Description
Description
Starting and Charging System
The starting system on the vehicle comprises a 12 V starter motor which drives the engine to start the combustion process. The starter converts electrical energy into mechanical power. The vehicle electrical system must be capable of supplying sufficient power to enable the engine to be cranked.
The charging system comprises a battery and an alternator. The battery must be of sufficient capacity to operate the starter motor and operate the vanous vehicle electrical systems. The alternator charges the battery when the engine is running and increases its output as demand on the battery increases.
The instrument pack incorporates a charge warning lamp which illuminates if the there is a low output or no output from the alternator.
Alternator
The alternators used on the V8 engines are different in construction but their principles of operation are similar. The alternator used on the V8 engine is located in a water cooled housing.
The alternators comprise a stator, a rotor, a rectifier pack and a regulator. A single output terminal is connected by a heavy duty cable to the battery positive terminal via the starter motor battery connection terminal. The alternator is connected to earth via its mountings.
The rotor comprises a field winding, wound around an iron core and mounted on a shaft. The iron core has extensions at each end which form North and South poles as current flows through the field winding. The rotor is located inside the stator and is mounted on bearings for smooth running and to support the rotor due to the high side loading applied by the drive belt tension.
The stator has three sets of coils made from copper wire. The three coil windings are connected in a 'star' connection, where one end of the winding is connected to the other two windings. The output current is supplied from the opposite end of each winding. Rotation of the rotor causes ac current to be produced in the coils.
The rectifier converts the ac current produced in the stator coils into dc (rectified) current required by the vehicle electrical system. The rectifier comprises semi-conductor diodes mounted on a heatsink to dissipate heat. An equal number of the diodes are on the negative and positive side with the remaining diodes staying neutral The rectifier also prevents current flow from the battery to the alternator when the output voltage is less than the battery voltage.
The integrated regulator controls the output voltage from the alternator to prevent the battery from being overcharged and to prevent the vehicle electrical systems from excessive voltage. The regulator which is temperature related to optimize battery charging sets the maximum output voltage to a nominal 14.5 V and varies the output voltage depending on the state of charge of the battery and the loads required by the vehicle electrical systems.
The regulator has transistors which rapidly switch on and off to regulate the voltage output according to the voltage sensed internally. The regulator also provides a signal output to the ECM which uses the signal to adjust the idle speed under varying electrical loads.
Initially, the ignition switch supply provides an excitation current to the rotor at low alternator speeds via brushes which contact slip rings at the end of the rotor shaft. As the alternator speed increases the alternator becomes self exciting.
V8 Alternator
The alternator is located at the front LH side of the engine. The alternator has an output of 90/150 Amps and is manufactured by Bosch. A polyvee belt drives the alternator pulley, which in turn is driven from the engine crankshaft pulley.
Starter Motor
The starter motors used on the V8 engine are different in their construction, but their principles of operation are similar.
Both starter motors are of conventional design with the motor in line with the drive pinion and the solenoid mounted above. Each starter motor is of the pre-engaged type and comprises of a series wound motor an overunning clutch and an integral solenoid. The starter solenoid is energised by a signal from the immobilisation ECU when the ignition switch is moved to the crank position. When engine cranking is requested, the immobilisation ECU checks that a valid key code has been received before granting the crank request. The power for starter operation is supplied on a substantial single cable connected direct from the battery positive terminal. The cable is connected to the solenoid via a copper threaded stud and secured with a nut.
V8 Starter Motor
The stater motor is located on the rear RH side of the engine block. The motor is secured to the block and protrudes through an aperture to drive the flywheel via a ring gear.
Battery
The battery is located between the bulkhead and the secondary bulkhead, on the passenger side. The battery is located in a tray and secured with clamp plates and bolts.
The battery terminal posts allow for the battery cables to be connected with clamp type connections. The battery positive terminal uses a pyrotechnic attachment which detaches the battery cable in the event of a crash of a seventy to trigger the airbags. Refer to the Supplementary Restraint System section for further details.
Battery Fitment Table
All models are fitted with lead-calcium, maintenance free battery. Each battery is identical in its construction with only the battery rating differing to compensate for the different output requirements for models variants.
The battery uses 'calcium expanded' technology which has both positive and negative plates with grids expanded from a strip lead-calcium alloy. This technology provides improved durability of the mechanical integrity of the plate packs and reduces water loss when compared to previous technologies.
The battery is fully sealed. Each casing has a vent to allow for thermal expansion and to vent oxygen and hydrogen gases which are produced should the battery become overcharged.
The battery incorporates an integral, temperature compensated hydrometer to provide a visual indication of the relative density and level of the electrolyte. The indicator shows different colours to show battery condition as follows:
- GREEN - shows that the battery is charged and in a serviceable condition
- DARK (turning to black) - shows that the battery is in a low state of charge and requires recharging
- CLEAR or YELLOW - the battery is no longer serviceable and must be replaced.
If the battery shows CLEAR or YELLOW the battery has an internal fault. Do not attempt to charge or jump start the vehicle with the battery in this condition.
When removing the battery, ensure that the alarm is disarmed and that the ignition is switched off. Always disconnect the negative terminal first and then the positive terminal. When refitting the battery always fit the positive terminal first followed by the negative terminal.
If the battery requires recharging, always use an approved constant current charger, designed for lead-calcium batteries. DO NOT use a fast charger, permanent damage to the battery may occur.
Fuseboxes
Fuses are mounted in one of three fuse boxes:
- The engine compartment fusebox
- The passenger compartment fusebox
- The rear fusebox.
Some additional fusible links are mounted in the engine compartment, on the bulkhead behind the battery
NOTE: The lighting circuits are not protected by conventional fuses. MOSFETS within the Light Check Module (LCM) protect the lighting circuits. Refer to the Lighting section for details.
Three different types of fuse are used on the vehicle:
- Blade type fuse; Small, pull out, male fuse, used to protect circuits from 5 A to 30 A.
- Max fuse; A larger version of the blade type fuse. Used to protect circuits at 50 A.
- Fusible links; These are bolt down fuses used to protect circuits from 50 A to 100 A.
Engine Compartment Fusebox
The engine compartment fuse box contains blade type fuses only. The fusebox is a small, grey coloured box located within the E-box in the engine compartment.
The following table shows the fuse locations, their ratings and functions.
Rear Fusebox
The rear fuse box contains blade type fuses and maxi-fuses. The fusebox is located in the right hand side of the luggage compartment, behind the removal trim panel. The fusebox also houses relays and provides locations for some ECU's.
The following table shows the fuse locations, their ratings and functions.
Blade Type Fuses
Maxi Fuses
Passenger Compartment Fusebox
The passenger compartment fusebox contain, blade type fuses max fuses and fusible links. The fusebox is boated at the rear of the glove box. A removable panel in the rear of the glove box allows access to the blade type fuses and the max fuses. Access to the fusible links and relays, which are also located on the fusebox, requires the removal of the glovebox assembly.
The following table shows the fuse locations, their ratings and functions.
Fusible Links
Blade Type Fuses
Maxi Fuses
Bulkhead Mounted Fusible Links
Three fusible links are located in a plastic box on the bulkhead behind the battery. The fusible links functions are given in the following table. Location description is taken from driver's seat, looking forwards.
Relay Locations
The following tables show locations for relays.
Passenger Compartment Fusebox
Rear Fusebox
Engine Compartment E-Box
Other Vehicle Locations
ECU Locations
The following table shows locations for the various electronic control units used on the vehicle.
Harness Routing
The following diagrams show the vehicle harnesses and routing.
