Chrysler Cirrus/Stratus/Sebring/Avenger/Breeze 1995-1998

Starter

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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 Figure 1


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

  1. Connect a volt-ampere tester (multimeter) to the battery terminals.
  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.  



Click image to see an enlarged view

Fig. Fig. 1: Volt-Amp tester connections for Cirrus, Stratus, Sebring convertible and Breeze models. (Sebring and Avenger coupe models utilize a conventional hook-up method)

  1. Verify that all lights and accessories are OFF, and the transaxle shift selector is in Park (automatic) or Neutral (manual). Set the parking brake.
  2.  
  3. 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 250 amps, go to the starter feed circuit resistance test (following this test).
     
    If the voltage reads 12.4 volts or greater and the amperage reads 0-10 amps, refer to the starter control circuit test.
     
    If the voltage reads below 9.6 volts and the amperage draw reads above 300 amps, the trouble is within the starter.
     

  4.  


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 ignition coil cable or ignition coil connector. Start the vehicle several times to assure the problem was corrected.
  2.  

Starter Feed Circuit Resistance

See Figures 2 and 3

Before proceeding with this test, refer to the battery tests and starter feed circuit test. 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:
    1. Connect the negative (-) lead of the voltmeter to the negative battery terminal, and the positive (+) lead to a point on the engine block near the battery cable attaching point. Rotate and hold the ignition switch in the START position. Observe the voltmeter. If the voltage reads above 0.2 volt, correct the poor contact at the ground cable mounting points.
    2.  
    3. Connect the positive (+) lead of the voltmeter to the positive battery terminal, and the negative (-) lead to the positive battery cable terminal on the starter solenoid. Rotate and hold the ignition switch key in the START position while observing the voltmeter. If voltage reads above 0.2 volt, correct the poor contact between the cable end and battery terminal.
    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.
    6.  

  4.  



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Fig. Fig. 2: Testing ground circuit resistance



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Fig. Fig. 3: Testing the positive battery cable's resistance

  1. Refer to removal and installation procedures to gain access to the starter motor and solenoid connections. Perform the following steps:
    1. 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.
    2.  
    3. 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.
    4.  
    5. If the resistance tests did not detect feed circuit failures, replace the starter motor.
    6.  

  2.  

REMOVAL & INSTALLATION



2.0L DOHC Engine

See Figure 4

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the starter motor electrical connections.
  4.  
  5. Remove the starter motor mounting bolts and remove the starter.
  6.  



Click image to see an enlarged view

Fig. Fig. 4: Exploded view of the starter motor mounting-2.0L engine

To install:
  1. Clean both surfaces of the starter motor flange and the rear plate. This is important since the starter grounds through its case and the transaxle flange to which it attached. Some remanufactured starters may have paint on these areas which should be cleaned off before installation. Install the starter motor onto the transaxle and secure with the retaining bolts. Tighten the bolts to 40 ft. lbs. (54 Nm).
  2.  
  3. Attach the electrical harness connectors to the starter.
  4.  
  5. Connect the negative battery cable and check the starter for proper operation.
  6.  

2.0L SOHC Engine With Manual Transaxle

See Figures 4 and 5

  1. Disconnect the negative battery cable from the left strut tower. The ground cable is equipped with a insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.
  2.  
  3. Remove the air cleaner resonator.
  4.  
  5. Remove the positive battery cable retaining nut from the starter.
  6.  
  7. Disconnect the positive battery cable and alternator output wire from the starter.
  8.  
  9. Disconnect the push-on solenoid connector from the starter.
  10.  
  11. Remove the 2 bolts that attach the starter to the transaxle.
  12.  
  13. Remove the starter from the vehicle.
  14.  



Click image to see an enlarged view

Fig. Fig. 5: Starter motor wiring terminal connections-2.0L engine

To install:
  1. Install the starter and the attaching bolts to the transaxle assembly.
  2.  
  3. Tighten the attaching bolts to 40 ft. lbs. (54 Nm).
  4.  

Clean all dirt and/or corrosion from the wire terminals before reconnecting the wiring to the solenoid.

  1. Reconnect the push-on solenoid connector to the starter.
  2.  
  3. Reconnect the alternator output wire and positive battery cable to the starter and tighten the retaining nut to 90 inch lbs. (10 Nm).
  4.  
  5. Install the air cleaner resonator.
  6.  
  7. Reconnect the negative battery cable.
  8.  

2.0L SOHC Engine With Automatic Transaxle; 2.4L Engine

See Figures 4, 5 and 6

  1. Disconnect the negative battery cable from the left strut tower. The ground cable is equipped with a insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.
  2.  
  3. Remove the air cleaner resonator.
  4.  
  5. Remove the 3 bolts attaching the Transmission Control Module (TCM). Do not disconnect the TCM wiring. Move the TCM to gain access to the upper starter mounting bolt.
  6.  
  7. Remove the upper starter mounting bolt.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Remove the positive battery cable nut and disconnect the cable from the starter.
  12.  
  13. Disconnect the push-on solenoid connector.
  14.  
  15. Remove the lower mounting bolt that attaches the starter to the transaxle.
  16.  
  17. Remove the starter from the vehicle.
  18.  



Click image to see an enlarged view

Fig. Fig. 6: Starter motor wiring terminal connections-2.0L SOHC engine with A/T; 2.4L engine

To install:
  1. Install the starter onto the transaxle and the lower mounting bolt.
  2.  
  3. Tighten the mounting bolts to 40 ft. lbs. (54 Nm).
  4.  

Before reconnecting the wiring to the starter solenoid, be sure to clean the wiring of any dirt or corrosion.

  1. Reconnect the positive battery cable to the solenoid post and tighten the retaining nut to 90 inch lbs. (10 Nm).
  2.  
  3. Reconnect the push-on solenoid connector.
  4.  
  5. Lower the vehicle.
  6.  
  7. Reinstall the upper attaching bolt and torque to 40 ft. lbs. (54 Nm).
  8.  
  9. Reinstall the TCM to its original location and install the mounting screws.
  10.  
  11. Reinstall the air cleaner resonator.
  12.  
  13. Reconnect the negative battery cable.
  14.  

2.5L (VIN N) Engine

See Figure 7

  1. Disconnect the negative battery cable.
  2.  
  3. Most vehicles will require the removal of the front exhaust pipe. Use penetrating oil on the fasteners to ease removal.
  4.  
  5. Disconnect the starter motor electrical connections.
  6.  
  7. Remove the starter motor mounting bolts and remove the starter.
  8.  



Click image to see an enlarged view

Fig. Fig. 7: Exploded view of the starter motor mounting-2.5L engine

To install:
  1. Clean both surfaces of the starter motor flange and the rear plate. This is important since the starter grounds through its case and the transaxle flange to which it attached. Some remanufactured starters may have paint on these areas which should be cleaned off before installation. Install the starter motor onto the transaxle and secure with the retaining bolts. Tighten the bolts to 20-25 ft. lbs. (26-33 Nm).
  2.  
  3. Connect the electrical harness connectors to the starter.
  4.  
  5. Connect the negative battery cable and check the starter for proper operation.
  6.  

2.5L (VIN H) Engine

See Figures 8 through 14

  1. Disconnect the negative battery cable from the left strut tower. The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Loosen, but do not remove, the exhaust pipe-to-manifold retaining nuts.
  6.  
  7. Place a drain pan under the oil filter to prevent oil spillage, then remove the oil filter. For additional details, refer to General Information & Maintenance .
  8.  



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Fig. Fig. 8: Loosen the exhaust pipe-to-manifold retaining nuts to provide removal clearance for the starter



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Fig. Fig. 9: Location of the positive battery cable nut (1) and the push-on solenoid connector (2)



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Fig. Fig. 10: After removing the oil filter for access, unfasten the retaining nut and disconnect the positive battery cable



Click image to see an enlarged view

Fig. Fig. 11: Disengage the push-on starter solenoid connector

  1. Remove the positive battery cable retaining nut and battery cable from the starter.
  2.  
  3. Disconnect the push-on solenoid connector.
  4.  
  5. Remove the 3 bolts that attach the starter unit to the transaxle.
  6.  
  7. Pull the exhaust pipe down just enough to provide clearance for the starter motor. The exhaust pipe does not have to be separated from the pipe-to-manifold threaded studs.
  8.  
  9. Remove the starter unit from the vehicle.
  10.  



Click image to see an enlarged view

Fig. Fig. 12: Remove the 3 starter motor-to-transaxle housing attaching bolts



Click image to see an enlarged view

Fig. Fig. 13: Pull the exhaust pipe down just enough to provide removal clearance for the starter



Click image to see an enlarged view

Fig. Fig. 14: Carefully remove the starter motor from the vehicle

To install:
  1. Install the starter unit onto the transaxle and install the 3 mounting bolts.
  2.  
  3. Tighten the mounting bolts to 40 ft. lbs. (54 Nm).
  4.  

Before reconnecting any wiring to the starter solenoid, clean the wire terminals of any dirt or corrosion.

  1. Reconnect the positive battery terminal and retaining nut to the starter solenoid post. Tighten the retaining nut to 90 inch lbs. (10 Nm).
  2.  
  3. Reconnect the push-on solenoid connector.
  4.  
  5. Reinstall the oil filter.
  6.  
  7. Lower the vehicle.
  8.  
  9. Reconnect the negative battery cable.
  10.  

RELAY REPLACEMENT



See Figure 15

On Cirrus, Stratus, Sebring convertible and Breeze models, 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.

On Sebring and Avenger coupes, the starter relay is located under the instrument panel, behind the instrument panel/center console panel. It may only be necessary to remove the center console panel to access the starter relay. However, if the entire console requires removal, refer to Body & Trim .



Click image to see an enlarged view

Fig. Fig. 15: Location of the starter relay on Sebring and Avenger coupes

 
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