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Charging System - Generators & Regulators Chrysler Town & Country IV

Charging System 3 illustrations ~4078 words

DESCRIPTION

All models use a Nippondenso generator. Generator consists of a rotor, stator, rectifiers, front and rear covers and drive pulley. On 3.3 and 3.8L engines, generator uses a decoupler pulley. Decoupler pulley is a one-way clutch type pulley, which is designed to help reduce belt tension fluctuation, fatigue loads, noise and has a low sensitivity to electrical load. It is a non-servicable, non-lubricated pulley. If found faulty decoupler pulley must be replaced as an assembly. On all engines, generator is serviced as a complete unit only. Voltage regulation is controlled by Powertrain Control Module (PCM). Electronic Voltage Regulator (EVR) is not a separate component, but a circuit located within PCM. If EVR circuit is defective, PCM must be replaced.

GENERATOR APPLICATION

ApplicationCase Number(1) Minimum Output-Amps
2.4L(2)125
3.3 & 3.8L(2)135 Or 145
(1) Engine speed at 2480-2520 RPM. (2) Part number is located on side of generator case.
(1)Engine speed at 2480-2520 RPM.
(2)Part number is located on side of generator case.

GENERATOR APPLICATION

OPERATION

Amperage produced by generator is controlled by Electronic Voltage Regulator (EVR) circuitry within Powertrain Control Module (PCM). EVR circuity is connected in series with generator field driver terminal and ground. A Battery Temperature Sensor (BTS), located on PCM printed circuit board, is used to sense battery temperature. BTS cannot be serviced separately. If BTS is found faulty, PCM must be replaced. Sensed battery temperature and data from monitored line voltage is used by PCM to adjust battery charging rate. This is accomplished by cycling ground path to control strength of generator rotor magnetic field. PCM compensates and regulates generator amperage output accordingly. PCM monitors critical input to control fuel injection, ignition, emission and other engine management functions. PCM is also programmed to monitor the following charging system-related circuits.

  1. Battery feed to PCM.
  2. Generator field control.
  3. Battery charging voltage (high and low).

Note. DTC is erased from memory if failure does not reoccur after 50 engine starts.

If a problem is sensed in a monitored circuit, a Diagnostic Trouble Code (DTC) will be stored in PCM memory. Malfunction Indicator Light (MIL) will illuminate, provided specific criteria have been met. DTCs can be retrieved by using Chrysler's Diagnostic Readout Box (DRB-III).

BELT TENSION

ApplicationNew Belt Lbs. (kg)Used Belt Lbs. (kg)
2.4L
A/C & Generator(1)(1)
Power Steering Pump120-170 (54-77)80-120 (36-54)
3.3L & 3.8L(1)(1)
(1) Dynamic tensioner is used. No adjustment is required.
(1)Dynamic tensioner is used. No adjustment is required.

BELT TENSION

TROUBLE SHOOTING

Verify customer's concern by operating system. Inspect for blown fuses, damaged fusible links, wiring or harness connectors. Check for loose or frayed drive belt, loose generator ground wire, or corroded battery terminals. Ensure battery is fully charged and in good condition, battery cables are in good condition with connections clean and secure. Inspect generator and PCM harness connections. Check engine ground strap. If fault is found, repair as necessary. If no fault is found, perform self-diagnostics. See SELF-DIAGNOSTIC SYSTEM .

SELF-DIAGNOSTIC SYSTEM

CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

A specific DTC results from a particular system failure. DTC only indicates problem circuit. It does not identify specific component failure in circuit.

If problem is repaired or ceases to exist, Powertrain Control Module (PCM) automatically clears DTCs after 40 engine warm-up cycles. DTCs can also be cleared using scan tool. See CLEARING DIAGNOSTIC TROUBLE CODES .

RETRIEVING DIAGNOSTIC TROUBLE CODES

Note. For more information on scan tool and PCM diagnostics, see SELF-DIAGNOSTICS article.

Note. Self-diagnostic tests are written specifically for Chrysler's Diagnostic Readout Box (DRB-III) scan tool. A generic scan tool may also be used for system diagnostics, but may have limited diagnostic capability.

With Scan Tool

Ensure battery is fully charged. Connect scan tool to Data Link Connector (DLC). DLC is located below instrument panel, near steering column. Using scan tool, retrieve and record DTCs. Perform appropriate test in accordance with DTC retrieved. See SCAN TOOL DTC MESSAGES table. Once repairs are made, clear DTCs from PCM. See CLEARING DIAGNOSTIC TROUBLE CODES .

DTC Definitions

DTCScan Tool Display
P0622GENERATOR FIELD NOT SWITCHING PROPERLY
P1478BATTERY TEMP SENSOR VOLTS OUT OF LIMIT (2.4L, 3.3L & 3.8L)
P1478BATTERY TEMP SENSOR VOLTS OUT OF LIMIT (3.5L)
P1492BATTERY TEMPERATURE SENSOR VOLTAGE TOO HIGH
P1493BATTERY TEMPERATURE SENSOR VOLTAGE TOO LOW
P1594CHARGING SYSTEM VOLTAGE TOO HIGH
P1682CHARGING SYSTEM VOLTAGE TOO LOW

SCAN TOOL DTC MESSAGES

CLEARING DIAGNOSTIC TROUBLE CODES

Powertrain Control Module (PCM) automatically clears DTCs from memory after 40 engine warm-up cycles. DTCs can also be cleared using scan tool and following scan tool manufacturer's instructions.

NO RESPONSE

If scan tool displays NO RESPONSE FROM PCM, repair communication concern. See PCM MESSAGES NOT RECEIVED under COMMUNICATIONS in BODY CONTROL MODULES - CARAVAN, TOWN & COUNTRY, & VOYAGER article in ACCESSORIES & EQUIPMENT.

DIAGNOSTIC TESTS

CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

Note. When using diagnostic tests, DO NOT skip any steps or incorrect diagnosis may result. Ensure battery is fully charged.

Diagnostic Aids

DTC is set when Powertrain Control Module (PCM) attempts to regulate generator field with no result during monitoring. Possible causes are: wire harness intermittent, open in Auto Shut Down (ASD) relay output circuit, generator field coil open or shorted, open in generator field driver circuit, short to ground in generator field driver circuit, defective generator or defective PCM.

Scheme 1

Scheme 1: Diagnostic Procedure
Scheme 1: Diagnostic Procedure

Scheme 2

Scheme 2
Scheme 2

Scheme 3

Scheme 3
Scheme 3
  1. Turn ignition switch to ON position. Using scan tool, actuate generator field driver circuit. Using a 12-volt test light connected to ground, backprobe Brown/Gray wire terminal at generator field driver harness connector. (Scheme 1) If 12-volt test light illuminates and flashes, go to next step. If 12-volt test light does not illuminate and flash, go to step 4.
  2. Using scan tool, read DTCs. With actuator test still running, wiggle generator harness from generator to Powertrain Control Module (PCM). If no DTCs reset, go to next step. If any DTCs reset, see «SCAN TOOL DTC MESSAGES»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators) table under SELF-DIAGNOSTIC SYSTEM. Repair as necessary. Perform «TEST VER-3»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-3) under VERIFICATION TESTS
  3. Turn ignition switch to OFF position. Inspect wiring and connector for any problems. See «WIRING DIAGRAMS»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__wiring-diagrams). If problem is found, repair as necessary. Perform «TEST VER-3»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-3) under VERIFICATION TESTS. If no problems are found, repair is complete.
  4. Disconnect generator field harness connector. Turn ignition switch to ON position. Using scan tool, actuate generator field driver circuit. Using a 12-volt test light connected to ground, probe terminal No. 1 (Brown/White wire) at generator field harness connector. (Scheme 2) If 12-volt test light illuminates, go to next step. If 12-volt test light does not illuminate, repair open in Brown/White wire between generator field and Auto Shut Down (ASD) relay. See «WIRING DIAGRAMS»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__wiring-diagrams). Perform «TEST VER-3»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-3) under VERIFICATION TESTS.
  5. Turn ignition switch to OFF position. Disconnect Powertrain Control Module (PCM) harness connector C1. Ensure generator field harness connector is still disconnected. Measure resistance between ground and terminal No. 8 (Brown/Gray wire) at PCM harness connector C1. (Scheme 3) If resistance is less than 5 ohms, repair short to ground in Brown/Gray wire between PCM and generator. See «WIRING DIAGRAMS»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__wiring-diagrams). Perform «TEST VER-3»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-3) under VERIFICATION TESTS. If resistance is 5 ohms or greater, go to next step.
  6. Measure resistance of Brown/Gray wire between terminal No. 8 at PCM harness connector C1 and terminal No. 2 at generator field harness connector. (Scheme 2)and (Scheme 3). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or greater, repair open in Brown/Gray wire between PCM and generator. See «WIRING DIAGRAMS»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__wiring-diagrams). Perform «TEST VER-3»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-3) under VERIFICATION TESTS.
  7. Measure resistance between generator field terminals (component side). If resistance is less than 5 ohms, replace generator. See «REMOVAL & INSTALLATION»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__removal-installation). Perform «TEST VER-3»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-3) under VERIFICATION TESTS. If resistance is 5 ohms or greater, replace PCM. Perform «TEST VER-3»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-3) under VERIFICATION TESTS.

DTC is set when with ignition on, the battery temperature sensor, internal to the Powertrain Control Module (PCM), goes above 4.9 volts or below 0.1 volt for more than 3.2 seconds. Possible causes are: faulty PCM.

Diagnostic Procedure

The PCM has detected a fault with the battery temperature sensor which is internal to the PCM. Replace and program the PCM. Perform TEST VER-3 under VERIFICATION TESTS.

DTC is set when with ignition on, and PCM monitoring the ambient air temp sensor voltage, PCM sees the voltage go above 4.9 volts or below 0.1 volt for more than 3.2 seconds. Possible causes are: intermittent condition, ambient air temp sensor voltage below 0.1 volt, high resistance in sensor ground circuit or sensor signal circuit, faulty Front Control Module (FCM).

  1. Turn ignition. Using scan tool, read DTCs. If Good Trip is displayed and equal to zero, go to next step. If not, go to step 7 .
  2. Turn ignition off. Disconnect ambient air temperature sensor harness connector. Turn ignition on. Using scan tool, read ambient air temp sensor voltage. If voltage above 4.9 volts, go to next step. If voltage is not as specified, go to step 4 .
  3. Turn ignition off. Using a jumper wire, jumper across ambient air temperature sensor harness connector. Turn ignition on. Using scan tool, read ambient air temp sensor voltage. If voltage is below 0.1 volt, replace ambient air temperature sensor. Perform «TEST VER-3»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-3) under VERIFICATION TESTS. If voltage is not as specified, go to next step.
  4. Perform a voltage drop test by backprobing between sensor ground circuit at the ambient air temperature sensor harness connector and the FCM harness connector. Start the engine and allow it to idle. If the voltage is below 0.10 volt, go to next step. If voltage is not as specified, repair high resistance in sensor ground circuit. Perform «TEST VER-3»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-3) under VERIFICATION TESTS.
  5. Perform a voltage drop test by backprobing between sensor signal circuit at the ambient air temperature sensor harness connector and the FCM harness connector. Start the engine and allow it to idle. If the voltage is below 0.10 volt, go to next step. If voltage is not as specified, repair high resistance in sensor signal circuit. Perform «TEST VER-3»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-3) under VERIFICATION TESTS.
  6. If there are no possible causes remaining, replace Front Control Module (FCM). Refer to «BODY CONTROL MODULES»(/chrysler/town-country/iv-2000-2005/remont/body-cab-control-systems/#body-control-modules) . Perform «TEST VER-3»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-3) under VERIFICATION TESTS.
  7. With engine running at normal operating temperature, monitor the scan tool parameters related to DTC while wiggling the wiring harness. Look for parameter values to change and/or a DTC to set. Review freeze frame information. If possible, try to duplicate the conditions under which the DTC was set. Refer to any technical service bulletins that may apply. Visually inspect related wiring harness. Look for any chafed, pierced, pinched or partially broken wires. Visually inspect the related wiring harness connectors. Look for broken, bent, pushed out or corroded terminals. If any of these conditions are found, repair as necessary. Perform «TEST VER-3»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-3) under VERIFICATION TESTS. If no conditions were found, test is complete.

DTC is set when with ignition on, the ambient temperature sensor voltage is greater than 4.9 volts at PCM for 3 seconds. Possible causes are: intermittent condition, ambient temperature sensor ground circuit open, sensor signal circuit open or shorted to battery voltage, sensor internal failure, faulty Front Control Module (FCM).

  1. Turn ignition off. Using scan tool, read ambient temperature sensor voltage. If voltage is above 4.8 volts, go to next step. If voltage is not as specified, go to step 7 .
  2. Turn ignition off. Disconnect ambient temperature sensor harness connector. Turn ignition on. Measure voltage of ambient temperature sensor signal circuit. in the ambient temperature sensor harness connector. If voltage is not above 5.2 volts, go to next step. If voltage is above 5.2 volts, repair ambient temperature sensor signal circuit for short to battery voltage. Perform «TEST VER-5»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-5) under VERIFICATION TESTS.
  3. Turn ignition off. Connect a jumper wire between ambient temperature sensor signal circuit and sensor ground circuit in the ambient temperature sensor harness connector. Turn ignition on. Using scan tool, read ambient temperature sensor voltage. If voltage is below 0.1 volt, replace ambient temperature sensor. Perform «TEST VER-5»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-5) under VERIFICATION TESTS. If voltage is not as specified, go to next step.
  4. Turn ignition off. Disconnect Front Control Module (FCM). Measure resistance of ambient temperature sensor signal circuit between ambient temperature sensor harness connector and FCM harness connector. If resistance is below 5.0 ohms, go to next step. If resistance is not as specified, repair ambient temperature sensor signal circuit for an open. Perform «TEST VER-5»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-5) under VERIFICATION TESTS.
  5. Measure resistance of ambient temperature sensor ground circuit between ambient temperature sensor harness connector and FCM harness connector. If resistance is below 5.0 ohms, go to next step. If resistance is not as specified, repair ambient temperature sensor ground circuit for an open. Perform «TEST VER-5»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-5) under VERIFICATION TESTS.
  6. If there are no possible causes remaining, replace Front Control Module (FCM). Refer to «BODY CONTROL MODULES»(/chrysler/town-country/iv-2000-2005/remont/body-cab-control-systems/#body-control-modules) . Perform «TEST VER-5»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-5) under VERIFICATION TESTS.
  7. With engine running at normal operating temperature, monitor the scan tool parameters related to DTC while wiggling the wiring harness. Look for parameter values to change and/or a DTC to set. Review freeze frame information. If possible, try to duplicate the conditions under which the DTC was set. Refer to any technical service bulletins that may apply. Visually inspect related wiring harness. Look for any chafed, pierced, pinched or partially broken wires. Visually inspect the related wiring harness connectors. Look for broken, bent, pushed out or corroded terminals. If any of these conditions are found, repair as necessary. Perform «TEST VER-5»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-5) under VERIFICATION TESTS. If no conditions were found, test is complete.

DTC is set when with ignition on, the ambient temperature sensor voltage is less than .098 volts at PCM for 3 seconds. Possible causes are: intermittent condition, ambient temperature sensor signal circuit shorted to ground or shorted to sensor ground circuit, sensor internal failure, faulty Front Control Module (FCM).

  1. Turn ignition off. Using scan tool, read ambient temperature sensor voltage. If voltage is below 0.3 volts, go to next step. If voltage is not as specified, go to step 6 .
  2. Turn ignition off. Disconnect ambient temperature sensor harness connector. Turn ignition on. Using scan tool, read ambient temperature sensor voltage. If voltage is not above 1.0 volt, go to next step. If voltage is above 1.0 volt, replace ambient temperature sensor. Refer to «BATTERY TEMPERATURE SENSOR»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system) . Perform «TEST VER-5»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-5) under VERIFICATION TESTS.
  3. Turn ignition off. Disconnect Front Control Module (FCM). Measure resistance of ambient temperature sensor signal circuit between chassis ground and ambient temperature sensor harness connector. If resistance is not below 100 ohms, go to next step. If resistance is below 100 ohms, repair ambient temperature sensor signal circuit for short to ground. Perform «TEST VER-5»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-5) under VERIFICATION TESTS.
  4. Measure resistance between ambient temperature sensor signal circuit and sensor ground circuit in the ambient temperature sensor harness connector. If resistance is not below 100 ohms, go to next step. If resistance is below 100 ohms, repair ambient temperature sensor signal circuit for a short to the sensor ground circuit. Perform «TEST VER-5»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-5) under VERIFICATION TESTS.
  5. If there are no possible causes remaining, replace Front Control Module (FCM). Refer to «BODY CONTROL MODULES»(/chrysler/town-country/iv-2000-2005/remont/body-cab-control-systems/#body-control-modules) . Perform «TEST VER-5»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-5) under VERIFICATION TESTS.
  6. With engine running at normal operating temperature, monitor the scan tool parameters related to DTC while wiggling the wiring harness. Look for parameter values to change and/or a DTC to set. Review freeze frame information. If possible, try to duplicate the conditions under which the DTC was set. Refer to any technical service bulletins that may apply. Visually inspect related wiring harness. Look for any chafed, pierced, pinched or partially broken wires. Visually inspect the related wiring harness connectors. Look for broken, bent, pushed out or corroded terminals. If any of these conditions are found, repair as necessary. Perform «TEST VER-5»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-5) under VERIFICATION TESTS. If no conditions were found, test is complete.

DTC is set when with engine running at speed greater than 380 RPM, monitored battery voltage is one volt greater than desired system voltage. Possible causes are: target voltage differs from battery voltage, intermittent condition, generator field driver circuit shorted to ground, shorted generator or defective Powertrain Control Module (PCM).

  1. Turn ignition switch to ON position. Using scan tool, actuate generator field driver circuit. Using a 12-volt test light connected to ground, backprobe Brown/Gray wire terminal at generator field harness connector. (Scheme 1) If 12-volt test light illuminates and flashes, go to next step. If 12-volt test light does not illuminate and flash, go to step 5.
  2. Using scan tool, stop generator field driver actuation, and read target charging voltage. If target charging voltage is 13 volts or greater, go to next step. If target charging voltage is less than 13 volts, go to step 4.
  3. Start engine. Using scan tool, manually set engine speed to 1600 RPM. Using scan tool, read and compare battery voltage and target charging voltage. Observe voltage for up to 5 minutes (if necessary) for a one volt difference between voltage and target charging voltage. If difference between voltage and target charging voltage is less than one volt, go to next step. If difference between voltage and target charging voltage is one volt or greater, replace Powertrain Control Module (PCM). Perform «TEST VER-3»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-3) under VERIFICATION TESTS.
  4. Allow engine running at operating temperature. Using scan tool, monitor parameters related to DTC retrieved, while wiggling generator harness. Look for parameter values to change and/or another DTC to set. Review freeze frame information. If possible, duplicate condition when DTC set. Refer to any Technical Service Bulletins (TSB) that may apply. Inspect harness for any chafed, pinched, pierced or broken wires. Inspect harness connectors for broken, bent pushed out or corroded terminals. If any above conditions are found, repair as necessary. Perform «TEST VER-3»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-3) under VERIFICATION TESTS. If all above conditions are not found, test is complete.
  5. Turn ignition switch to OFF position. Disconnect PCM harness connector C1. Disconnect generator field harness connector. Measure resistance between ground and terminal No. 8 (Brown/Gray wire) at PCM harness connector C1. (Scheme 3) If resistance is less than 5 ohms, repair short to ground in Brown/Gray wire between PCM and generator. Perform «TEST VER-3»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-3) under VERIFICATION TESTS. If resistance is 5 ohms or greater, go to next step.
  6. Measure resistance between ground and No. 2 terminal (Brown/Gray wire) at generator field harness connector. (Scheme 2) If resistance is less than 5 ohms, replace shorted generator. See «REMOVAL & INSTALLATION»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__removal-installation) Perform «TEST VER-3»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-3) under VERIFICATION TESTS. If resistance is 5 ohms or greater, replace PCM. Perform «TEST VER-3»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-3) under VERIFICATION TESTS.

DTC is set when with ignition on and engine speed greater than 1152 RPM, and no other charging system DTCs set, monitored battery voltage is one volt less than charging system lower limit threshold for 14 seconds. PCM turns off field driver and monitors battery voltage. If voltage remains low, DTC P1682 is set. Possible causes are: open in Auto Shut Down (ASD) relay output circuit, high resistance in battery supply circuit between generator and battery, open in field driver circuit, high resistance in ground circuit, defective generator, intermittent condition.

  1. Start engine and allow it to idle. Using scan tool, read target charging voltage. If voltage is not greater than 15.1 volts, go to next step. If voltage is greater than 15.1 volts, go to step 8.
  2. Turn ignition switch to ON position. Measure voltage between generator B+ terminal and positive battery post. (Scheme 1) Start engine. If voltage is 0.4 volt or greater, repair high resistance in Red wire between generator and battery. Perform «TEST VER-3»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-3) under VERIFICATION TESTS. If voltage is less than 0.4 volt, go to next step.
  3. Allow engine to run at operating temperature. Measure voltage between generator case and negative battery post. If voltage is 0.1 volt or greater, repair high resistance in ground circuit between generator case and battery ground side. See «WIRING DIAGRAMS»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__wiring-diagrams). Perform «TEST VER-3»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-3) under VERIFICATION TESTS. If voltage is less than 0.1 volts, go to next step.
  4. Turn all accessories on, manually set engine speed to 1600 RPM. Using scan tool, read target charging and charging voltage. Compare both readings. If difference in voltage is 1.0 volt or greater, go to next step. If difference in voltage is less than 1.0 volt, go to step 8.
  5. Turn ignition switch to OFF position. Disconnect Powertrain Control Module (PCM) harness connector C1. Disconnect generator field harness connector. Measure resistance of Brown/Gray wire between terminal No. 8 at PCM harness connector C1 and terminal No. 2 at generator field harness connector. (Scheme 2)and (Scheme 3). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or greater, repair open in Brown/Gray wire between PCM and generator. See «WIRING DIAGRAMS»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__wiring-diagrams). Perform «TEST VER-3»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-3) under VERIFICATION TESTS.
  6. Ensure generator field driver harness connector is still disconnected. Turn ignition switch to ON position. Using scan tool, actuate generator field driver circuit. Using a 12-volt test light connected to ground, probe terminal No. 1 (Brown/White wire) at generator field driver harness connector. (Scheme 2) If 12-volt test light illuminates brightly, go to next step. If 12-volt test light does not illuminate brightly, repair open in Brown/White wire between ASD relay and generator. Perform «TEST VER-3»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-3) under VERIFICATION TESTS.
  7. If there are no possible causes remaining, replace generator. See «REMOVAL & INSTALLATION»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__removal-installation) Perform «TEST VER-3»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-3) under VERIFICATION TESTS.
  8. Allow engine to run at operating temperature. Using scan tool, monitor parameters related to DTC retrieved, while wiggling wiring harness. Look for parameter values to change and/or another DTC to set. Review freeze frame information. If possible, duplicate condition when DTC set. Refer to any Technical Service Bulletins (TSB) that may apply. Inspect harness for any chafed, pinched, pierced or broken wires. Inspect harness connectors for broken, bent pushed out or corroded terminals. If any above conditions are found, repair as necessary. Perform «TEST VER-3»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators__test-ver-3) under VERIFICATION TESTS. If all above conditions are not found, test is complete.

TEST VER-3

CAUTIONIf Powertrain Control Module (PCM) is replaced, correct Vehicle Identification Number (VIN) and mileage must be programmed or Anti-Lock Brake System (ABS), Air Bag Control Module (ACM), and Sentry Key Immobilizer Module (SKIM) DTCs will be set. Refer to PROGRAMMING in BODY CONTROL MODULES - CARAVAN, TOWN & COUNTRY & VOYAGER article

Note. If vehicle is equipped with Sentry Key Immobilizer System (SKIS), secret key data must be updated for programming information. See SENTRY KEY IMMOBILIZER SYSTEM under PROGRAMMING in BODY CONTROL MODULES - CARAVAN, TOWN & COUNTRY & VOYAGER article.

  1. Inspect vehicle to ensure all engine components are connected. Reassemble and connect components as necessary. Connect scan tool to Data Link Connector (DLC). DLC is located below instrument panel, near steering column. Using scan tool, enter correct Vehicle Identification Number (VIN) and mileage into Powertrain Control Module (PCM). Using scan tool, clear DTCs.
  2. Perform generator output test. Start engine and Increase engine speed to 2000 RPM for at least 30 seconds. Allow engine to idle. Turn ignition switch to OFF, then to ON positions.
  3. Using scan tool, check for stored DTCs. If repaired DTC has reset, repair is not complete. Return to appropriate DTC test under SELF-DIAGNOSTIC TESTS. See «SCAN TOOL MESSAGES»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators) table under SELF-DIAGNOSTIC SYSTEM. If any other DTC exists, perform appropriate test in accordance to DTC retrieved. If no other DTCs exist, repair is complete.

TEST VER-5

CAUTIONIf Powertrain Control Module (PCM) is replaced, correct Vehicle Identification Number (VIN) and mileage must be programmed or Anti-Lock Brake System (ABS), Air Bag Control Module (ACM), and Sentry Key Immobilizer Module (SKIM) DTCs will be set. Refer to PROGRAMMING in BODY CONTROL MODULES - CARAVAN, TOWN & COUNTRY & VOYAGER article

Note. If vehicle is equipped with Sentry Key Immobilizer System (SKIS), secret key data must be updated for programming information. See SENTRY KEY IMMOBILIZER SYSTEM under PROGRAMMING in BODY CONTROL MODULES - CARAVAN, TOWN & COUNTRY & VOYAGER article.

  1. Inspect vehicle to ensure that all engine components are properly installed and connected. Reassemble and reconnect components as necessary.
  2. Connect scan tool to Data Link Connector (DLC). DLC is located below instrument panel, near steering column.
  3. Ensure fuel tank has at least a quarter tank of fuel. Turn off all accessories.
  4. If a comprehensive component DTC was repaired, perform steps 3-6. If a major OBDII Monitor DTC was repaired, skip those steps and continue verification.
  5. After the ignition has been turned off for at least 10 seconds, restart the vehicle and run 2 minutes.
  6. If the Good Trip counter changed to one or more and there are no new DTCs, the repair was successful and is now complete. Erase DTCs and disconnect scan tool.
  7. If another DTC has set, return to «SCAN TOOL MESSAGES»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators) table and follow the path specified for that DTC.
  8. With scan tool, monitor the appropriate pretest enabling conditions until all conditions have been met. Once the conditions have been met, switch screen to appropriate OBDII monitor (audible beeps when the monitor is running).
  9. If monitor ran, and the Good Trip counter changed to one or more, the repair was successful and is now complete. Erase all DTCs and disconnect scan tool.
  10. If the repaired OBDII trouble code has reset or was seen in the monitor while on the road test, the repair is not complete. Check for any related technical service bulletins or flash updates and return to «SCAN TOOL MESSAGES»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators) table.
  11. If another DTC has set, return to «SCAN TOOL MESSAGES»(/chrysler/town-country/iv-2000-2005/remont/charging-system/#charging-system-generators-regulators) table and follow the path specified for that DTC. If any DTCs are present, repair is not complete. Refer to appropriate DTC. If DTCs are not present, repair is complete.

REMOVAL & INSTALLATION

Note. For component removal and installation procedures, refer to CHARGING .

TORQUE SPECIFICATIONS

DESCRIPTIONN.mFt. Lbs.In. Lbs.
Battery Hold Down Clamp Bolt2014.7180
Generator B+ Nut12.49.2110
Battery Terminal Nut435
Generator Mounting Bolt 2.4L28.220.8250
Generator Mounting Bolts 3.3/3.8L54.240
Starter Solenoid Battery Nut 3.3/3.8L11.38.3100
Generator Decoupler109.881

TORQUE SPECIFICATIONS

WIRING DIAGRAMS

Note. For charging system wiring diagram, refer to STARTING/CHARGING .

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