chrysler dakota part8

7/28/2019 chrysler dakota part8

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BATTERY/STARTER/GENERATOR SERVICE

CONTENTS

page page

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 9

STARTER AND STARTER RELAY . . . . . . . . . . . . . 4

GENERAL INFORMATION

Group 8B covers battery, starter and generator ser-vice procedures. For diagnosis of these componentsand their related systems, refer to Group 8A - Bat-

tery/Starting/Charging Systems Diagnostics. Refer to

Group 8W - Wiri ng Diagrams for complete circuit de-

scriptions and diagrams.

BATTERYGENERAL INFORMATION

This section covers battery service procedures only.

For battery maintenance procedures, refer to Group 0

- L ubrication and Maintenance. While battery charg-

ing can be considered a service or maintenance pro-

cedure, this information is located in Group 8A -

Battery/Starting/Charging Systems Diagnostics. This

was done because the battery must be fully charged

before any diagnosis can be performed.

I t is important that the battery, starting, and

charging systems be thoroughly tested and inspected

any time a battery needs to be charged or replaced.

The cause of abnormal discharge, over-charging, or

premature failur e of the battery must be diagnosed

and corrected before a battery is replaced or returned

to service. Refer to Group 8A - Battery/Starting/

Charging Systems Diagnostics.

The factory-installed maintenance-free battery (Fig.

1) has non-removable battery vent caps. Water can-

not be added to this battery. The chemical composi-

tion within the maintenance-free battery reduces

battery gassing and water loss at normal charge and

discharge rates. Therefore, the battery should not re-

quire additional water in normal service.

The factory-installed battery also has a built-in test

indicator (hydrometer). The color visible in the sightglass of the indicator will reveal the battery condi-

tion, as follows:

GreenBattery is fully charged. Black or DarkBattery is discharged. Yellow or BrightE lectrolyte level is low.

I f battery electrolyte level becomes l ow, the batterymust be replaced. However, low electrolyte can becaused by an over-charging condition. Be certain todiagnose charging system before returning vehicle toservice. Refer to Gr oup 8A - Battery/Starting/Charg-ing Systems Diagnostics for more information.

BATTERYREMOVE/INSTALL

(1) Turn ignition switch to OFF position. Make

sure all electri cal accessories are off.

(2) L oosen the cable terminal clamps and remove

both battery cables, negative cable first. I f necessary,

use a puller to remove terminal clamps from battery

posts (Fig. 2).

(3) I nspect the cable terminals for corrosion and dam-

age. Remove corrosion using a wire brush or post andterminal cleaning tool, and a sodium bicarbonate (bak-

ing soda) and warm water cleaning solution (Fig. 3). Re-

place cables that have damaged or deformed terminals.

WARNING: WEAR A SUITABLE PAIR OF RUBBER

GLOVES (NOT THE HOUSEHOLD TYPE) WHEN RE-

MOVING A BATTERY BY HAND. SAFETY GLASSES

SHOULD ALSO BE WORN. IF THE BATTERY IS

CRACKED OR LEAKING, THE ELECTROLYTE CAN

BURN THE SKIN AND EYES.

Fig. 1 Maintenance-Free Battery

BATTERY/STARTER/GENERATOR SERVICE 8B - 1


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(4) Remove battery holddowns (Fig. 4) and remove

battery from vehicle.

(5) I nspect battery tray and holddowns for corro-sion or damage. Remove corrosion using a wire brushand a sodium bicarbonate (baking soda) and warmwater cleaning solution. Paint any exposed baremetal and r eplace any damaged parts.

(6) I nspect the battery case for cracks or otherdamage that could result in electrolyte leaks. Also

check battery terminal posts for looseness. Batterieswith damaged cases or loose posts must be replaced.

(7) Inspect battery built-in test indicator sightglass for indication of battery condition. I f electrolytelevel is low, battery must be replaced. I f battery isdischarged, charge as required. Refer to Group 8A -Battery/Starting/Charging Systems Diagnosis formore information.

(8) I f the battery is to be reinstalled, clean outsideof battery case and top cover with sodium bicarbon-ate (baking soda) and warm water cleaning solution(Fig. 5) to remove acid film. Flush with clean water.

Ensure that cleaning solution does not enter cellsthrough the vent holes. I f the battery is being re-placed, see Specifications to confirm replacement has

correct classification and ratings for the vehicle.

Fig. 2 Remove Battery Terminal Clamp

Fig. 3 Clean Battery Cable Terminal

Fig. 4 Battery Holddown

Fig. 5 Clean Battery

8B - 2 BATTERY/STARTER/GENERATOR SERVICE


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(9) Clean corrosion from battery posts (Fig. 6) with

a wire brush or post and terminal cleaner, and so-

dium bicarbonate (baking soda) and warm water

cleaning soluti on.

(10) Position battery in tray. Ensure that positive

and negative posts are correctly positioned. The cable

terminals must reach the correct battery post with-

out stretching (Fig. 7).

(11) L oosely install battery holddown hardware.

Ensure that battery base is correctly positioned in

tray, then tighten holddowns to 2.2 N m (20 in. lbs.)

torque.

CAUTION: Be certain that battery cables are con-

nected to the correct battery terminals. Reverse po-

larity can damage electrical components.

(12) Place oiled felt washer on battery positive ter-

minal post.

(13) I nstall and ti ghten battery positive cable ter-

minal clamp. T hen install and tighten negative cable

terminal clamp. Both cable clamp bolts require

torque of 8.5 N m (75 in. lbs.).

(14) Apply a thin coating of petroleum jelly or

chassis grease to cable terminals and battery posts.

Fig. 6 Clean Battery Post

Fig. 7 Battery Cables



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STARTER AND STARTER RELAY

GENERAL INFORMATION

This section covers starter and starter relay serviceprocedures only. For diagnostic procedures, refer toGroup 8A - Battery/Starting/Charging Systems Diag-nostics. Service procedures for other starting system

components can be found as follows: battery - see Battery, in this group ignition switch - refer to Group 8D - Ignition Sys-tems clutch pedal position switch - refer to Group 6 -Clutch park/neutral position switch (automatic transmis-sion) - refer to Group 21 - Transmission and TransferCase. wiring harness and connectors - refer to Group 8W- Wiring Diagrams.

STARTER

The starter motor incorporates several features tocreate a reliable, efficient, compact and lightweightunit. A planetary gear system (intermediate trans-mission) is used between the electric motor and pin-ion gear. T his feature makes it possible to reduce thedimensions of the starter. At the same time, it allowshigher armature rotational speed and delivers in-creased torque through the pinion gear to the fly-wheel or drive plate ring gear.

The use of a permanent magnet field on 2.5L en-gine starters also reduces size and weight. This fieldcontains high-strength permanent magnets. Themagnets are aligned according to their polarity andare permanently fixed in the starter field frame.

The starter motors for all engines are activated bya solenoid mounted to the overrunning clutch hous-ing. H owever, the starter motor/solenoid are servicedonly as a complete assembly. I f either componentfails, the entir e assembly must be replaced.

Permanent magnet starters are highly sensitive tohammeri ng, shocks and external pressure.

CAUTION: The 2.5L engine starter motor MUST NOTBE CLAMPED in a vise by the starter field frame.

Doing so may damage the magnets. Starter may beclamped by the mounting flange ONLY.

CAUTION: Do not connect 2.5L engine starter motorincorrectly when tests are being performed. The

permanent magnets may be damaged and renderedunserviceable.

STARTER RELAY

The starter relay i s an I nternational Standards Or-ganization (I SO) type relay. I t is l ocated in the Power

Distribution Center (PDC). T he PDC is attached to

the drivers side inner fender shield, next to the bat-

tery. See underside of PDC cover for relay i dentifica-

tion and location.

STARTER REMOVE/INSTALL2.5L(1) Disconnect battery negative cable. Raise and

support vehicle.

(2) Remove starter heat shield clamp and heat

shield (Fig. 1).

(3) Remove nut from battery lead terminal at

starter solenoid.

(4) R emove nut from solenoid lead terminal atstarter solenoid.

(5) Remove molded starter wiring connector from

starter solenoid.

(6) Remove lower bolt from starter mounting

flange (Fig. 1).

(7) Remove starter upper mounting bolt and nut

from bell housing. Remove starter assembly.

(8) Reverse removal procedure to install. Torque

starter hardware as follows:

starter mounting bolts and nut - 54 Nm (40 ft.

lbs.)

battery lead terminal nut - 10 Nm (90 in. lbs.)

solenoid lead terminal nut - 2.5 Nm (22 in. lbs.)

STARTER REMOVE/INSTALL3.9L/5.2L

TWO-WHEEL DRIVE MODELS

(1) Disconnect battery negative cable. Raise and

support vehicle.

Fig. 1 Starter Remove/Install (2.5L)



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(2) Remove starter lower mounting nut and lock

washer. Then remove starter upper mounting bolt

(Fig. 2).

(3) M ove starter towards front of vehicle until

starter gear housing nose clears bellhousing. Then

tilt starter nose downwards past exhaust pipe (Fi g.

3).(4) Remove nuts from terminal adapter for starter

battery lead and solenoid lead connector (Fig. 4).(5) Remove starter motor.(6) Reverse removal procedure to install. Torque

starter hardware as follows: starter mounting bolt - 68 Nm (50 ft. lbs.) starter mounting nut - 27 Nm (20 ft. lbs.) battery lead terminal nut - 10 Nm (90 in. lbs.) solenoid lead terminal nut - 2.5 Nm (22 in. lbs.)

FOUR-WHEEL DRIVE MODELS

(1) Remove battery negative cable. Raise and sup-

port vehicle.(2) Remove front axle skid plate, if so equipped.

Refer to Gr oup 13 - Frame and Bumpers for proce-dure.

(3) Remove lower starter mounting nut and lockwasher (Fig. 2). Access from front of vehicle with along extension.

(4) L ower vehicle and remove the 15mm interme-diate steering shaft coupler bolt (Fi g. 5).

(5) Rotate coupler clip on the steering shaft andslide upper half of shaft toward the rear of vehicle.

(6) Remove upper starter mounting bolt.

(7) Move starter towards front of vehicle until itclears lower mounting stud, then lift upwards to gain

access to wiring connector (Fi g. 6).

(8) Remove nuts from terminal adapter for starter

battery lead and solenoid lead connector (Fig. 4).(9) Remove starter motor.(10) Reverse removal procedure to install. Torque

starter hardware as follows: starter mounting bolt - 68 Nm (50 ft. lbs.) starter mounting nut - 27 N m (20 ft. lbs.) battery lead terminal nut - 10 Nm (90 in. lbs.) solenoid lead terminal nut - 2.5 Nm (22 in. lbs.)

Fig. 2 Starter Mounting Hardware (3.9L/5.2L)

Fig. 3 Remove/Install Starter (3.9L/5.2L-2WD)

Fig. 4 Remove/Install Starter Connector (3.9L/5.2L)



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intermediate steering shaft coupler bolt - 47 N m

(35 ft. lbs.)STARTER RELAY REMOVE/INSTALL

(1) Disconnect battery negative cable.

(2) Remove starter relay by unplugging unit from

Power Distribution Center (PDC) (Fig. 7). See under-

side of PDC cover for relay location.

(3) I nstall starter relay by aligning relay terminals

with cavities in PDC and plugging relay i n.

(4) Connect negative cable to battery.

(5) Test relay operation.

Fig. 5 Intermediate Steering Shaft

Fig. 6 Remove/Install Starter (3.9L/5.2L-4WD)

Fig. 7 Power Distribution Center



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GENERATOR

GENERAL INFORMATION

This section covers generator service procedures

only. For generator or charging system diagnosis, re-

fer to Group 8A - Battery/Starting/Charging SystemsDiagnostics.

The generator is belt-driven by the engine. All en-gines use serpentine drive. The generator is servicedonly as a complete assembly. I f the generator fails forany reason, the entir e assembly must be replaced.

Three generator output ratings are available onthis vehicle, depending upon optional equipment. Becertain that the replacement generator has the sameoutput rating as the original unit. Refer to Group 8A- Battery/Starting/Charging Systems Diagnostics andsee Specifications.

The generator field control (voltage regulator) cir-

cuitry is internal to the P owertrain Control Module(PCM). I f faulty, the entire PCM must be r eplaced.Refer to Group 14 - Fuel System for PCM serviceprocedure.

GENERATOR REMOVE/INSTALL2.5L

WARNING: DISCONNECT NEGATIVE CABLE FROMBATTERY BEFORE REMOVING BATTERY OUTPUTWIRE FROM GENERATOR. FAILURE TO DO SO

CAN RESULT IN INJURY.

(1) Disconnect battery negative cable.(2) Remove generator drive belt. Refer to Group 7 -

Cooli ng System for procedure.(3) Remove the generator pivot and mounting bolts

(Fig. 1 or 2). Position generator for access to wireconnectors.

(4) Remove nuts from harness holddown, batteryterminal, ground terminal and 2 field terminals (F ig.3). Remove wire connectors.

(5) Remove the generator.(6) Reverse removal procedure to install. Torque

generator hardware as follows: generator mounting bolt - 54 Nm (40 ft. lbs.) generator pivot bolt - 54 Nm (40 ft. lbs.)

battery terminal nut - 8.5 N

m (75 in. lbs.) ground terminal nut - 8.5 N m (75 in. lbs.) harness holddown nut - 8.5 Nm (75 in. lbs.) field terminal nuts - 2.8 N m (25 in. lbs.)

CAUTION: Never force a belt over a pulley rim us-ing a screwdriver. The synthetic fiber of the belt can

be damaged.

CAUTION: When installing a serpentine accessorydrive belt, the belt MUST be routed correctly. Thewater pump will be rotating in the wrong direction if

the belt is installed incorrectly, causing the engine

to overheat. See the belt routing label in enginecompartment, or refer to Belt Schematics in Group

7 - Cooling System.

GENERATOR REMOVE/INSTALL3.9L/5.2L

WARNING: DISCONNECT NEGATIVE CABLE FROMBATTERY BEFORE REMOVING BATTERY OUTPUTWIRE FROM GENERATOR. FAILURE TO DO SO

CAN RESULT IN INJURY.

(1) Disconnect battery negative cable.

Fig. 1 Remove/Install Generator (2.5L w/A/C)

Fig. 2 Remove/Install Generator (2.5L w/o A/C)



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(2) Remove generator drive belt. Refer to Group 7 -

Cooli ng System for procedure.

(3) Remove the generator pivot and mounting bolts

(Fig. 4). Position generator for access to wire connec-

tors.

(4) Remove nuts from harness holddown, batteryterminal, ground terminal and 2 field terminals (F ig.5). Remove wire connectors.

(5) Remove the generator.(6) Reverse removal procedure to install. Torque

generator hardware as follows: generator mounting bolt - 41 Nm (30 ft. lbs.) generator pivot bolt - 41 Nm (30 ft. lbs.) battery terminal nut - 8.5 N m (75 in. lbs.)

ground terminal nut - 8.5 N

m (75 in. lbs.) harness holddown nut - 8.5 N m (75 in. lbs.) field terminal nuts - 2.8 N m (25 in. lbs.)

CAUTION: Never force a belt over a pulley rim us-ing a screwdriver. The synthetic fiber of the belt can

be damaged.

CAUTION: When installing a serpentine accessorydrive belt, the belt MUST be routed correctly. Thewater pump will be rotating in the wrong direction if

the belt is installed incorrectly, causing the engine

to overheat. See the belt routing label in enginecompartment, or refer to Belt Schematics in Group7 - Cooling System.

Fig. 3 Remove/Install Generator Connectors

Fig. 4 Remove/Install Generator (3.9L/5.2L)

Fig. 5 Remove/Install Generator Connectors



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SPECIFICATIONS

BATTERYSPECIFICATIONS

STARTINGSYSTEM SPECIFICATIONS

BATTERY CLASSIFICATIONS AND RATINGS

STARTER AND SOLENOID TESTING SPECIFICATIONS



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CHARGING SYSTEM SPECIFICATIONS

GENERATOR RATINGS


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