness is attached directly to the sensor. The display a DTC by flashing on and off. There is a
opposite end of this harness connects the sensor to short pause between flashes and a longer pause
the engine wiring harness. between digits. All DTC’s displayed are two-digit
(2) Disconnect the two-wire pigtail harness from numbers, with a four-second pause between codes.
the engine harness. An example of a DTC is as follows:
(3) Attach ohmmeter leads to the wire terminals of (1) Lamp on for 2 seconds, then turns off.
the pigtail harness. (2) Lamp flashes 4 times pauses and then flashes
(4) At room temperature of 25° C (75–80° F), an ohm- 1 time.
meter reading of 9 to 11K ohms should be observed. (3) Lamp pauses for 4 seconds, flashes 4 times,
(5) If reading is above or below the specification, pauses, then flashes 7 times.
replace the sensor. (4) The two DTC’s are 41 and 47. Any number of DTC’s
(6) Refer to the Removal and Installation section can be displayed, as long as they are in memory. The lamp
for procedures. will flash until all stored DTC’s are displayed, then it will
flash a DTC 55 to indicate the test is complete.
ZJ CHARGING SYSTEM 8C - 7
DIAGNOSIS AND TESTING (Continued)

Fig. 3 Generator Diagnostic Trouble Code

ERASING DIAGNOSTIC TROUBLE CODES
The DRB Scan Tool must be used to erase a DTC.

REMOVAL AND INSTALLATION

GENERATOR
WARNING: DISCONNECT NEGATIVE CABLE FROM
BATTERY BEFORE REMOVING BATTERY OUTPUT
WIRE FROM GENERATOR. FAILURE TO DO SO
CAN RESULT IN INJURY.

(1) Disconnect negative battery cable.

(2) Remove generator drive belt. Refer to Group 7,
Cooling System for procedure.
(3) Remove the generator pivot and mounting bolts (Fig.
4). Position generator for access to wire connectors. Fig. 4 Remove/Install Generator—Typical
(4) Remove nuts from harness holddown, battery • Field terminal nuts - 2.8 N·m (25 in. lbs.)
terminal, ground terminal and 2 field terminals (Fig.
5). Remove wire connectors. CAUTION: Never force a belt over a pulley rim
(5) Remove the generator. using a screwdriver. The synthetic fiber of the belt
(6) Reverse removal procedures to install. Tighten can be damaged.
generator hardware as follows:
• Generator mounting bolt 5.2L engines - 41 N·m
(30 ft. lbs.) CAUTION: When installing a serpentine accessory
• Generator pivot bolt 5.2L engines - 41 N·m (30 drive belt, the belt MUST be routed correctly. The
ft. lbs.) water pump will be rotating in the wrong direction if
• Generator mounting bolt 4.0L engine - 55 N·m the belt is installed incorrectly, causing the engine
(41 ft. lbs.) to overheat. Refer to belt routing label in engine
• Generator pivot bolt 4.0L engine - 55 N·m (41 ft. lbs.) compartment, or refer to Belt Schematics in Group
• Battery terminal nut - 8.5 N·m (75 in. lbs.) 7, Cooling System.
• Ground terminal nut - 8.5 N·m (75 in. lbs.)
• Harness holddown nut - 8.5 N·m (75 in. lbs.)
8C - 8 CHARGING SYSTEM ZJ
REMOVAL AND INSTALLATION (Continued)

Fig. 6 Battery Temperature Sensor Location

(2) Disconnect the sensor pigtail harness from the
engine wire harness.
(3) Pry the sensor straight up from the battery
tray mounting hole.
Fig. 5 Remove/Install Generator Connectors— INSTALLATION
Typical (1) Feed the pigtail harness through the hole in
BATTERY TEMPERATURE SENSOR top of battery tray and press sensor into top of bat-
The battery temperature sensor is located under tery tray.
vehicle battery (Fig. 6) and is attached to a mounting (2) Connect the pigtail harness.
hole on battery tray. (3) Install the battery. Refer to Group 8A, Battery
REMOVAL for procedures.
(1) Remove the battery. Refer to Group 8A, Battery
for procedures.

SPECIFICATIONS
GENERATOR RATINGS
TYPE PART NUMBER RATED SAE AMPS ENGINES MINIMUM TEST
AMPS
DENSO 56005685 117 4.0L 90
DENSO 56005686 136 4.0L 120
DENSO 56027912 117 5.2L 90
DENSO 56027913 136 5.2L 120

TORQUE SPECIFICATIONS

Description Torque Description Torque

Generator Mounting Bolt— Generator Pivot Bolt—
5.2L Engine . . . . . . . . . . . . . . . .41 N·m (30 ft. lbs.) 4.0L Engine . . . . . . . . . . . . . . . .55 N·m (41 ft. lbs.)
Generator Pivot Bolt— Battery Terminal Nut . . . . . . . . .8.5 N·m (75 in. lbs.)
5.2L Engine . . . . . . . . . . . . . . . .41 N·m (30 ft. lbs.) Ground Terminal Nut . . . . . . . . .8.5 N·m (75 in. lbs.)
Generator Mounting Bolt— Harness Hold-down Nut . . . . . . .8.5 N·m (75 in. lbs.)
4.0L Engine . . . . . . . . . . . . . . . .55 N·m (41 ft. lbs.) Field Terminal Nuts . . . . . . . . . .2.8 N·m (25 in. lbs.)