To the top of the document
Captiva
To Previous PageTo Next Page
GMDE Start PageLoad static TOCLoad dynamic TOCHelp?

SECTION

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE



C7A11C01
Display graphicTranslations of text in graphics


Generator

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the intake air temperature (IAT) sensor connector.
  3. Remove the air cleaner assembly. Refer to Section 1C1, Engine Mechanical – FAM II 2.4D.


  4. C7A11C22
    Display graphicTranslations of text in graphics


  5. Disconnect the harness connector from the generator.
  6. Remove the generator upper bracket mounting bolts and the generator-to-intake manifold strap bracket bolts.


  7. C7A11E76
    Display graphicTranslations of text in graphics


  8. Raise and suitably support the vehicle.
  9. Remove the serpentine accessory drive belt. Refer to Section 1C1, Engine Mechanical – FAM II 2.4D.
  10. Disconnect the generator lead-to-starer motor wire from the generator.


  11. C7A11E77
    Display graphicTranslations of text in graphics


    Notice : Do not remove the generator through bolt, nut and washers at this stage.

  12. Loosen the nut and washers which hold the generator lower bracket-to-generator bolt.
  13. Remove the generator lower support bracket bolts.
  14. Carefully remove the generator with the lower support bracket.


  15. J3B11E08
    Display graphicTranslations of text in graphics


  16. Remove the generator-to-lower support bracket through bolt, nut and washer.


J3B11E08
Display graphicTranslations of text in graphics


Installation Procedure

  1. Install the generator lower support bracket to the generator and insert the through bolt.
  2. Notice : Do not tighten the generator through bolt at this stage.



    C7A11E77
    Display graphicTranslations of text in graphics


  3. Install the generator and the lower support bracket assembly to the engine block.
  4. Tighten
    Tighten the generator lower support bracket bolts to 25 N•m (18 lb-ft).

  5. Tighten the generator-to-generator lower support bracket through bolt.
  6. Tighten
    Tighten the generator through bolt to 40 N•m (30 lb-ft).



    C7A11E76
    Display graphicTranslations of text in graphics


  7. Connect the generator lead-to-starer motor wire to the generator.
  8. Install the serpentine accessory drive belt. Refer to Section 1C1, Engine Mechanical – FAM II 2.4D.
  9. Lower the vehicle.


  10. C7A11C0X
    Display graphicTranslations of text in graphics


  11. Install the generator upper bracket and the generator-to-intake manifold strap bracket.
  12. Install the generator upper bracket mounting bolts and the generator-to-intake manifold strap bracket bolts.
  13. Tighten
    Tighten the generator upper bracket retaining bolts (1) to 25 N·m (18 lb-ft) and the bolt (2) to 35 N•m (26 lb-ft).
    Tighten the generator-to-intake manifold strap bracket retaining bolt (3) to 35 N•m (26 lb-ft) and the bolt (4) to 25 N•m (18 lb-ft).



    C7A11C01
    Display graphicTranslations of text in graphics


  14. Connect the harness connector to the generator.
  15. Install the air cleaner assembly and connect the IAT sensor connector. Refer to Section 1C1, Engine Mechanical – FAM II 2.4D.
  16. Connect the negative battery cable.


C7A11C0N
Display graphicTranslations of text in graphics


Starter

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the transaxle rear mount bracket. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D.


  3. C7A11E79
    Display graphicTranslations of text in graphics


  4. Remove the nuts which secure the battery lead wire and the generator lead wire from the starter solenoid terminals.


  5. C7A11E80
    Display graphicTranslations of text in graphics


  6. Remove the starter-to-engine block mounting bolt and the starter-to-transmission mounting bolt.
  7. Remove the starter assembly.


C7A11E80
Display graphicTranslations of text in graphics


Installation Procedure

  1. Install the starter mounting bolts.
  2. Tighten
    Tighten the starter-to-engine block mounting bolt to 75 N•m (55 lb-ft).
    Tighten the transmission-to-starter mounting bolt to 75 N•m (55 lb-ft).



    C7A11E79
    Display graphicTranslations of text in graphics


  3. Install the ignition solenoid nut and the generator lead wire nut to the starter solenoid terminals.
  4. Tighten
    Tighten the starter solenoid terminal-to-battery lead wire nut to 15 N•m (11 lb-ft).
    Tighten the starter solenoid terminal-to-generator lead wire nut to 15 N•m (11 lb-ft).



    C7A11C0N
    Display graphicTranslations of text in graphics


  5. Install the transaxle rear mount bracket. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D.
  6. Tighten
    Tighten the transaxle rear mount bracket retaining bolts to 90 N•m (66 lb-ft).
    Tighten the transaxle rear mount-to-bracket through bolt and nut to 90 N•m (66 lb-ft).



C7A11E53
Display graphicTranslations of text in graphics


Battery and Battery Tray

Removal Procedure

  1. Disconnect the batty negative cable and then disconnect the battery positive cable.
  2. Loosen the nuts that fasten the battery hold-down bar bracket.


  3. C7A11E54
    Display graphicTranslations of text in graphics


  4. Remove the battery hold-down bar bracket with the nuts attached.
  5. Remove the battery from the battery tray.


  6. C7A11E56
    Display graphicTranslations of text in graphics


  7. Remove the ECM. Refer to Section 1F2, Engine Controls – FAM II 2.4D.


  8. C7A11E58
    Display graphicTranslations of text in graphics


  9. Remove the engine fuse block upper cover.
  10. Remove the engine fuse block retaining bolts.


  11. C7A11E59
    Display graphicTranslations of text in graphics


  12. Remove the engine fuse box from the lower cover.
  13. Remove the engine fuse block lower cover retaining nuts.
  14. Notice : Remove the power steering oil pump to ease to remove the engine fuse box, if necessary.

  15. Separate the engine fuse block from the welded bolts on the battery tray and the body frame.


  16. C7A11E60
    Display graphicTranslations of text in graphics


  17. Check the battery tray for obvious cracks or damage.
  18. Remove the battery tray retaining bolts.
  19. Remove the battery tray.


C7A11E60
Display graphicTranslations of text in graphics


Installation Procedure

  1. Install the battery tray.
  2. Install the battery tray retaining bolts.
  3. Tighten
    Tighten the battery tray bolts to 10 N•m (89 lb-in.).



    C7A11E59
    Display graphicTranslations of text in graphics


  4. Install the engine fuse block.
  5. Tighten
    Tighten the engine fuse block lower cover retaining nuts to 10 N•m (89 lb-in.).



    C7A11E58
    Display graphicTranslations of text in graphics


  6. Install the engine fuse block retaining bolts.
  7. Tighten
    Tighten the engine fuse block retaining bolts to 3 N•m (27 lb-in.).

  8. Install the engine fuse block upper cover.


  9. C7A11E56
    Display graphicTranslations of text in graphics


  10. Install the ECM. Refer to Section 1F2, Engine Controls – FAM II 2.4D.


  11. C7A11E54
    Display graphicTranslations of text in graphics


  12. Install the battery.
  13. Tighten
    Tighten the battery hold-down bar bracket retaining nuts to 4 N•m (35 lb-in.).

  14. Connect the positive battery cable.
  15. Connect the negative battery cable.

UNIT REPAIR



T3B11E09
Display graphicTranslations of text in graphics


Starter Motor

Disassembly Procedure

    1. Remove the starter. Refer to "Starter" in this section.
    2. Remove the starter through-bolts.


    3. T3B11E11
      Display graphicTranslations of text in graphics


    4. Remove the commutator end frame and brush holder assembly.
    5. Inspect the brushes, the pop-out springs, and the brush holders for wear and damage. Replace the assembly, if needed.


    6. T3B11E11
      Display graphicTranslations of text in graphics


    7. Check the armature to see if it turns freely. If the armature does not turn freely, break down the assembly immediately, starting with Step 14. Otherwise, give the armature a no-load test.


    8. T3B11E12
      Display graphicTranslations of text in graphics


      Notice : Complete the testing in a minimum amount of time to prevent overheating and damaging the solenoid.

      Important : If the specified current draw does not include the solenoid, deduct from the armature reading the specified current draw of the solenoid hold-in winding.

    9. To begin the no-load test, close the switch and compare the rpm, the current, and the voltage readings with the specifications. Refer to "Starter Specifications" in this section. Make disconnections only with the switch open. Use the test results as follows:
      1. Rated current draw and no-load speed indicate a normal condition for the starter motor.
      2. Low rpm combined with high current draw is an indication of excessive friction caused by tight, dirty, or worn bearings, a bent armature shaft; a shorted armature; or a shorted field coils.
      3. Failure to operate with high current draw indicates a direct ground in the terminal or fields, or "frozen" bearings.
      4. Failure to operate with no current draw indicates an open field circuit, open armature coils, broken brush springs, worn brushes, high insulation between the commutator bars, or other causes which would prevent good contact between the brushes and the commutator.
      5. Low, no-load speed and low current indicate high internal resistance and high current draw, which usually mean shorted fields.


      T3B11E13
      Display graphicTranslations of text in graphics


    10. Remove the solenoid assembly screws.


    11. T3B11E13
      Display graphicTranslations of text in graphics


    12. Remove the field connector nut. Disconnect the field connector.


    13. T3B11E15
      Display graphicTranslations of text in graphics


    14. Remove the plunger return spring.


    15. T3B11E16
      Display graphicTranslations of text in graphics


      Important : If the solenoid is not removed from the starting motor, the connector strap terminals must be removed from the terminal on the solenoid before making these tests.

    16. Test the solenoid windings by checking the current draw.
      1. Check the hold-in windings by connecting an ammeter in series with a 12-volt battery, the switch terminal, and to ground.
      2. Connect the carbon pile across the battery.
      3. Adjust the voltage to 10 volts. The ammeter reading should be 13 to 19 amperes.Current will decrease as the windings heat up. Current draw readings that are over specifications indicate shorted turns or a ground in the windings of the solenoid. Both conditions require replacement of the solenoid. Current draw readings that are under specifications indicate excessive resistance. No reading indicates an open circuit.

      Important : Current will decrease as the windings heat up. Current draw readings that are over specifications indicate shorted turns or a ground in the windings of the solenoid. Both conditions require replacement of the solenoid. Current draw readings that are under specifications indicate excessive resistance. No reading indicates an open circuit.

    17. Check both windings, connecting them according to the preceding test.
      1. Ground the solenoid motor terminal.
      2. Adjust the voltage to 10 volts. The ammeter reading should be 59 to 79 amperes.
      3. Check the connections and replace the solenoid, if necessary.


      T3B11E17
      Display graphicTranslations of text in graphics


    18. Slide the field frame with enclosed armature assembly away from the starter assembly.
    19. Remove the shield.


    20. T3B11E18
      Display graphicTranslations of text in graphics


    21. Separate the field frame from the armature.


    22. T3B11E19
      Display graphicTranslations of text in graphics


    23. Inspect the shaft and the pinion for discoloration, damage, or wear. Replace, if necessary.
    24. Inspect the armature commutator. If the commutator is rough, it should be turned down. The outside diameter of the commutator must measure at least 26.9 - 27.1mm (1.059 - 1.067 in.) after it is undercut or turned. Do not turn out-of-round commutators.
    25. Inspect the points where the armature conductors join the commutator bars. Make sure they have a good connection. A burned commutator bar is usually evidence of a poor connection.
    26. If test equipment is available, check the armature for short circuits by placing it on a growler, and holding back a saw blade over the armature core while the armature is rotated. If the saw blade vibrates, replace the armature.
    27. Recheck the armature after cleaning between the commutator bars. If the saw blade vibrates, replace the armature.


    28. T3B11E20
      Display graphicTranslations of text in graphics


    29. Remove the locking ring from the groove in the driveshaft.


    30. T3B11E21
      Display graphicTranslations of text in graphics


    31. Remove the pinion stop and the drive from the driveshaft.


    32. T3B11E13
      Display graphicTranslations of text in graphics


    33. If not done in the previous steps, remove the screws that hold the solenoid assembly into the housing, and remove the nut from the field coil connector.


    34. T3B11E15
      Display graphicTranslations of text in graphics


    35. Rotate the solenoid 90 degrees and remove it along with the return spring.


    36. T3B11E22
      Display graphicTranslations of text in graphics


    37. Remove the plunger with the boot and the shift lever assembly. Test the solenoid windings, if not done in Step 11.


    38. T3B11E23
      Display graphicTranslations of text in graphics


      Important : The pinion clearance must be correct to prevent the buttons on the shift lever yoke from rubbing on the clutch collar during the cranking.

    39. When the starter motor is disassembled and the solenoid is replaced, it is necessary to check the pinion clearance.


    40. T3B11E24
      Display graphicTranslations of text in graphics


    41. Disconnect the motor field coil connector from the solenoid motor terminal and carefully insulate the connector.
    42. Connect one 12-volt battery lead to the solenoid switch terminal and the other to the starter frame.
    43. Flash a jumper lead momentarily from the solenoid motor terminal to the starter frame, allowing shifting of the pinion in the cranking position, where it will remain until the battery is disconnected.
    44. Important : A means for adjusting the pinion clearance is not provided on the starter motor. If the clearance does not fall within the limits, check for improper installation and replace all worn parts.

    45. Push the pinion back as far as possible to take up any movement, and check the clearance with a feeler gauge. The clearance should be 0.25 to 3.56 mm (0.01 to 0.14 inch).


    T3B11E21
    Display graphicTranslations of text in graphics


    Assembly Procedure

    1. Install the drive and the pinion stop on the driveshaft.


    2. T3B11E20
      Display graphicTranslations of text in graphics


    3. Install the lock ring into the groove on the driveshaft and insert the collar.


    4. T3B11E22
      Display graphicTranslations of text in graphics


    5. Install the shift lever, washer and the cushion.


    6. T3B11E19
      Display graphicTranslations of text in graphics


    7. Lubricate the drive end of the armature shaft with lubricant.


    8. T3B11E15
      Display graphicTranslations of text in graphics


    9. Position the solenoid assembly.


    10. T3B11E13
      Display graphicTranslations of text in graphics


    11. Fasten the solenoid assembly with the screws.
    12. Tighten
      Tighten the starter solenoid assembly screws to 8 N•m (71 lb-in).

    13. Install the field coil connection to the starter terminal. Install the nut.
    14. Tighten
      Tighten the starter field coil connector nut to 8 N•m (71 lb-in).



      T3B11E17
      Display graphicTranslations of text in graphics


    15. Position the armature assembly into the field frame.
    16. Place the shield on the armature and field frame assembly.
    17. Install the armature and field frame assembly with the shield into the starter housing.


    18. T3B11E22
      Display graphicTranslations of text in graphics


    19. Position the commutator end frame/brush holder assembly, lining up the end frame holes with the through-bolt holes in the housing.


    20. T3B11E09
      Display graphicTranslations of text in graphics


    21. Install the starter through-bolts.
    22. Install the starter. Refer to "Starter"in this section.
    23. Tighten
      Tighten the starter through-bolts to 6 N•m (53 lb-in).



    T3B11E25
    Display graphicTranslations of text in graphics


    Generator

    Disassembly Procedure

    1. Remove the generator. Refer to "Generator"in the On-Vehicle Service section.
    2. Mark a match line that cannot easily be removed on the end frame to make assembly easier.
    3. Pry off the plastic cover to expose the stator connections.


    4. T3B11E26
      Display graphicTranslations of text in graphics


      Notice : If the stator connections are not welded, melt the lead. Avoid excessive heating, as it can damage the diodes in the rectifier bridge.

    5. Remove the stator connections from the rectifier bridge terminals by cutting the wires.


    6. T3B11E27
      Display graphicTranslations of text in graphics


    7. Pry off the baffle.
    8. Remove the rectifier/regulator/brush holder assembly screws.
    9. Remove the brush holder assembly and the regulator.
    10. Important : If the brush can be reused, reassmble the brush to the holder with the retaining pin, after cleaning the brush with a soft, clean cloth.



      T3B11E28
      Display graphicTranslations of text in graphics


    11. Test the rectifier bridge by connecting the ohmmeter terminals to the brdge and the heat sink.


    12. T3B11E29
      Display graphicTranslations of text in graphics


    13. Retest by connecting the ohmmeter terminals in reverse.


    14. T3B11E28
      Display graphicTranslations of text in graphics


    15. Replace the rectifier bridge, if each reading is the same.
    16. Test the remaining two diodes after the above procedure.
    17. Notice : Some kinds of digital ohmmeters are not suited for the test of the bridge diode. In this case, consult the manufacturer regarding the test capacity.

    18. Test the diodes by connecting the ohmmeter terminals to the bridge terminal and the base plate. If the reading is the same, the rectifier bridge should be replaced.


    19. T3B11E30
      Display graphicTranslations of text in graphics


    20. Remove the generator through - bolts.


    21. T3B11E31
      Display graphicTranslations of text in graphics


      Important : The fastening torque of this nut is 81 N•m (60 lb-ft) and may not normally be unfastened using hand strength.

    22. Move to the drive end of the generator and remove the drive end bearing nut.
    23. Remove the pulley and the collars.


    24. T3B11E32
      Display graphicTranslations of text in graphics


    25. Test the rotor for an open circuit using the ohmmeter with the drive end frame assembled. The reading should be sufficiently high, or the rotor must be replaced.


    26. T3B11E33
      Display graphicTranslations of text in graphics


    27. Test the rotor for open and short circuits. The reading should be 1.7 to 2.3 Ω, or the rotor should be replaced.


    28. T3B11E34
      Display graphicTranslations of text in graphics


    29. Remove the drive end frame from the shaft.
    30. For vehicles with an internal generator fan, remove the drive end frame and the fan.


    31. T3B11E35
      Display graphicTranslations of text in graphics


    32. Remove the rotor assembly.


    33. T3B11E36
      Display graphicTranslations of text in graphics


    34. Remove the stator.


    35. T3B11E37
      Display graphicTranslations of text in graphics


    36. Test the stator for an open circuit using the ohmmeter.


    37. T3B11E38
      Display graphicTranslations of text in graphics


    38. Remove the ring in the slip ring end frame.


    T3B11E30
    Display graphicTranslations of text in graphics


    Assembly Procedure

    1. Install the new ring in the slip ring end frame.
    2. Install the stator.


    3. T3B11E30
      Display graphicTranslations of text in graphics


    4. Position the rotor assembly shaft with the drive end frame in the slip ring end assembly until the gap between the outer lace and the end frame casting is 1.9 mm (0.075 inch).
    5. Install the generator through-bolts.
    6. Tighten
      Tighten the generator through-bolts to 10 N•m (89 lb-in).



      T3B11E31
      Display graphicTranslations of text in graphics


    7. Position the fan, the collars, and the pulley on the rotor shaft and secure with the nut.
    8. Tighten
      Tighten the generator drive end bearing nut to 81 N•m (60 lb-ft).

    9. Install the generator. Refer to "Generator"in the On-Vehicle Service section.


    10. T3B11E27
      Display graphicTranslations of text in graphics


    11. Weld the brush holder terminal to the regulator terminal, if removed.
    12. Fix the brush holder with the retainer pin, and weld the regulator/brush holder assembled terminal to the rectifier terminal.
    13. Apply silicone grease between the bridge and the end frame for radiation purposes.
    14. Fasten the screws holding the rectifier regulator/brush holder assembly to the end frame.
    15. Punch the new baffle with the pin into the brush.


    16. T3B11E26
      Display graphicTranslations of text in graphics


      Notice : Take care to prevent damage to the vehicle by protecting the diode in the rectifier bridge from excessive heat while welding.

    17. Weld the connectors of the rectifier bridge.

    GENERAL DESCRIPTION AND SYSTEM OPERATION

    Battery

    The sealed battery is standard on all cars. There are no vent plugs in the cover. The battery is completely sealed, except for two small vent holes in the sides. These vent holes allow the small amount of gas produced in the battery to escape. The battery has the following advantages over conventional batteries :
    The battery has three major functions in the electrical system. First, the battery provides a source of energy for cranking the engine. Second, the battery acts as a voltage stabilizer for the electrical system. Finally, the battery can, for a limited time, provide energy when the electrical demand exceeds the output of the generator.

    Ratings

    A battery has two ratings: (1) a reserve capacity rating designated at 27°C (80°F), which is the time a fully charged battery will provide 25 amperes current flow at or above 10.5 volts; (2) a cold cranking amp rating determined under testing at –18°C (0°F), which indicates the cranking load capacity.

    Reserve Capacity

    The reserve capacity is the maximum length of time it is possible to travel at night with the minimum electrical load and no generator output. Expressed in minutes, Reserve Capacity (or RC rating) is the time required for a fully charged battery, at a temperature of 27°C (80°F) and being discharged at a current of 25 amperes, to reach a terminal voltage of 10.5 volts.

    Cold Cranking Amperage

    The cold cranking amperage test is expressed at a battery temperature of –18°C (0°F). The current rating is the minimum amperage, which must be maintained by the battery for 30 seconds at the specified temperature, while meeting a minimum voltage requirement of 7.2 volts. This rating is a measure of cold cranking capacity.
    The battery is not designed to last indefinitely. However, with proper care, the battery will provide many years of service.
    If the battery tests well, but fails to perform satisfactorily in service for no apparent reason, the following factors may point to the cause of the trouble :

    Built - In Hydrometer

    The sealed battery has a built–in, temperature–compensated hydrometer in the top of the battery. This hydrometer is to be used with the following diagnostic procedure :
    1. When observing the hydrometer, make sure that the battery has a clean top.
    2. Under normal operation, two indications can be observed :
    3. Occasionally, a third condition may appear :

    Charging Procedure

    1. Batteries with the green dot showing do not require charging unless they have just been discharged (such as in cranking a vehicle).
    2. When charging sealed–terminal batteries out of the vehicle, install the adapter kit. Make sure all the charger connections are clean and tight. For best results, batteries should be charged while the electrolyte and the plates are at room temperature. A battery that is extremely cold may not accept current for several hours after starting the charger.
    3. Charge the battery until the green dot appears. The battery should be checked every half–hour while charging. Tipping or shaking the battery may be necessary to make the green dot appear.
    4. After charging, the battery should be load tested. Refer to "Starter Motor" in this section.

    Charging Time Required

    The time required to charge a battery will vary depending upon the following factors :

    Charging A Completely Discharged Battery (Off The Vehicle)

    Unless this procedure is properly followed, a perfectly good battery may need to be replaced. The following procedure should be used to recharge a completely discharged battery :
    1. Measure the voltage at the battery terminals with an accurate voltmeter. If the reading is below 10 volts, the charge current will be very low, and it could take some time before the battery accepts the current in excess of a few milli-amperes. Refer to "Charging Time Required" in this section, which focuses on the factors affecting both the charging time required and the rough estimates in the table below. Such low current may not be detectable on ammeters available in the field.
    2. Set the battery charger on the high setting.

    Important : Some chargers feature polarity protection circuitry, which prevents charging unless the charger leads are correctly connected to the battery terminals. A completely discharged battery may not have enough voltage to activate this circuitry, even though the leads are connected properly, making it appear that the battery will not accept charging current. Therefore, follow the specific charger manufacturer’s instruction for bypassing or overriding the circuitry so that the charger will turn on and charge a low–voltage battery.

    1. Continue to charge the battery until the charge current is measurable. Battery chargers vary in the amount of voltage and current provided. The time required for the battery to accept a measurable charge current at various voltages may be as follows :
    2. Continue to charge the battery until the charge current is measurable. Battery chargers vary in the amount of voltage and current provided. The time required for the battery to accept a measurable charge current at various voltages may be as follows :
    Voltage
    Hours
    16.0 or more
    Up to 4 hours
    14.0-15.9
    Up to 8 hours
    13.9 or less
    Up to 16 hours

    Important : It is important to remember that a completely discharged battery must be recharged for a sufficient number of ampere hours (AH) to restore the battery to a usable state. As a general rule, using the reserve capacity rating (RC) as the number of ampere hours of charge usually brings the green dot into view.

    Jump Starting Procedure

    1. Position the vehicle with the good (charged) battery so that the jumper cables will reach.
    2. Turn off the ignition, all the lights, and all the electrical loads in both vehicles. Leave the hazard flasher on if jump starting where there may be other traffic and any other lights needed for the work area.
    3. In both vehicles, apply the parking brake firmly.

    Notice : To avoid vehicle damage, make sure the cables are not on or near pulleys, fans, or other parts that will move when the engine starts.

    1. Shift an automatic transaxle to PARK, or a manual transaxle to NEUTRAL.
    2. Shift an automatic transaxle to PARK, or a manual transaxle to NEUTRAL.

    Caution : In order to avoid injury, do not use cables that have loose or missing insulation.

    1. Clamp one end of the first jumper cable to the positive terminal on the battery. Make sure it does not touch any other metal parts. Clamp the other end of the same cable to the positive terminal on the other battery. Never connect the other end to the negative terminal of the discharged battery.
    2. Clamp one end of the first jumper cable to the positive terminal on the battery. Make sure it does not touch any other metal parts. Clamp the other end of the same cable to the positive terminal on the other battery. Never connect the other end to the negative terminal of the discharged battery.

    Caution : To avoid injury do not attach the cable directly to the negative terminal of the discharged battery. Doing so could cause sparks and a possible battery explosion.

    1. Clamp one end of the second cable to the negative terminal of the booster battery. Make the final connection to a solid engine ground (such as the engine lift bracket) at least 450 mm (18 in) from the discharged battery.
    2. Clamp one end of the second cable to the negative terminal of the booster battery. Make the final connection to a solid engine ground (such as the engine lift bracket) at least 450 mm (18 in) from the discharged battery.
    3. Start the engine of the vehicle with the good battery. Run the engine at a moderate speed for several minutes. Then start the engine of the vehicle which has the discharged battery.
    4. Remove the jumper cables by reversing the above sequence exactly. Remove the negative cable from the vehicle with the discharged battery first. While removing each clamp, take care that it does not touch any other metal while the other end remains attached.

    Generator

    The charging system of this vehicle is the KDAC AD237 type. The number denotes the outer diameter in millimeters of the stator lamination.
    AD type generators are equipped with internal regulators. A Delta stator, a rectifier bridge, and a rotor with slip rings and brushes are electrically similar to earlier generators. A conventional pulley and fan are used. There is no test hole.
    Unlike three–wire generators, the AD 237 may be used with only two connections: The "L" and "F" terminals are connected to the engine control module (ECM).
    As with other charging systems, the charge indicator lamp is controlled by the ECM when the ignition switch is turned to ON and goes out when the engine is running. If the charge indicator lamp is ON with the engine running, a charging system defect is indicated.
    This indicator light will glow at full brilliance for several kinds of defects as well as when the system voltage is too high or too low.
    The regulator voltage setting varies with temperature and limits the system voltage by controlling rotor field current.

    Charging System

    AD type generators use a new type of regulator that incorporates a diode trio. A Delta stator, a rectifier bridge, and a rotor with slip rings and brushes are electrically similar to earlier generators. A conventional pulley and fan are used. There is no test hole.

    Starter

    Wound field starter motors have pole pieces, arranged around the armature, which are energized by wound field coils.
    Enclosed shift lever cranking motors have the shift lever mechanism and the solenoid plunger enclosed in the drive housing, protecting them from exposure to dirt, icy conditions, and splashes.
    In the basic circuit, solenoid windings are energized when the switch is closed. The resulting plunger and shift lever movement causes the pinion to engage the engine flywheel ring gear. The solenoid main contacts close. Cranking then takes place.
    When the engine starts, pinion overrun protects the armature from excessive speed until the switch is opened, at which time the return spring causes the pinion to disengage. To prevent excessive overrun, the switch should be released immediately after the engine starts.

    Starting System

    The engine electrical system includes the battery, the ignition, the starter, the generator, and all the related wiring. Diagnostic tables will aid in troubleshooting system faults.
    When a fault is traced to a particular component, refer to that component section of the service manual. The starting system circuit consists of the battery, the starter motor, the ignition switch, and all the related electrical wiring. All of these components are connected electrically.


    To Previous PageTo Next Page
    © Copyright Chevrolet Europe. All rights reserved