Charging System

WARNING
To avoid personal injury and/or vehicle damage, refer to the service precautions at the
beginning of this section.

General Information

An automobile’s charging system provides electrical power for the operation of the ignition,
starting system, and all electrical accessories. The battery serves as a storage device
holding a supply of electricity and is regenerated by the generator when the engine is
running. The generator is constantly in motion while the engine is running. To prevent too
much energy from being stored in the battery the generator is equipped with a regulating
device designed to read the amount of voltage in the battery and to turn itself on and off at
specific times to maintain the proper charge. On newer vehicles, the computer also
maintains a vigil on battery storage capacity activating the regulator when needed.

Storage batteries are a chemical device incorporating parallel lead plates in a tank
containing a solution of sulfuric acid and water. Adjacent plates are dissimilar and the
chemical reaction of the two dissimilar plates produces electrical energy. The chemical
reaction is reversible, so that when the generator is producing current greater than that
produced by the battery, electricity is forced into the battery, and the battery is returned to
full charge.

The generator is belt driven by a pulley from the engine’s crankshaft. Generators actually
produce alternating current (AC) commonly used in homes. As the current leaves the
generator it is converted to direct current (DC) that is used by the storage battery, ignition
and accessories. A generator contains a rotating field winding (or rotor), a stationary
induction winding (or stator) and a diode assembly (or rectifier bridge). There is also a
voltage regulator built into the generator and two internal fans to promote cooling to the
circuits.

As the generator spins with engine rpm, two stationary carbon brushes ride on two rotating
slip rings located at one end of the rotor. The rotor field winding is attached at either end to
a slip ring permitting current to flow through the field winding. The regulator monitors the
battery and stator voltage and changes the rotor field current to adjust generator output.
The conversion of AC to DC is done by the Diode Rectifier Bridge. An alternating magnetic
field is formed as the rotor assembly rotates within the stator winding. This spinning
induces an AC voltage into the stator. Depending on the speed of the rotor and the
magnetic field the voltage provided to the stator will vary.
Generator

Voltage Test

1. Make sure the engine is OFF, and turn the headlights on for 15-20 seconds to
remove any surface charge from the battery.
2. Using a DVOM set to volts DC, probe across the battery terminals.
3. Measure the battery voltage.
4. Write down the voltage reading and proceed to the next test.

Load Test

1. With the engine running, turn on the blower motor and the high beams (or other
electrical accessories to place a load on the charging system).
2. Increase and hold engine speed to 2000 rpm.
3. Measure the voltage reading at the battery.
4. The voltage should increase at least 0.5 volts from the voltage test. If the voltage
does not meet specifications, the charging system is malfunctioning.

NOTE: Faulty wiring and other problems can cause the charging system to malfunction.
Further testing, which is not covered by this book, will reveal the exact component failure.
When all affected wires and components have been confirmed in good working order,
under and overcharging is caused by a defective generator or internal regulator.
Replacement of these components will then repair the condition

No-Load Test

1. Connect a tachometer to the engine

CAUTION
Place the transmission in P (Park), set the emergency brake and chock the rear
wheels to prevent vehicle movement.

2. Turn off all electrical loads (radio, blower motor, wipers, etc.)

NOTE: it is a good practice to turn off all electrical accessories prior to shutting off
the engine.

3. Start the engine and increase engine speed to 1500 rpm.

4. Measure the voltage reading at the battery with the engine holding a steady 1500
rpm. Voltage should have raised at least 0.5 volts, but no more than 2.5 volts.
5. If the voltage does not go up more than 0.5 volts, the generator is not charging. If
the voltage goes up more than 2.5 volts, the generator is overcharging.

NOTE: Faulty wiring and other problems can cause the charging system to malfunction.
Further testing, which is not covered by this book, will reveal the exact component failure.
When all affected wires and components have been confirmed in good working order,
under and overcharging is caused by a defective generator or internal regulator.
Replacement of these components will then repair the condition.

Removal & Installation

4.2L Engine

To Remove:

1. Disconnect the negative battery cable from the battery.

2. Remove drive belt from the pulleys.
3. Detach the A/C line mounting bracket from the engine lift hook.
4. Detach the right engine lift hook from the engine.

Generator removal and installation

 5. Detach the generator from the engine.
6. Detach the battery positive cable from the generator.

To Install:

1. Attach the battery positive cable to the generator. Torque the nut to 80 in-lb (9
Nm).
2. Attach the generator to the engine. Torque the bolts to 37 ft-lb (50 Nm).
3. Attach the right engine lift hook to the engine. Torque the bolts to 37 ft-lb (50 Nm).
4. Attach the A/C line mounting bracket to the engine lift hook. Torque the bolt to 89
in-lb (10 Nm).
5. Install the drive belt onto the pulleys.
6. Connect the negative battery cable to the battery.

5.3L & 6.0L Engines

To Remove:

1. Disconnect the negative battery cable from the battery.

2. Remove the drive belt from of the pulleys.
3. Disconnect the generator connector.
4. Detach the generator cable from the generator.

Generator removal and installation

 5. Detach the generator from the engine.

To Install:

1. Attach the generator to the engine. Torque the bolts to 37 ft-lb (50 Nm).
2. Attach the generator cable to the generator. Torque the nut to 80 in-lb (9 Nm).
3. Connect the generator connector.
4. Install the accessory drive belt on to the pulleys.
5. Connect the negative battery cable to the battery.