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Simple free hack to keep your charging voltage at 14.4V

 
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Old 11 Nov 2016, 10:45 pm
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Talking Simple free hack to keep your charging voltage at 14.4V

From the service manual;

Quote:
VOLTAGE REGULATOR
The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced.

The amount of DC current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground.

Voltage is regulated by cycling the ground path on SBEC vehicles or the power side on the NGC vehicles, to control the strength of the rotor magnetic field. The EVR circuitry monitors system line voltage at the PDC and calculated battery temperature or inlet air temperature sensor (refer to Inlet Air Temperature Sensor, if equipped, for more information ). It then determines a target charging voltage. If sensed battery voltage is lower than the target voltage, the PCM feeds the field winding until sensed battery voltage is at the target voltage. A circuit in the PCM cycles the feed side of the generator field at 250 times per second (250 Hz) , but has the capability to feed the field control wire 100% of the time (full field) to achieve the target voltage. If the charging rate cannot be monitored (limp-in), a duty cycle of 20% is used by the PCM in order to have some generator output. Also refer to Charging System Operation for additional information.
Have you checked your alternator charging voltage lately ? How about when your car is warmed up and running, and just after you cranked it to start ?
A properly operating charging system should never really go below 14.4 volts. After starting the car, the charging system should go to 14.7 volts and slowly decline to 14.2 or 14.4.
In fact, my charging system never went higher than 13.7 volts when cold, and as the engine warmed up it would often stay at 13.2 volts, which is far too low.

With winter season upon us, a low charging voltage will recharge batteries slower and could end up by contributing to battery failure.
We can determine on turbo models the battery temperature sensor determines the alternator voltage. The sensor is a simple thermistor. Over time, the material in the thermistor breaks down and becomes out of calibration. The engine computer sends 5 volts to the temperature sensor and determines the voltage drop as a function of its temperature, which is used as an actuating signal to drive the voltage intensity the generator can produce.

I installed a 47K, 1/8 watt resistor in series with the wiring harness leading to the battery temperature sensor. My sensor measures about 10K ohm at room temperature. Adding these values up gave 57K, and before choosing that resistor size I had used a 100K ohm potentiometer to test what and acceptable range would be to keep a high charging voltage without triggering any engine codes. Initially I had used a 39K resistor but it was a little bit too low and I chose to go with a 47K. In my case, the resistor was in my electronics parts bin, and so I consider it free as well !

Hope this can be a free little hack to those who were wondering why there alternator voltages were always low for no good reason.
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Old 12 Nov 2016, 07:04 am
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Default Re: Simple free hack to keep your charging voltage at 14.4V

I don't suppose you have a picture of this, do you? And where did you purchase the resistor?
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Old 12 Nov 2016, 09:38 am
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Default Re: Simple free hack to keep your charging voltage at 14.4V

You should monitor your voltage before deciding whether to do this or not. I have a voltage gauge in my Ford and after modifying my charging system, i watch the gauge sit high in the morning on the freeway when all the lights and heat are off and the rpm's are up..

What is your voltage after driving on the expressway for 20 minutes with all accessories off? Any way you can check? You might be surprised.
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Old 12 Nov 2016, 06:16 pm
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Default Re: Simple free hack to keep your charging voltage at 14.4V

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Originally Posted by rob302 View Post
You should monitor your voltage before deciding whether to do this or not. I have a voltage gauge in my Ford and after modifying my charging system, i watch the gauge sit high in the morning on the freeway when all the lights and heat are off and the rpm's are up..


What is your voltage after driving on the expressway for 20 minutes with all accessories off? Any way you can check? You might be surprised.
Of course. I have already addressed monitoring my voltage before deciding to do this, or else there would be no point of doing this modification.
14.5 volts. I have a radar detector that displays the system voltage. And as well I have a fluke multi meter which displays the average voltage over time.
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2003 GT M/T in Onyx Green Pearl on Michelin Pilot Sport AS 3 Plus Tires 205/50ZR17. Dark Slate Gray Interior. OEM cargo net, parcel shelf, slush mats and trunk protector, mud flaps, mopar subwoofer. Platinum edition pedals, Neon SX 2.0 steering wheel with black+grey wrapped leather cover. Generic lowering springs, KYB gas shocks, Valeo solid flywheel conversion and clutch kit. Urethane insert engine mounts. Energy suspension full body urethane bushing kit. Chrysler premium front speakers, Jenson 6x9 rears. Boston Audio 4x55W amp. Panasonic head unit with xtenzi bluetooth. 300W AC power inverter. Escort 360max and Escort Shifter ZR4, dual front+rear dash camera. stage 1 blow off valve and syked tune computer . Boost and oil pressure gauges with Turbo-Timer. Needswings 3" exhaust elbow, Electric valve actuated Y-pipe with catalytic converter. To do: coilovers, 2step controller, quaife diff, Air-Fuel Meter

Last edited by _PTGT03; 12 Nov 2016 at 06:18 pm.
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Old 12 Nov 2016, 06:21 pm
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Default Re: Simple free hack to keep your charging voltage at 14.4V

Quote:
Originally Posted by chuzz View Post
I don't suppose you have a picture of this, do you? And where did you purchase the resistor?


Shown in here photo is a 39K resistor. I later changed it to a 47K resistor. You can find a resistor in pretty much any electronics supply store. If you wanted to undertake this project you would need to solder some wires and use a resistor colour code sheet.
I later covered all the connections with heat shrink wrap.
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2003 GT M/T in Onyx Green Pearl on Michelin Pilot Sport AS 3 Plus Tires 205/50ZR17. Dark Slate Gray Interior. OEM cargo net, parcel shelf, slush mats and trunk protector, mud flaps, mopar subwoofer. Platinum edition pedals, Neon SX 2.0 steering wheel with black+grey wrapped leather cover. Generic lowering springs, KYB gas shocks, Valeo solid flywheel conversion and clutch kit. Urethane insert engine mounts. Energy suspension full body urethane bushing kit. Chrysler premium front speakers, Jenson 6x9 rears. Boston Audio 4x55W amp. Panasonic head unit with xtenzi bluetooth. 300W AC power inverter. Escort 360max and Escort Shifter ZR4, dual front+rear dash camera. stage 1 blow off valve and syked tune computer . Boost and oil pressure gauges with Turbo-Timer. Needswings 3" exhaust elbow, Electric valve actuated Y-pipe with catalytic converter. To do: coilovers, 2step controller, quaife diff, Air-Fuel Meter
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