Chrysler Caravan/Voyager/Town n Country 1984-1995

Starter

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Fig. Fig. 1: Bosch direct drive starter



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Fig. Fig. 2: Nippondenso direct drive starter



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Fig. Fig. 3: Nippondenso reduction gear starter

TEST PROCEDURES (ON VEHICLE)



The battery is the heart of the electrical system. If the battery is not up to specification it will not deliver the necessary amperage for proper starter operation.

Starter Does Not Operate

CAUTION
Before performing this test, disconnect the coil wire from the distributor cap center tower and secure to a good engine ground. This will prevent the engine from starting.

  1. Connect a voltmeter across the battery terminals and confirm that battery voltage (12.4 volts) is available for the ignition and cranking system.
  2.  
  3. Turn the headlights on.
  4.  
  5. If the headlights do not operate. Check the battery cables for loose or corroded connection.
  6.  
  7. If the headlights glow normally, have a helper operate the ignition switch. Headlights should remained reasonably bright when ignition switch is operated. If the headlights dim considerably or go out when the ignition switch is operated, the problem is battery related.
  8.  
  9. If headlights remain bright when the ignition switch is operated. The problem is at the starter relay, wiring, or starter motor.
  10.  
  11. Connect a test light to the battery feed terminal of the starter relay. The test light should go on. If the test light is off, check the battery feed wire to starter relay.
  12.  
  13. Connect the test light to the ignition switch terminal of starter relay and a known good engine ground. Have a helper operate the ignition switch. If the test light does not come on when the ignition switch is operated, check the wiring from the ignition switch to the relay. The test light should have come on.
  14.  
  15. Connect a heavy jumper wire, between the battery relay feed and the relay solenoid terminal. If the starter motor operates replace the starter relay. If the motor does not operate, remove the starter for repairs.
  16.  

REMOVAL & INSTALLATION



See Figures 4, 5, 6, 7, 8 and 9



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Fig. Fig. 4: Starter motor mounting-2.2L and 2.5L engines



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Fig. Fig. 5: Working from under the vehicle, disconnect the starter motor heat shield clamp



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Fig. Fig. 6: View of the starter motor with the heat shield removed while looking over the crossmember



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Fig. Fig. 7: Removing the starter motor mounting stud nut where the air pump tube bracket is also attached



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Fig. Fig. 8: Removing a starter motor mounting bolt



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Fig. Fig. 9: Starter motor mounting-2.6L engines with automatic transaxles

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle. The starter can be removed by reaching over the crossmember.
  4.  
  5. Remove the heat shield and its clamps, if so equipped.
  6.  
  7. On the 2.2L and 2.5L engines, loosen the air pump tube at the exhaust manifold and move the tube bracket away from the starter.
  8.  
  9. Remove the electrical connections from the starter.
  10.  
  11. Remove the bolts attaching the starter to the flywheel housing and the rear bracket to the engine or transaxle.
  12.  
  13. Remove the starter from the engine.
  14.  

To install:
  1. Position the replacement starter against the mounting surface.
  2.  
  3. Install the mounting bolts.
  4.  
  5. Connect the starter wiring.
  6.  
  7. On 2.2L and 2.5L engines, position the air pump tube toward the starter, then connect the tube bracket to the exhaust manifold.
  8.  
  9. Install the heat shield and clamp.
  10.  
  11. Connect the negative battery cable.
  12.  

SOLENOID REPLACEMENT



See Figures 10, 11 and 12



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Fig. Fig. 10: Bosch starter solenoid mounting screws



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Fig. Fig. 11: Bosch starter solenoid mounting screws



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Fig. Fig. 12: Exploded view of the Bosch starter

  1. Remove the starter as previously outlined.
  2.  
  3. Disconnect the field coil wire from the solenoid.
  4.  
  5. Remove the solenoid mounting screws.
  6.  
  7. Work the solenoid off of shift fork lever and remove the solenoid.
  8.  

To install:
  1. Install plunger on replacement solenoid.
  2.  
  3. Install plunger on shift fork lever.
  4.  
  5. Secure the solenoid with the mounting screws.
  6.  
  7. Install the starter motor assembly.
  8.  

STARTER GEAR & CLUTCH REPLACEMENT



See Figure 13



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Fig. Fig. 13: Removing the pinion and clutch and drive gear

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the starter from the vehicle.
  4.  
  5. Remove the 2 gear housing attaching screws from the starter.
  6.  
  7. Separate the gear housing from the solenoid housing. The pinion, pinion gear bearing and drive gear will all be loose between the 2 housings. The starter gear and clutch can also be removed at this time.
  8.  

To install:
  1. To reinstall the pinion gear and bearing, wipe clean with a rag and coat with light weight wheel bearing grease.
  2.  
  3. Place the bearing and gear over the shaft in the housing. Reinstall the starter gear and clutch if removed.
  4.  
  5. Install the housings and reinstall the retaining screws.
  6.  
  7. Install the starter in the vehicle, then connect the negative battery cable.
  8.  

 
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