Caravan, Town & Country 2006-2007

Starter

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Starter harness connectors
     
    Starter motor
     

  4.  

To install:

  1. Install or connect the following:

    Starter motor. Torque the bolts to 35 ft. lbs. (47 Nm).
     
    Starter harness connectors. Torque the battery cable nut to 100 inch lbs. (11 Nm).
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Starter harness connectors
     
    Starter motor
     

  4.  

To install:

  1. Install or connect the following:

    Starter motor. Torque the bolts to 35 ft. lbs. (47 Nm).
     
    Starter harness connectors. Torque the battery cable nut to 100 inch lbs. (11 Nm).
     
    Negative battery cable
     

  2.  

Testing & Troubleshooting



Feed Circuit Test

CAUTION
The ignition and fuel systems must be disabled to prevent engine start while performing the tests.

  1. Connect a volt-ampere tester to the battery terminals. Refer to the operating instructions provided with the tester.
  2.  
  3. Disable the ignition and fuel systems by disconnecting the Automatic Shutdown (ASD) relay, located in the Power Distribution Center (PDC) in the engine compartment.
  4.  
  5. Verify that all lights and accessories are OFF , and the transaxle shift selector is in PARK . Set the parking brake.
  6.  
  7. Rotate and hold the ignition switch in the START position. Observe the volt-ampere tester:
    WARNING
    Do not overheat the starter motor or draw the battery voltage below 9.6 volts during cranking operations.



    If the voltage reads above 9.6 volts, and the amperage draw reads above 280 amps, check for engine seizing or a faulty starter, then go to the starter feed circuit resistance test.
     
    If the voltage reads 12.4 volts or greater and the amperage reads 0-10 amps, check for corroded cables and/or bad connections.
     
    If the voltage reads below 9.6 volts and the amperage draw reads above 300 amps, the trouble is within the starter.
     

  8.  
  9. After the starting system problems have been corrected, verify the battery-s state of charge, and charge the battery if necessary. Disconnect all of the testing equipment and connect the ASD relay. Start the vehicle several times to assure the problem was corrected.

    Click image to see an enlarged view

    Fig. This is the type of volt-ampere tester required for this type of testing



    Click image to see an enlarged view

    Fig. Proper connection for the volt-ampere tester

  10.  

The following test will require a voltmeter, which is capable of accuracy to within 0.1 volt.


CAUTION
The ignition and fuel systems must be disabled to prevent engine start while performing the tests.

  1. Disable the ignition and fuel systems by disconnecting the Automatic Shutdown (ASD) relay, located in the Power Distribution Center (PDC) in the engine compartment.
  2.  
  3. With all wiring harnesses and components properly connected, perform the following:

    Click image to see an enlarged view

    Fig. Testing the battery connection resistance

    1. Connect the negative (-) lead of the voltmeter to the negative battery post, and the positive (+) lead to the negative battery cable clamp. Rotate and hold the ignition switch in the START position. Observe the voltmeter. If voltage is detected, correct the poor contact between the cable clamp and battery post.

      Click image to see an enlarged view

      Fig. Testing the ground circuit resistance

    2.  
    3. Connect the positive (+) lead of the voltmeter to the positive battery post, and the negative (-) lead to the positive battery cable clamp. Rotate and hold the ignition switch key in the START position while observing the voltmeter. If voltage is detected, correct the poor contact between the cable clamp and battery post.
    4.  
    5. Connect the negative lead of the voltmeter to the negative (-) battery terminal, and the positive lead to the engine block near the battery cable attaching point. Rotate and hold the ignition switch in the START position. If the voltage reads above 0.2 volt, correct the poor contact at the ground cable attaching point. If the voltage reading is still above 0.2 volt after correcting the poor contact, replace the negative ground cable with a new one.

      Click image to see an enlarged view

      Fig. Testing the starter motor ground



      Click image to see an enlarged view

      Fig. Testing the battery positive cable resistance

    6.  
    7. Connect the positive (+) voltmeter lead to the starter motor housing and the negative (-) lead to the negative battery terminal. Hold the ignition switch key in the START position. If the voltage reads above 0.2 volt, correct the poor starter to engine ground.
    8.  
    9. Connect the positive (+) voltmeter lead to the positive battery terminal, and the negative lead to the battery cable terminal on the starter solenoid. Rotate and hold the ignition key in the START position. If the voltage reads above 0.2 volt, correct the poor contact at the battery cable to the solenoid connection. If the reading is still above 0.2 volt after correcting the poor contact, replace the positive battery cable with a new one.
    10.  
    11. If the resistance tests did not detect feed circuit failures, replace the starter motor.
    12.  

  4.  

Testing Preparation

Before commencing with the starting system diagnostics, verify:



The battery posts/terminals are clean.
 
The alternator drive belt tension and condition is correct.
 
The battery state-of-charge is correct.
 
The battery cable connections at the starter and engine block are clean and free from corrosion.
 
The wiring harness connectors and terminals are clean and free from corrosion.
 
The circuit is properly grounded.
 

Voltage Drop Test

NOTE
The battery must be in good condition and fully charged prior to performing this test.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disable the ignition system by unplugging the ignition system fuse. Verify that the vehicle will not start.
  4.  
  5. Connect a voltmeter between the positive terminal of the battery and the main terminal on the starter solenoid from the battery.
  6.  
  7. Turn the ignition key to the START position and note the voltage on the meter.
  8.  
  9. If voltage reads 0.5 volts or more, there is high resistance in the starter cables or the cable ground, repair as necessary. If the voltage reading is ok proceed to the next step.
  10.  
  11. Connect a voltmeter between the positive terminal of the battery and the terminal on the solenoid leading to the starter.
  12.  
  13. Turn the ignition key to the START position and note the voltage on the meter.
  14.  
  15. If voltage reads 0.5 volts or more, there is high resistance in the starter. Repair or replace the starter as necessary.
    NOTE
    Many automotive parts stores have starter bench testers available for use by customers. A starter bench test is the most definitive way to determine the condition of your starter.

  16.  

 
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