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Jeep Wrangler TJ. Manual - part 285

TORQUE

DESCRIPTION

N-m

Ft. Lbs.

In. Lbs.

Generator Mounting Bolts

(2.4L)

Generator Mounting Bolt

(4.0L)

Generator Pivot Bolt/Nut

(4.0L)

Generator B+ Cable Nut

115

SPECIAL TOOLS

BATTERY TEMPERATURE
SENSOR

DESCRIPTION

The Battery Temperature Sensor (BTS) is attached

to the battery tray located under the battery.

OPERATION

The BTS is used to determine the battery temper-

ature and control battery charging rate. This temper-
ature data, along with data from monitored line
voltage, is used by the PCM to vary the battery
charging rate. System voltage will be higher at colder
temperatures and is gradually reduced at warmer
temperatures.

The PCM sends 5 volts to the sensor and is

grounded through the sensor return line. As temper-
ature increases, resistance in the sensor decreases
and the detection voltage at the PCM increases.

The BTS is also used for OBD II diagnostics. Cer-

tain faults and OBD II monitors are either enabled
or disabled, depending upon BTS input (for example,
disable purge and enable Leak Detection Pump
(LDP) and O2 sensor heater tests). Most OBD II
monitors are disabled below 20 degrees F.

REMOVAL

The battery temperature sensor is located under

the vehicle battery (Fig. 1) and is attached to a
mounting hole on battery tray.

GENERATOR DECOUPLER TOOL #8433

GENERATOR DECOUPLER TOOL #8823

Fig. 1 Battery Temperature Sensor Remove/Install

1 - BATTERY TEMPERATURE SENSOR
2 - BATTERY TRAY

CHARGING

8F - 23

CHARGING (Continued)

(1) Remove battery. Refer to 8, Battery for proce-

dures.

(2) Disconnect sensor pigtail harness from engine

wire harness.

(3) Pry sensor straight up from battery tray

mounting hole.

INSTALLATION

The battery temperature sensor is located under

the vehicle battery and is attached to a mounting
hole on battery tray.

(1) Feed pigtail harness through hole in top of bat-

tery tray and press sensor into top of battery tray.

(2) Connect pigtail harness.
(3) Install battery. Refer to 8, Battery for proce-

dures.

GENERATOR

DESCRIPTION

The generator is belt-driven by the engine using a

serpentine type drive belt. It is serviced only as a
complete assembly. If the generator fails for any rea-
son, the entire assembly must be replaced.

OPERATION

As the energized rotor begins to rotate within the

generator, the spinning magnetic field induces a cur-
rent into the windings of the stator coil. Once the
generator begins producing sufficient current, it also
provides the current needed to energize the rotor.

The Y type stator winding connections deliver the

induced AC current to 3 positive and 3 negative
diodes for rectification. From the diodes, rectified DC
current is delivered to the vehicle electrical system
through the generator battery terminal.

Although the generators appear the same exter-

nally, different generators with different output rat-
ings are used on this vehicle. Be certain that the
replacement generator has the same output rating
and part number as the original unit. Refer to Gen-
erator Ratings in the Specifications section at the
back of this group for amperage ratings and part
numbers.

Noise emitting from the generator may be caused

by: worn, loose or defective bearings; a loose or defec-
tive drive pulley; incorrect, worn, damaged or misad-
justed

fan

drive

belt;

loose

mounting

bolts;

misaligned drive pulley or a defective stator or diode.

REMOVAL

WARNING: DISCONNECT NEGATIVE CABLE FROM
BATTERY BEFORE REMOVING BATTERY OUTPUT
WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO

DO SO CAN RESULT IN INJURY OR DAMAGE TO
ELECTRICAL SYSTEM.

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

ing System for procedure.

(3) Remove generator pivot and mounting bolts/nut

(Fig. 2) , or (Fig. 3). Position generator for access to
wire connectors.

(4) If equipped, unsnap plastic cover from B+ ter-

minal.

(5) Remove B+ cable output terminal mounting

nut at rear of generator (Fig. 4), (Fig. 5), or (Fig. 6).
Disconnect terminal from generator.

(6) Disconnect field wire connector at rear of gen-

erator by pushing on connector tab.

(7) Remove generator from vehicle.

INSTALLATION

(1) Position generator to engine and snap field

wire connector into rear of generator.

(2) Install B+ terminal to generator mounting

stud. Tighten mounting nut. Refer to Torque Specifi-
cations.

(3) If equipped, snap plastic cover to B+ terminal.
(4) Install

generator

mounting

fasteners

and

tighten. Refer to Torque Specifications.

CAUTION: Never force a belt over a pulley rim
using a screwdriver. The synthetic fiber of the belt
can be damaged.

Fig. 2 GENERATOR REMOVE/INSTALL - 4.0L

1 - GENERATOR
2 - UPPER BOLT
3 - LOWER BOLT

8F - 24

CHARGING

BATTERY TEMPERATURE SENSOR (Continued)

CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. The
water pump will be rotating in the wrong direction if
the belt is installed incorrectly, causing the engine
to overheat. Refer to belt routing label in engine
compartment, or refer to Belt Schematics in 7, Cool-
ing System.

(5) Install generator drive belt. Refer to 7, Cooling

System for procedure.

(6) Install negative battery cable to battery.

Fig. 3 GENERATOR MOUNTING- 2.4L

1 - UPPER MOUNTING BOLT
2 - GENERTOR
3 - LOWER MOUNTING BOLT

Fig. 4 GENERATOR CONNECTORS (TYPICAL

DENSO)

1 - FIELD WIRES
2 - B+ (OUTPUT TERMINAL)
3 - FIELD WIRE CONNECTOR

Fig. 5 GENERATOR CONNECTORS - 4.0L

1 - FIELD WIRE CONNECTOR
2 - B+ CABLE
3 - GENERATOR
4 - B+ CABLE MOUNTING NUT
5 - CABLE PROTECTOR

Fig. 6 GENERATOR ELECTRICAL CONNECTORS -

2.4L - TYPICAL

1 - PROTECTIVE CAP
2 - B+ NUT
3 - B+ TERMINAL
4 - FIELD ELECTRICAL CONNECTOR

CHARGING

8F - 25

GENERATOR (Continued)

GENERATOR DECOUPLER
PULLEY

DESCRIPTION

The generator decoupler is used only with

certain engines. The decoupler is used in place of
the standard generator drive pulley (Fig. 7).

OPERATION

The generator decoupler is used only with

certain engines. The decoupler (Fig. 7) is a one-way
clutch designed to help reduce belt tension fluctua-
tion, vibration, reduce fatigue loads, improve belt life,
reduce hubloads on components, and reduce noise.
Dry operation is used (no grease or lubricants). The
decoupler is not temperature sensitive and also has a
low sensitivity to electrical load. The decoupler is a
non-serviceable item and is to be replaced as an
assembly.

DIAGNOSIS AND TESTING - GENERATOR DECOUPLER

CONDITION

POSSIBLE CAUSES

CORRECTION

Does not drive generator

(generator not charging)

Internal failure

Replace decoupler

Noise coming from

decoupler

Internal failure

Replace decoupler

REMOVAL

The generator decoupler is used only with

certain engines.

Two different type generator decoupler pulleys are

used. One can be identified by the use of machined
splines (Fig. 8). The other can be identified by a hex
opening (Fig. 9) and will not use splines.

Different special tools are required to service each

different decoupler. Refer to following procedure.

INA Decoupler

(1) Disconnect negative battery cable.
(2) Remove generator and accessory drive belt.

Refer to Generator Removal.

(3) Position Special Tool #8823 (VM.1048) into

decoupler (Fig. 10).

(4) Determine if end of generator shaft is hex

shaped (Fig. 11) or is splined (Fig. 12). If hex is used,
insert a 10MM deep socket into tool #8823 (VM.1048)
(Fig. 13). If splined, insert a 5/16” 6-point hex driver,
or a 10MM 12-point triple square driver into tool
#8823 (VM.1048) (Fig. 14).

Fig. 7 GENERATOR DECOUPLER PULLEY

Fig. 8 GENERATOR DECOUPLER PULLEY (INA)

1 - GENERATOR
2 - DECOUPLER (INA)
3 - MACHINED SPLINES

8F - 26

CHARGING

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