Chrysler Caravan/Voyager/Town and Country 1996-1999

Starter

Print

TESTING



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.
 

Starter Feed Circuit

See Figures 1 and 2



Click image to see an enlarged view

Fig. Fig. 1: This is the type of volt-ampere tester required for this type of testing



Click image to see an enlarged view

Fig. Fig. 2: Proper connection for the volt-ampere tester


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:

    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.  


WARNING
Do not overheat the starter motor or draw the battery voltage below 9.6 volts during cranking operations.

  1. 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.
  2.  

Starter Feed Circuit Resistance

See Figures 3, 4, 5 and 6

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:
  4.  



Click image to see an enlarged view

Fig. Fig. 3: 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. Fig. 4: 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. Fig. 5: Testing the starter motor ground



    Click image to see an enlarged view

    Fig. Fig. 6: 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.  

REMOVAL & INSTALLATION



See Figures 7, 8, 9, 10 and 11



Click image to see an enlarged view

Fig. Fig. 7: Disengage the solenoid wiring connector, then the battery positive (B+) nut and wire from the starter motor



Click image to see an enlarged view

Fig. Fig. 8: Remove the 3 starter motor-to-transaxle bellhousing mounting bolts



Click image to see an enlarged view

Fig. Fig. 9: Remove the starter motor from the vehicle



Click image to see an enlarged view

Fig. Fig. 10: After removing the starter motor, examine the teeth of the flywheel for excessive wear or damage. Repair if necessary



Click image to see an enlarged view

Fig. Fig. 11: If the old starter is going to be re-installed, check the condition of the pinion gear teeth. Replace the starter if the pinion gear shows excessive wear or damage

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the front of the vehicle securely on jackstands.
  4.  
  5. Disengage the solenoid wiring connector from the terminal. This connection may be held in place by a retaining nut, or it could be a push-in connector.
  6.  
  7. Remove the B+ nut and wire from the starter motor terminal.
  8.  
  9. Remove the starter motor-to-transaxle bellhousing mounting bolts.
  10.  
  11. Remove the starter from the vehicle. If equipped, remove the starter motor spacer.
  12.  

To install:
  1. If equipped, hold the starter motor spacer in position.
  2.  
  3. Install the starter motor into position on the vehicle.
  4.  
  5. Install the starter motor-to-transaxle bellhousing mounting bolts. Tighten the mounting bolts to 40 ft. lbs. (54 Nm).
  6.  
  7. Engage the solenoid wiring connector onto the starter terminal.
  8.  
  9. Connect the B+ wire and tighten the retaining nut to 90 inch lbs. (10 Nm).
  10.  
  11. Lower the vehicle.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Verify starter motor operation.
  16.  

RELAY REPLACEMENT



The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the underside of the PDC cover for starter relay location.

To remove the relay from the vehicle, simply grasp the relay and firmly pull straight up to disengage from the PDC.

 
label.common.footer.alt.autozoneLogo