Charging System - Service Information: Overview Dodge Journey I

DESCRIPTION

The charging system consists of

1. Generator
2. Decoupler Pulley (2.4L and Diesel Only)
3. Electronic Voltage Regulator (EVR) circuitry within the Powertrain Control Module (PCM)
4. Ignition switch (refer to «IGNITION CONTROL - SERVICE INFORMATION»(ref-353602) for information)
5. Battery (refer to «BATTERY SYSTEM»(ref-353573) for information)
6. Inlet Air Temperature (calculated battery temperature) (If equipped)
7. Voltmeter (refer to «INSTRUMENT CLUSTER - SERVICE INFORMATION»(ref-353595) for information if equipped)
8. Wiring harness and connections (refer to «SYSTEM WIRING DIAGRAMS»(ref-313026) for information)
9. Accessory drive belt (refer to «COOLING»(ref-353584) for more information)

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The charging system is turned on and off with the Powertrain Control Module (PCM) (2) and ignition switch with engine running. The field circuit will not be energized until engine is running and ignition switch is on. This voltage is connected through the PCM (2) and supplied to the generator field circuit (1) at the back of the generator (6). The generator (6) is internally grounded through the generator case ground (8). The generator (6) regulates the field using Pin 1 of the field connector (High side driver).

The generator (6) is driven by the engine through a serpentine belt and pulley or decoupler pulley arrangement.

The PCM (2) receives a voltage input from the generator (6) via the B+ sense circuit (10) and also a battery sense input (3) from the Gateway (Totally Integrated Power Module, Integrated Power Module) (4), 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 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 PCM (2).

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. Refer to INSTRUMENT CLUSTER - SERVICE INFORMATION for additional information.

Voltage is monitored at B+ sense circuit (10) to insure the cable is connected. If the B+ circuit (generator output) (9) cable is loose anywhere in the circuit the B+ sense circuit (10) will show high voltage. This condition causes the PCM (2) to shut down the generator field circuit (1). Because of this feature, pin 2 of the field connector is internally connected to the B+ circuit (9).

The diesel generator is internally regulated. The generator and PCM communicate for diagnostics, etc. If the generator regulator becomes disconnected from the PCM it will operate, but in a default mode.

The generator is belt-driven by the engine. It is serviced only as a complete assembly. If the generator fails for any reason, the entire assembly must be replaced. The generator produces DC voltage.

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.

The Y type stator winding connections deliver the induced AC current to positive and negative diodes for rectification. From the diodes, rectified DC current is delivered to the vehicles electrical system through the generator, battery, and ground terminals.

Noise emitting from the generator may be caused by

1. Worn, loose or defective bearings
2. Loose or defective drive pulley
3. Incorrect, worn, damaged or misadjusted drive belt
4. Loose mounting bolts
5. Misaligned drive pulley
6. Defective stator or diode
7. Damaged internal fins

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1. Remove engine cover.
2. Disconnect and isolate the negative battery cable.
3. Remove accessory drive belt. Refer to «Cooling/Accessory Drive/BELT, Serpentine - Removal»(ref-353584-S03638748182010011200000) .
4. Disconnect battery cable from generator.
5. Disconnect electrical connector from generator.
6. Remove cap from idler pulley mounting bolt.
7. Remove idler pulley bolt.
8. It may be necessary to remove the two engine mounting bolts (2) from the right engine mount (1) and reposition engine in order to remove the lower generator mounting bolt. Reposition ground strap (3) if required. Refer to «Engine/Engine Mounting/INSULATOR, Engine Mount - Removal»(ref-353574-S41762128812010011200000) .
9. Remove lower generator mounting bolt.
10. Remove upper generator mounting bolt.
11. Remove generator.

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1. Disconnect and isolate negative battery cable.
2. Remove underbody air dam.
3. Remove right front wheelhouse splash shield. Refer to «Cooling/Accessory Drive/BELT, Serpentine - Removal»(ref-353584-S03638748182010011200000) .
4. Remove generator drive belt. Refer to «Cooling/Accessory Drive/BELT, Serpentine - Removal»(ref-353584-S03638748182010011200000) . NOTE: Do not disconnect the A/C lines when relocating the A/C compressor. CAUTION: Support the A/C compressor when relocating. Failure to properly support the A/C compressor can cause damage to the lines and or seals. This can cause a leak in the A/C system.
5. Relocate A/C compressor. Refer to «Heating and Air Conditioning/Plumbing/COMPRESSOR, A/C - Removal»(ref-353571-S03338883732010011200000) . CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.
6. Unsnap plastic protective cover (1) from B+ mounting stud.
7. Remove B+ terminal mounting nut (2) and B+ terminal (3) from generator.
8. Disconnect field wire electrical connector (4) by pushing on connector tab.
9. Remove bolt and lower idler pulley.
10. Remove upper mounting bolt (3) from generator (1).
11. Remove lower mounting bolt (2) from generator (1).
12. Remove generator (1) from engine mounting bracket.
13. Rotate generator so that the pulley faces down.
14. Position generator in order to move past the A/C compressor and out of vehicle.

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1. Disconnect and isolate negative battery cable. CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.
2. Remove generator drive belt. Refer to «Cooling/Accessory Drive/BELT, Serpentine - Removal»(ref-353584-S03638748182010011200000) .
3. Unsnap plastic protective cover (1) from B+ mounting stud.
4. Remove B+ terminal mounting nut (2) and B+ terminal (3) at top of generator.
5. Disconnect field wire electrical connector (4) by pushing on connector tab.
6. Remove upper mounting bolts (3) from generator (1).
7. Remove lower mounting bolt (2) from generator (1).
8. Remove generator (1) from engine mounting bracket.

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1. Disconnect and isolate negative battery cable.
2. Remove generator drive belt. Refer to «Cooling/Accessory Drive/BELT, Serpentine - Removal»(ref-353584-S03638748182010011200000) .
3. Unsnap plastic protective cover (4) from B+ mounting stud.
4. Remove B+ terminal mounting nut (3) and B+ terminal (2) at top of generator.
5. Disconnect field wire electrical connector (1) by pushing on connector tab.
6. Remove short mounting bolt (3) from generator (1).
7. Remove long mounting bolt (2) from generator (1).
8. Remove generator (1) from engine mounting bracket.

Scheme 46

1. If reinstalling the old generator, install a generator mounting bolt and tap bushing out slightly to ease mounting of generator.
2. Install generator.
3. Loosely install lower generator mounting bolt.
4. Install upper generator mounting bolt.
5. Tighten generator mounting bolts to 54 N.m (40 ft. lbs.).
6. If removed, install two engine mounting bolts (2) to right engine mount (1). Reposition ground strap (3) if required. Refer to «Engine/Engine Mounting/BRACKET, Engine Mount - Installation»(ref-353586-S05039204382010011200000) .
7. Install idler pulley and tighten bolt. Refer to «Cooling/Accessory Drive/PULLEY, Idler - Installation»(ref-353584-S12092423862010011200000) .
8. Install idler bolt cap.
9. Connect battery cable to generator and tighten nut to 10 N.m (88.5 in. lbs.).
10. Connect electrical connector to generator.
11. Install accessory drive belt. Refer to «Cooling/Accessory Drive/BELT, Serpentine - Installation»(ref-353584-S15414070972010011200000) .
12. Reconnect negative battery cable.
13. Install engine cover.