Alternador Voyager 91

1991
1991Plymouth
PlymouthVoyager
VoyagerLE
LE
ALTERNATOR & REGULATOR
ALTERNATOR 1991
& REGULATOR ELECTRICAL
1991 Chrysler
ELECTRICAL Motors
Chrysler Corp.
Motors Alternators
Corp. & Regulators
Alternators &
Regulators
ALTERNATOR & REGULATOR
1991 ELECTRICAL Chrysler Motors Corp. Alternators & Regulators
DESCRIPTION
Chrysler Motors light trucks use either a Bosch or a Denso alternator. The alternator consists of a rotor, stator,
rectifiers, front and rear covers and drive pulley. Voltage regulation is controlled by the Single Board Engine
Controller (SBEC) on all models except diesel. On diesel models, voltage regulation is controlled by a
transistorized voltage regulator.
The SBEC monitors critical input to control fuel injection, ignition, emission and other engine management
functions. The SBEC has also been programmed to monitor several charging system related circuits:
 Battery feed to SBEC

 Alternator field control
 Battery charging voltage (high and low)
If a problem is sensed in a monitored circuit, a fault code is stored in the SBEC's memory and the CHECK
ENGINE light will be turned on (with a few exceptions). Fault codes can be read using the CHECK ENGINE
light or with the Chrysler Diagnostic Readout Box-II (DRB-II).
NOTE: Fault codes remain in memory for 50 engine starts. Fault is erased
from memory if failure does not reoccur .
For certain fault codes, CHECK ENGINE light will illuminate and engine controller will enter limp-in mode. In
limp-in mode, engine controller attempts to compensate for particular component failure by substituting
information from other sources. This allows vehicle operation until proper repairs are made.
ALTERNATOR APPLICATION
(1)
Application Case Number Pulley Grooves
Caravan, Town & Country & Voyager
Bosch 90 Amp 4557431 4
Bosch 90 Amp 5234231 4
Denso 90 Amp 5234031 4
Denso 90 Amp 5234032 6
Denso 120 Amp 5234208 4
Denso 120 Amp 5234033 6
Dakota
Bosch 90 Amp 5234231 4
Bosch 90 Amp 5235028 2
Denso 75 Amp 4557301 4
Denso 75 Amp 5234026 2
Denso 75 Amp 5234027 6
lunes, 13 de septiembre de 2021 10:01:07 p.m. Page 1 © 2011 Mitchell Repair Information Company, LLC.
lunes, 13 de septiembre de 2021 10:00:56 p.m. Page 1 © 2011 Mitchell Repair Information Company,
1991 Plymouth Voyager LE
ALTERNATOR & REGULATOR 1991 ELECTRICAL Chrysler Motors Corp. Alternators & Regulators
Denso 90 Amp 5234031 4

Denso 90 Amp 5234028 2
Denso 90 Amp 5234032 6
Denso 120 Amp 5234199 2
Denso 120 Amp 5234208 4
Denso 120 Amp 5234033 6
Pickup & Ramcharger
Bosch 90 Amp 5235028 2
Denso 75 Amp 5234026 2
Denso 90 Amp 5234028 2
Denso 120 Amp 5234199 2
Denso 120 Amp 5234374 8
RWD Van
Denso 75 Amp 5234026 2
Denso 90 Amp 5234028 2
Denso 120 Amp 5234199 2
(1) Located on tag on bottom of alternator case.
ADJUSTMENTS
BELT TENSION ADJUSTMENT
BELT TENSION
(1)
Application New: Lbs. (kg) Used: Lbs. (kg)
2.5L 125 (57) 80 (36)
3.0L (2) (2) *
3.3L (2) (2) *
Dakota
2.5L 160 (73) 80 (36)
3.9L 100-140 (45-64) 60-90 (27-41)
5.2L (2) (2) *
Pickup & Ramcharger
3.9L & 5.2L 100-140 (45-64) 60-90 (27-41)
5.9L
Gas 100-140 (45-64) 60-90 (27-41)
Diesel (2) (2) *
RWD Van (All) 100-140 (45-64) 60-90 (27-41)
(1) Any belt operated for 15 minutes.
(2) Dynamic tensioner used, no adjustment is required.
TROUBLE SHOOTING
INITIAL CHECKS
Before proceeding with charging system diagnosis, ensure:
 Battery is fully charged and in good condition

 Battery cables are in good condition with connections clean and secure
 Alternator belt is in good condition and properly tightened
 Alternator and SBEC wiring harness connections are clean and tight.
 Engine ground strap is in place
UNSTEADY OR LOW CHARGING
Check for loose alternator belt, charging resistance too high, defective alternator, loose alternator ground wire
or corroded battery terminals.
OVERCHARGING
Check for grounded alternator field wiring or faulty alternator.
NOISY ALTERNATOR
Check for worn alternator bearings or loose alternator mounting.
NOTE: For additional trouble shooting information, refer to the TROUBLE SHOOTING
- BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section.
TESTING (ON-VEHICLE)
NOTE: ALTERNATOR OUTPUT WIRE RESISTANCE TEST will show amount of voltage
drop across alternator output wire between alternator BAT terminal and
positive battery post.
ALTERNATOR OUTPUT WIRE RESISTANCE TEST
1. Charge battery as necessary. Turn ignition off. Disconnect negative battery cable. Disconnect alternator
output wire from alternator BAT terminal.
2. Using a 0-150-ampere scale DC ammeter, connect positive ammeter lead to alternator BAT terminal and
negative lead to disconnected alternator output wire. See Fig. 1 and Fig. 2 .
3. Using a voltmeter (0-18 volts minimum), connect positive voltmeter lead to disconnected
alternator output wire and negative lead to positive battery cable.
CAUTION: Alternator has 2 field terminals. One field terminal has Dark Green
wire and other field terminal has Dark Blue wire. DO NOT connect
jumper wire to alternator field terminal Dark Blue wire.
4. On Caravan, Town & Country and Voyager, remove air hose between SBEC and air cleaner. On all
models, connect one end of jumper wire to ground and other end to alternator field terminal Dark
Green wire on rear side of alternator.
5. Connect engine tachometer and reconnect negative battery cable. Connect carbon pile rheostat between
battery terminals. Ensure carbon pile is in OFF position before connecting leads.
6. Start engine. Reduce engine speed to idle. Adjust engine speed and carbon pile to maintain 20 amps
flowing in circuit. Observe voltmeter reading. Voltage drop should be .5 volt or less.
7. If voltage drop is more than .5 volt, inspect, clean and tighten all connections between alternator BAT
terminal and positive battery post. Voltage drop test may be performed at each connection to locate
connection with excessive resistance. If resistance tests satisfactorily, reduce engine speed, turn off
carbon pile and ignition switch.
8. Disconnect negative battery cable. Remove test ammeter, voltmeter, carbon pile and tachometer.
Remove jumper wire between alternator Dark Green field wire and ground. Connect alternator output
wire to alternator BAT terminal. Reconnect negative battery cable and hose between SBEC and air
cleaner.
Fig. 1: Testing Alternator Output Wire Resistance (Gasoline)

Courtesy of CHRYSLER MOTORS.
Fig. 2: Testing Alternator Output Wire Resistance (Diesel)

CURRENT OUTPUT TEST
NOTE: CURRENT OUTPUT TEST determines if alternator is capable of delivering

its rated current output.
1. Charge battery as necessary. Disconnect negative battery cable. Disconnect alternator output wire at
alternator BAT terminal. See Fig. 3. Using a 0-150-ampere scale DC ammeter, connect positive ammeter
lead to alternator BAT terminal and negative lead to disconnected alternator output wire. See Fig. 4 and
Fig. 5 .
2. Using a voltmeter (0-18 volts range minimum), connect positive voltmeter lead to disconnected
alternator BAT terminal and negative lead to good ground.
3. Connect engine tachometer and reconnect negative battery cable. Connect carbon pile rheostat between
battery terminals. Ensure carbon pile is in OFF position before connecting leads.
CAUTION: Alternator has 2 field terminals. One field terminal has Dark Green
wire and other field terminal has Dark Blue wire. DO NOT connect
jumper wire to alternator field terminal Dark Blue wire.
4. On Caravan, Town & Country and Voyager, remove air hose between SBEC and air cleaner. On all
models, connect one end of jumper wire to ground and other end to alternator field terminal Dark
Green wire on back of alternator.
5. Start engine and reduce engine speed to idle. Adjust carbon pile and engine speed in increments until
engine speed is 1250 RPM and voltmeter reads 15 volts. DO NOT allow voltage to read more than 16
volts.
6. Ammeter should read within specification. Refer to the ALTERNATOR MINIMUM OUTPUT table. If
alternator amperage reads less than specified and alternator output wire resistance is not excessive,
replace alternator. After CURRENT OUTPUT TEST is completed, reduce engine speed, turn off carbon
pile and ignition switch.
7. Disconnect negative battery cable. Remove test ammeter, voltmeter, tachometer and carbon pile.
Remove jumper wire between alternator field terminal Dark Green wire and ground. Reconnect
alternator output wire to alternator BAT terminal. Reconnect negative battery cable and hose between
SBEC and air cleaner.
Fig. 3: Identifying Alternator Terminals

Fig. 4: Testing Alternator Current Output (Gasoline)

Fig. 5: Testing Alternator Current Output (Diesel)

VOLTAGE REGULATOR TEST (DIESEL)
1. Charge battery as necessary. Turn ignition off. Using a voltmeter with a minimum of a 0-18 volt scale,
connect the positive lead to the positive battery post. Connect voltmeter negative lead to chassis ground.
Connect a tachometer to the engine See Fig. 6.
2. Start engine and adjust idle to 1250 RPM. Turn all lights and accessories off. Observe voltmeter
readings. Voltage regulator is working properly if voltage readings are within specifications. See the
VOLTAGE REGULATOR SPECIFICATIONS table.
3. If voltage is out of range, or is fluctuating, check the following:
 Voltage regulator is properly grounded
 Voltage regulator terminals are not spread causing an open
 Battery voltage is present at both terminals with ignition on
4. If voltage regulator ground connection and wiring check okay, replace regulator.
VOLTAGE REGULATOR SPECIFICATIONS

Temperature (1) Volts
20° (-30°C) 14.6-15.8
80° (27°C) 13.9-14.4
140° (60°C) 13.0-13.7
Above 140° (60°) Less than 13.7
(1) Ambient at voltage regulator.
Fig. 6: Testing Voltage Regulator (Diesel)

BENCH TESTING
NOTE: Alternators are non-serviceable and must be replaced as complete units.
SELF-DIAGNOSTIC SYSTEM
The self-diagnostic capabilities of this system, if properly used, can simplify testing. SBEC monitors several
different engine control system circuits.
If a problem is sensed with a monitored circuit, a fault code is stored in SBEC, CHECK ENGINE light
illuminates and SBEC enters limp-in mode. In limp-in mode, SBEC compensates for component failure by
substituting information from other sources. This allows vehicle operation until repairs can be made.
Once codes are known, refer to CHARGING SYSTEM FAULT CODES table to determine the questionable
circuit. Test circuits and repair or replace components as required. If problem is repaired or ceases to exist, the
SBEC cancels that fault code after 50 ignition on/off cycles. To clear codes, refer to ERASING FAULT
CODES under ENTERING ON-BOARD SELF DIAGNOSTICS.
A specific fault code results from a particular system failure. Components in that system are NOT necessarily
the reason for that failure. The fault code does not condemn a specific component, it calls out a CIRCUIT
malfunction.
HARD FAILURES
Hard failures cause CHECK ENGINE light to illuminate and remain on until the malfunction is repaired. If
light comes on and remains on (light may flash) during vehicle operation, cause of malfunction must be
determined using diagnostic (code) charts. If a sensor fails, SBEC will use a substitute value in its calculations,
allowing engine operation in limp-in mode. In this condition, vehicle will run, but driveability may be poor.
INTERMITTENT FAILURES
Intermittent failures may cause CHECK ENGINE light to flicker or stay on until the intermittent fault goes
away. The corresponding trouble code will be retained in SBEC memory, however. If fault does not reoccur
within a certain time frame, corresponding trouble code will be erased from SBEC memory. Intermittent
failures can be caused by faulty sensor, bad connector or wiring related problems. See INTERMITTENTS in
H- TESTS W/O CODES article in the ENGINE PERFORMANCE section.
SELF-DIAGNOSTIC PROCEDURE
Refer to ENTERING ON-BOARD SELF DIAGNOSTICS to retrieve fault codes. If fault codes are NOT
present and/or DRB-II (Diagnostic Readout Box-II) is used, proceed to TEST CH-1, BATTERY TEST.
NOTE: When using trouble shooting charts for diagnosis, DO NOT skip any steps
in chart or incorrect diagnosis may result.
Before proceeding with diagnosis, the following precautions must be followed:
 Vehicle must have a fully charged battery and functional charging system. See appropriate
TROUBLE SHOOTING and TESTING (ON-VEHICLE) in this article.
 Probe SBEC connector from pin side. DO NOT backprobe SBEC connector.
 DO NOT cause short circuits when performing electrical tests. This will set additional fault codes,
making diagnosis of original problem more difficult.
 DO NOT use a test light in place of a voltmeter.
 Always repair lowest fault code number (CHECK ENGINE light) or first fault displayed (DRB-II) first.
 Always perform verification procedure test after repairs are made.
 Always disconnect DRB-II after use.
 Always disconnect DRB-II before charging battery.
ENTERING ON-BOARD SELF DIAGNOSTICS

CAUTION: Before entering on-board diagnostics, check charging system for other
problems. See INITIAL CHECKS TRBL SHTN. DO NOT connect DRB-II to
vehicle with battery charger connected, as damage to DRB-II may
result.
READING TROUBLE CODES
Trouble codes may be read by using the CHECK ENGINE light on the instrument panel or with the DRB-II.
See CHECK ENGINE LIGHT DIAGNOSTIC MODE and DIAGNOSIS USING DRB-II. A more complete
diagnosis is possible using the DRB-II.
NOTE: The SBEC CANNOT diagnose every charging system problem. If a fault
still exists after performing self-diagnostic procedures, go to TESTING
(ON- VEHICLE).
TROUBLE CODE DEFINITIONS
1. See CHARGING SYSTEM FAULT CODES table for charging-related faults.

2. Code 12 will set if battery feed to the SBEC has been disconnected within last 50-100 starts.
SBEC monitors this circuit whenever ignition is on.
3. Code 41 will set if the alternator field control fails to switch properly. SBEC monitors this circuit
whenever ignition is on.
4. If battery temperature sense voltage goes out of range, Code 44 will be set in memory. The SBEC
monitors this circuit any time ignition is on.
5. If battery sense voltage is more than one volt above desired control voltage for more than 20 seconds, a
Code 46 will be set in memory. SBEC monitors this signal whenever the engine is running.
6. If battery sense voltage is more than one volt below desired control voltage for more than 20 seconds and
no significant change in voltage is detected during active test of alternator, Code 47 will be set. The
SBEC monitors this signal whenever engine speed is more than 1500 RPM.
CHARGING SYSTEM FAULT CODES

"CHECK ENGINE" Light
Code Circuit On?
12 Battery Feed to SBEC No
Alternator Field Control Yes
41 (1)
(2) Yes
44 (1) Battery Temp. Sensor
High Battery Voltage Yes
46 (1)
Low Battery Voltage No
47 (1)
55 End of Diagnostic Mode No
(1)This code will cause limp-in mode.
(2)Sensor inside SBEC. If failed, replace SBEC.
NOTE: Only charging system-related codes are listed here. For engine-related
codes, see appropriate G-TESTS W/ CODES article in the ENGINE
PERFORMANCE section.
CHECK ENGINE LIGHT DIAGNOSTIC MODE
1. Start engine (if possible). On models equipped with automatic transmission, place foot on brake and cycle
transmission shift lever through all positions, ending in Park. On all models, turn A/C switch on and
then off (if equipped).
2. Turn engine off. Without starting engine again, turn ignition on, off, on, off and on. CHECK ENGINE
light will come on for 2 seconds as a bulb check, followed by fault codes. Record 2-digit fault codes as
displayed by flashing CHECK ENGINE light.
3. For example, Code 23 is displayed as flash, flash, 4 second pause, then flash, flash, flash. After a
slightly longer pause, any other codes stored are displayed in numerical order.
4. Once check engine light begins to flash fault codes, it cannot be stopped. Go to step 1) to enter
diagnostic mode again. Code 55 indicates end of fault code display. For more information on vehicle
self- diagnostics, see appropriate G-TEST W/ CODES article in the ENGINE PERFORMANCE section.
5. Refer to CHARGING SYSTEM FAULT CODES table to translate trouble code number to a system
fault description (DRB-II display). Once trouble area is identified, refer to appropriate charging system
test procedures.
NOTE: CHECK ENGINE light CANNOT be used to perform actuation test mode, sensor
test modes or engine running test. Fault codes can only be erased using DRB-
II. Fault codes will be erased from SBEC memory after 50 key starts if fault does
not reoccur.
DIAGNOSIS USING DRB-II
The DRB-II is used as part of a charging system diagnostic procedure. Perform tests CH-1, BATTERY TEST
through CH-VER, CHARGING VERIFICATION.
DRB-II DIAGNOSTIC MODE
1. Turn ignition off. Attach DRB-II to engine diagnostic connector. Connector is located in engine
compartment, near SBEC.
2. Start engine (if possible). On models equipped with automatic transmission, place foot on brake pedal and
cycle transmission shift lever through all positions, ending in Park. On all models, turn A/C switch on and
then off (if equipped).
3. Turn engine off. Without starting engine again, turn ignition on. Enter CHARGING MENU. To enter
CHARGING MENU see SELF DIAGNOSIS DRB-II TEST FUNCTIONS. At CHARGING MENU,
press "2" (READ FAULTS) key. Press ENTER key. After fault codes are accessed, refer to TEST CH-1,
BATTERY TEST.
ERASING FAULT CODES
1. To erase faults, press ATM key. At DRB-II display, press "2" (ERASE) key. DRB-II will display ERASE
FAULTS ARE YOU SURE? (ENTER TO ERASE). Press ENTER key.
2. When DRB-II is finished erasing fault codes, it will display FAULTS ERASED. This display will remain
until ATM key is pressed. After ATM key is pressed, display will return to CHARGING MENU screen.
SELF-DIAGNOSTICS DRB-II TEST FUNCTIONS
NOTE: DO NOT touch DRB-II keypad during DRB-II power-up sequence, or an

error message will result.
1. To perform diagnostic tests using DRB-II, DRB-II must be in the CHARGING MENU. At the
CHARGING MENU, fault codes and DRB-II test functions can be accessed.
2. To reach CHARGING MENU, turn ignition off. Attach DRB-II to engine diagnostic connector.
Connector is located in engine compartment, near SBEC. Turn ignition switch to RUN
position.
3. All DRB-II character positions will illuminate and copyright information will appear on screen for
several seconds. If DRB-II screen is blank or any error messages appear, see SELF DIAGNOSIS DRB-II
PROBLEMS & ERROR MESSAGES.
4. After several seconds DRB-II menu will appear. At DRB-II menu, press "4" (SELECT SYSTEM) key.
Press ENTER key. At SELECT SYSTEM menu, press "1" (ENGINE) key. Press ENTER key. DRB-II
menu will appear, indicating engine year and size, type of transmission and SBEC part number.
5. After several seconds AIR COND menu will appear. Press "1" (WITH A/C) or press "2" (WITHOUT
A/C). DRB-II display will change to ENGINE SYSTEMS menu. At ENGINE SYSTEMS menu, press
"2" (CHARGING) key. Press ENTER key.
6. Display will change to CHARGING MENU. At CHARGING menu of engine diagnostic program,
specific test functions programmed into DRB-II can be performed. The following DRB-II modes can be
accessed: SYSTEM TEST, READ FAULTS, STATE DISPLAYS, ACTUATOR TEST and
ADJUSTMENTS.
SYSTEM TEST MODE
This function is not available in the engine diagnostics program.
READ FAULTS MODE
1. This function allows the user to read and erase fault codes. A fault counter will appear along with fault
displayed on DRB-II. As an example, DRB-II will display 1 OF 2 FAULTS. SBEC will store up to 8 fault
messages. Faults are numbered in reverse order of setting. The most recent fault to occur will be number
one. Vehicles without A/C will always have A/C CLUTCH RELAY CKT (circuit) stored in memory.
This fault will always be number one if vehicle is not equipped with A/C. If no fault messages are stored,
DRB-II will display NO FAULTS DETECTED and start counter will show 0 STARTS SINCE ERS.
2. A start counter will appear below DRB-II fault counter display. Start counter counts the number of times
vehicle is started since faults were last set, erased, or battery was disconnected. This helps determine if
fault is intermittent. Memory space limits start counter to first 3 faults. Start counter of zero equals a
hard fault. Start counter of more than zero indicates an intermittent fault. Start counter will count up to
255 starts. If no fault messages are stored, DRB-II will display NO FAULTS DETECTED and start
counter will show 0 STARTS SINCE ERS.
STATE DISPLAYS MODE
1. This function allows user to read states or values of a variety of sensors, inputs/outputs and components.
2. The SBEC can only recognize high and low states on switch circuits. SBEC cannot differentiate
between an open or short circuit or a defective switch. If DRB-II displays a change between INPUT
HIGH and INPUT LOW, it can be assumed that the entire switch circuit to the SBEC is functioning.
ACTUATOR TEST MODE
1. This function allows the user to check for proper operation of output circuits or devices, which the
SBEC cannot internally recognize. DRB-II allows SBEC to activate these outputs or devices, allowing
an observer to verify proper operation.
2. Most of the tests available in this mode provide an audible or visual indication of device operation (click
of relay contacts, spray fuel, etc.). With the exception of an intermittent condition, if a device functions
properly during its test, it can be assumed that the device, wiring and its driver circuit are functioning
properly.
ADJUSTMENTS MODE
This function allows the user to erase fault codes. Function also allows user to reset Emission Maintenance
Reminder (EMR) light and mileage (trucks only).
DRB-II VOLT/OHMMETER MODE
1. To access volt/ohmmeter mode of DRB-II, connect Red volt/ohmmeter test lead to Red port, located on
right-top side of DRB-II.
NOTE: Because DRB-II is grounded through engine diagnostic connector, only

one volt/ohmmeter test lead is required when using volt/ohmmeter
option. DRB-II volt/ohmmeter should only be used when diagnostic
procedures require the use of this option.
2. To access voltmeter, press VOLT/OHM key once. DRB-II is now in voltmeter mode. Touch test probe to
connector or wire to be measured. Read voltage on DRB-II display. When voltage testing is complete,
press VOLT/OHM key 3 times to exit voltmeter mode.
3. To access ohmmeter, press VOLT/OHM key twice. DRB-II is now in ohmmeter mode. Touch test probe
to connector or wire to be measured. Read resistance to circuit ground on DRB-II display. When
resistance testing is complete, press VOLT/OHM key twice to exit ohmmeter mode.
DRB-II CONTINUITY METER MODE
Press VOLT/OHM key 3 times. Display will read NO CONTINUITY. Touch test probe to connector or wire to
be measured. Read continuity on DRB-II display. When continuity testing is complete, press VOLT/OHM key
once to exit continuity meter mode.
VEHICLES TESTED MODE
1. Mode is used to show what vehicles are covered by DRB-II cartridge. To access vehicles tested
mode, turn ignition off. Attach DRB-II to engine diagnostic connector. Connector is located in engine
compartment, near SBEC.
2. Turn ignition switch to RUN position. All DRB-II character positions will illuminate and copyright
information will appear on screen for several seconds. After several seconds DRB-II menu will
appear.
3. At DRB-II menu, press "1" (VEHICLES TESTED) key. Press ENTER key. DRB-II will display vehicles
covered by cartridge. Screen will display for 5 seconds and return to DRB-II menu.
HOW TO USE MODE
Enter DRB-II menu display. Refer to steps 1) and 2) under VEHICLES TESTED MODE. At DRB-II menu,
press "2" (HOW TO USE) key. Press ENTER key. A series of screens will be displayed explaining the use of
DRB-II keys used to move through engine diagnostic program.
CONFIGURE MODE
1. Configure option allows user to customize DRB-II display. For example, if metric system is more useful
to use, simply select METRIC from the appropriate menu.
2. All selections made under CONFIGURE option remain active until user changes selection. To
enter configure mode, enter DRB-II menu display. Refer to steps 1) and 2) under VEHICLES
TESTED MODE. At DRB-II menu, press "3" (CONFIGURE) key. Press ENTER key. DRB-II will
display CONFIGURE menu.
SELF DIAGNOSIS DRB-II PROBLEMS & ERROR MESSAGES

BLANK MESSAGE SCREEN
1. Connect DRB-II to a different vehicle. If message screen is still blank, DRB-II or cable adapter is faulty.
Substitute to find faulty component.
2. If message screen is not blank, DRB-II and cable adapter are functioning properly. Inspect diagnostic
connector for proper wire placement, damaged terminals or pushed out pins. Repair as necessary.
3. If diagnostic connector is okay, using an ohmmeter, check resistance between Black/White or
Black/Yellow wire and ground at engine diagnostic connector. If resistance is greater than 10 ohms,
repair open in Black/White or Black/Yellow wire.
NO RESPONSE MESSAGE
1. Connect DRB-II to another vehicle. If DRB-II displays NO RESPONSE message again, DRB-II or
cable adapter is faulty. Substitute to find faulty component. If message screen does not display NO
RESPONSE, DRB-II and cable adapter are functioning properly. Go to next step.
2. Turn ignition off. Disconnect DRB-II. Using an ohmmeter, check Pink or Black/Red wire for resistance
between SBEC and engine diagnostic connectors. If resistance is more than 10 ohms, repair open in
Pink or Black/Red wire.
3. If resistance is less than 10 ohms, check Light Green/Orange or Black/Pink wire for resistance between
SBEC and engine diagnostic connectors. If resistance is more than 10 ohms, repair open in Light
Green/Orange or Black/Pink wire.
RAM TEST FAILURE MESSAGE
Replace DRB-II.
CARTRIDGE ERROR MESSAGE
Replace DRB-II cartridge.
KEY PAD TEST FAILURE MESSAGE
Power up DRB-II again with fingers off the keypad. If error message returns, replace DRB-II.
HIGH OR LOW BATTERY MESSAGE
Correct condition of vehicle battery and reconnect DRB-II.
NOTE: For more information on SBEC diagnostic capabilities and using DRB-II, see
appropriate G-TESTS W/ CODES article in the ENGINE PERFORMANCE
section.
TEST CH-1, BATTERY TEST
NOTE: Perform visual check before proceeding.
CAUTION: If battery shows signs of freezing or leakage, battery posts are loose
or battery has low electrolyte level, DO NOT test.
1. If battery has a built-in hydrometer, go to step 2). Turn ignition and all accessories off. Using a
voltmeter, check battery voltage across battery posts. If voltage is 12.3 volts or more, go to step 3). If
voltage is less than 12.3 volts, charge battery and go to step 3).
2. If battery hydrometer is Green, go to step 3). If battery hydrometer is Yellow or a bright color, replace
battery and perform TEST CH-VER, CHARGING VERIFICATION. If battery hydrometer is dark in
color, charge battery and go to step 3).
3. Disconnect battery cables and check terminals and posts. Clean terminals and posts as necessary and
retest. Connect a load tester to battery posts. Apply 300-amp load for 15 seconds. Wait 15 seconds to
allow battery to stabilize. Apply a load equal to 50 percent of battery cold cranking rating for 15 seconds
and record minimum voltage reading.
4. Determine battery operating temperature and check battery minimum voltage specification. See
MINIMUM VOLTAGE SPECIFICATION table. If voltage is not to specification, replace battery and
perform TEST CH-VER, CHARGING VERIFICATION. If voltage reading is to specification, go to
step 5).
MINIMUM VOLTAGE SPECIFICATION

Battery Minimum Volts
Temperature
70°F (21°C) Or More 9.6
60°F (16°C) 9.5
50°F (12°C) 9.4
40°F (4°C) 9.3
30°F (-1°C) 9.1
20°F (-7°C) 8.9
10°F (-12°C) 8.7
0°F (-18°C) 8.5
5. Reconnect battery cables. Inspect alternator belt tension and condition. Replace belt as necessary. Start
engine. Set engine speed to 2000 RPM for 30 seconds. Turn ignition off. Connect DRB-II. Turn
ignition on with engine off. Read faults.
6. If DRB-II displays BATTERY TEMP SENSOR OUT OF LIMIT, replace SBEC and perform TEST
CH- VER, CHARGING VERIFICATION test. If DRB-II displays ALTERNATOR FIELD NOT
SWITCHING PROPERLY, proceed to TEST CH-2, ALTERNATOR FIELD NOT SWITCHING
PROPERLY. If DRB-II does not display either message, go to next step.
7. If DRB-II displays CHARGING SYSTEM VOLTAGE TOO LOW, go to TEST CH-3, CHARGING
SYSTEM VOLTAGE LOW. If DRB-II displays CHARGING SYSTEM VOLTAGE TOO HIGH, go to
TEST CH-4, CHARGING SYSTEM VOLTAGE HIGH. If DRB-II does not display any faults, there
are either no fault messages or faults are intermittent.
8. Actuate the alternator field. Put DRB-II in voltmeter mode. Probe Dark Green wire at rear of
alternator. Voltage reading should fluctuate between zero and battery voltage every 1.4 seconds. While
watching DRB-II, wiggle wires between alternator harness and SBEC.
9. If there is no interruption in normal voltage cycle, test is complete. Perform TEST CH-VER,
CHARGING VERIFICATION. If normal voltage cycle is interrupted, repair harness as necessary.
Perform TEST CH-VER, CHARGING VERIFICATION.
TEST CH-2, ALTERNATOR FIELD NOT SWITCHING PROPERLY
NOTE: Perform TEST CH-1, BATTERY TEST before proceeding.
1. Put DRB-II in voltmeter mode and probe Dark Blue wire at back of alternator. If voltage is less than 10
volts, repair open circuit from ignition switch. If voltage is 10 volts or more, probe Dark Green wire at
back of alternator. If voltage is less than 10 volts, go to step 2). If voltage is 10 volts or more , go to step
3).
2. Turn ignition off. Disconnect and inspect SBEC connector. If connector is damaged, repair as necessary.
If connector is okay, turn ignition on and probe Dark Green wire at back of alternator. If voltage is 10
volts or more, replace SBEC. Perform TEST CH-VER, CHARGING VERIFICATION. If voltage is
less than 10 volts, turn ignition off and put DRB-II in ohmmeter mode. Probe Dark Green wire in
alternator harness. If resistance less than 10 ohms, repair Dark Green wire for short to ground. If
resistance is 10 ohms or more, replace alternator. Perform TEST CH-VER, CHARGING
VERIFICATION.
3. Turn ignition off. Disconnect and inspect SBEC connector. If connector is damaged, repair as necessary.
If connector is okay, turn ignition on and put DRB-II in voltmeter mode. Probe cavity No. 20. See Fig. 7.
If voltage is 10 volts or more, replace SBEC. Perform TEST CH-VER, CHARGING
VERIFICATION. If voltage is less than 10 volts, repair open circuit in Dark Green wire. Perform
TEST CH-VER, CHARGING VERIFICATION.
Fig. 7: Identifying SBEC Connector Cavity No. 20

TEST CH-3, CHARGING SYSTEM VOLTAGE LOW
1. Read voltage goal. If voltage goal is 15.1 volts or more, replace SBEC. If voltage goal is less than 15.1
volts, use an external voltmeter and connect positive lead to the alternator BAT (B+) and negative lead
to battery positive terminal.
CAUTION: Ensure all wires are clear of moving parts.
2. Start engine. If voltage is 0.4 volt or more, repair Black or Red wire for high resistance between alternator
and battery. If voltage is less than 0.4 volt, turn ignition off. Using an external voltmeter, connect positive
lead to alternator case and negative lead to negative battery terminal.
3. Start engine. If voltage is 0.1 volt or more, repair high resistance between alternator and negative battery
cable. If the voltage is less than 0.1 volt, manually set engine speed to 1600 RPM. Compare voltage goal
on DRB-II and reading on external meter. If difference is 1.0 volt or more, replace alternator. If
difference is less than 1.0 volt, see TEST CH-5, CHECKING FOR INTERMITTENT PROBLEMS.
TEST CH-4, CHARGING SYSTEM VOLTAGE HIGH
1. Turn ignition on. Put DRB-II in voltmeter mode. Probe Dark Green wire at back of alternator. Go to step
3) if voltage is 10.0 volts or more. If voltage is less than 10.0 volts, turn ignition off. Disconnect SBEC
connector, inspect and repair if necessary. If connector is okay, turn ignition on. Probe Dark Green
wire at back of alternator. If the voltage is 10.0 volts or more, replace SBEC. Perform TEST CH-
VER, CHARGING VERIFICATION. If the voltage is less than 10.0 volts, go to step 2).
2. Turn ignition off. Disconnect alternator harness from alternator. Put DRB-II in ohmmeter mode.
Probe Dark Green wire in alternator harness. If resistance is less than 10.0 ohms, repair Dark Green
wire for short to ground. If resistance is 10.0 ohms or more, replace alternator. Perform TEST CH-
VER, CHARGING VERIFICATION.
3. With ignition on and engine off, read voltage goal. If voltage goal is less than 13.0 volts, replace the
SBEC and perform TEST CH-VER, CHARGING VERIFICATION. If voltage goal is 13.0 volts or
more, start engine and read voltage goal. Compare readings. Watch for up to 5 minutes, if necessary, for a
1.0-volt difference. If voltage difference is 1.0 volt or more, replace SBEC. Perform TEST CH-VER,
CHARGING VERIFICATION. If voltage difference is less than 1.0 volt, go to TEST CH-5,
CHECKING FOR INTERMITTENT PROBLEMS.
TEST CH-5, CHECKING FOR INTERMITTENT PROBLEMS
NOTE: Perform TEST CH-4, CHARGING SYSTEM VOLTAGE HIGH before proceeding.
1. Actuate the alternator field. Put DRB-II in voltmeter mode. Probe the Dark Green wire at back of
alternator.
NOTE: Voltage should cycle from zero to battery voltage every 1.4 seconds.
2. While watching the DRB-II, wiggle wires between alternator and SBEC. If there is any interruption in the
voltage cycle, repair wire at point cycle at which was interrupted. If there is no interruption of voltage
cycle, test is complete. Perform the TEST CH-VER, CHARGING VERIFICATION test.
TEST CH-VER, CHARGING VERIFICATION
1. Inspect and ensure that all engine components are connected.

2. If the SBEC has been changed and if vehicle is equipped with a factory theft alarm, start vehicle at least
20 times so alarm will activate when desired. If the vehicle is a minivan or truck body, write the Emission
Maintenance Reminder (EMR) mileage into the new SBEC.
3. Connect DRB-II to engine diagnostic and erase faults.
4. Ensure no other charging system problems remain by doing the following:
 Start engine.
 Raise engine speed to 2000 RPM for at least 30 seconds.
 Allow engine to idle.
 Turn engine off.
 Turn ignition on.
 With DRB-II, read fault messages.
5. If repaired fault has reset, repair is incomplete. Check all pertinent SERVICE BULLETINS in the TECH
SERVICE BULLETINS section and return to TEST CH-1, BATTERY TEST if necessary. If there are
no other faults, repair is complete.
OVERHAUL
Overhaul information is not available.
ALTERNATOR SPECIFICATIONS
ALTERNATOR MINIMUM OUTPUT
(2)
Minimum
(1)
Application Case Number Amps
Bosch 90 Amp 4557431 84
Bosch 90 Amp 5234231 88
Denso 90 Amp 5234031 86
Denso 90 Amp 5234032 90
Denso 120 Amp 5234208 98
Denso 120 Amp 5234033 102
Dakota
Bosch 90 Amp 5234231 90
Bosch 90 Amp 5235028 90
Denso 75 Amp 4557301 75
Denso 75 Amp 5234026 75
Denso 75 Amp 5234027 75
Denso 90 Amp 5234031 90
Denso 90 Amp 5234028 90
Denso 90 Amp 5234032 90
Denso 120 Amp 5234199 90
Denso 120 Amp 5234208 120
Denso 120 Amp 5234033 120
Pickup & Ramcharger
Bosch 90 Amp 5235028 90
Denso 75 Amp 5234026 75
Denso 90 Amp 5234028 90
Denso 120 Amp 5234199 120
Denso 120 Amp 5234374 120
RWD Van
Denso 75 Amp 5234026 75
Denso 90 Amp 5234028 90
Denso 120 Amp 5234199 120
Located on tag on bottom of alternator case.
(1)
(2) Full-fielded at 1250 RPM.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (ALTERNATOR MOUNTING BOLTS)
Application Ft. Lbs. (N.m)
2.5L 40 (54)
3.0L
Upper 18 (24)
Lower 21 (28)
3.3L 40 (54)
3.9L & 5.2L 30 (41)
5.9L
Gas (1) *
Diesel
Upper 18 (24)
Lower 32 (43)
(1) Information not available from manufacturer.

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1991

ALTERNATOR & REGULATOR

1991 ELECTRICAL Chrysler Motors Corp. Alternators & Regulators

 Battery feed to SBEC

Denso 90 Amp 5234031 4

(2) Dynamic tensioner used, no adjustment is required.

Before proceeding with charging system diagnosis, ensure:

 Battery is fully charged and in good condition

UNSTEADY OR LOW CHARGING

Check for grounded alternator field wiring or faulty alternator.

Check for worn alternator bearings or loose alternator mounting.

ALTERNATOR OUTPUT WIRE RESISTANCE TEST

Fig. 1: Testing Alternator Output Wire Resistance (Gasoline)

Fig. 2: Testing Alternator Output Wire Resistance (Diesel)

CURRENT OUTPUT TEST

NOTE: CURRENT OUTPUT TEST determines if alternator is capable of delivering

Fig. 3: Identifying Alternator Terminals

Fig. 4: Testing Alternator Current Output (Gasoline)

Fig. 5: Testing Alternator Current Output (Diesel)

VOLTAGE REGULATOR TEST (DIESEL)

VOLTAGE REGULATOR SPECIFICATIONS

Fig. 6: Testing Voltage Regulator (Diesel)

NOTE: Alternators are non-serviceable and must be replaced as complete units.

Before proceeding with diagnosis, the following precautions must be followed:

ENTERING ON-BOARD SELF DIAGNOSTICS

READING TROUBLE CODES

TROUBLE CODE DEFINITIONS

1. See CHARGING SYSTEM FAULT CODES table for charging-related faults.

CHARGING SYSTEM FAULT CODES

CHECK ENGINE LIGHT DIAGNOSTIC MODE

DIAGNOSIS USING DRB-II

DRB-II DIAGNOSTIC MODE

ERASING FAULT CODES

SELF-DIAGNOSTICS DRB-II TEST FUNCTIONS

NOTE: DO NOT touch DRB-II keypad during DRB-II power-up sequence, or an

SYSTEM TEST MODE

This function is not available in the engine diagnostics program.

READ FAULTS MODE

STATE DISPLAYS MODE

ACTUATOR TEST MODE

DRB-II VOLT/OHMMETER MODE

NOTE: Because DRB-II is grounded through engine diagnostic connector, only

DRB-II CONTINUITY METER MODE

VEHICLES TESTED MODE

HOW TO USE MODE

SELF DIAGNOSIS DRB-II PROBLEMS & ERROR MESSAGES

RAM TEST FAILURE MESSAGE

CARTRIDGE ERROR MESSAGE

Replace DRB-II cartridge.

KEY PAD TEST FAILURE MESSAGE

HIGH OR LOW BATTERY MESSAGE

Correct condition of vehicle battery and reconnect DRB-II.

TEST CH-1, BATTERY TEST

NOTE: Perform visual check before proceeding.

MINIMUM VOLTAGE SPECIFICATION

0°F (-18°C) 8.5

TEST CH-2, ALTERNATOR FIELD NOT SWITCHING PROPERLY

NOTE: Perform TEST CH-1, BATTERY TEST before proceeding.

Fig. 7: Identifying SBEC Connector Cavity No. 20

TEST CH-3, CHARGING SYSTEM VOLTAGE LOW

NOTE: Perform TEST CH-1, BATTERY TEST before proceeding.

CAUTION: Ensure all wires are clear of moving parts.

TEST CH-4, CHARGING SYSTEM VOLTAGE HIGH

NOTE: Perform TEST CH-1, BATTERY TEST before proceeding.