Chrysler Concorde/Intrepid/LHS/New Yorker/Vision 1993-1997

Starter

Print

TESTING



Before performing any starter tests, the ignition and fuel systems must be disabled.

Testing Preparation

Before commencing with the starting system diagnostics, verify:



The battery top posts, and 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.
 
Proper circuit grounding.
 

Starter Feed Circuit

See Figures 1 and 2

  1. Connect a volt-ampere tester (multimeter) to the battery terminals.
  2.  



Click image to see an enlarged view

Fig. Fig. 1: Volt ampere tester

  1. To disable the ignition and fuel systems, disconnect the Automatic Shutdown Relay (ASD). The ASD relay is located in the Power Distribution Center (PDC).
  2.  


CAUTION
The ignition system must be disabled to prevent engine start while performing the following tests.



Click image to see an enlarged view

Fig. Fig. 2: The ASD relay is located in the Power Distribution Center #4

  1. Verify that all lights and accessories are OFF , and the transaxle shift selector is in P . 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 solenoid and relay tests.
     
    Voltage below 9.6 volts and amperage draw above 300 amps, the problem is 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 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

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 0.1 volt.

  1. To disable the ignition and fuel systems, disconnect the Automatic Shutdown Relay (ASD). The ASD relay is located in the Power Distribution Center (PDC).
  2.  



Click image to see an enlarged view

Fig. Fig. 3: Connect the positive (+) lead of the voltmeter to the positive battery post, and the negative - to the positive battery cable clamp

  1. With all wiring harnesses and components properly connected, perform the following:
    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 the voltage is detected, correct the poor contact between the cable clamp and post.
    2.  
    3. Connect the positive (+) lead of the voltmeter to the positive battery post, and the negative - to the positive battery cable clamp. Rotate and hold the ignition switch key in the START position. Observe the voltmeter. If voltage is detected, correct the poor contact between the cable clamp and post.
    4.  
    5. Connect the negative lead of the voltmeter to the negative - battery terminal, and 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 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.  

  2.  



Click image to see an enlarged view

Fig. Fig. 4: Connect the negative lead of the voltmeter to the negative - battery terminal, and positive lead to the engine block near the battery cable attaching point

  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.  



Click image to see an enlarged view

Fig. Fig. 5: Connect the positive (+) voltmeter lead to the starter motor housing and the negative - lead to the negative battery terminal

  1. 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 poor contact at the battery cable to the solenoid connection. If the reading is still above 0.2 volt after correcting the poor contacts, replace the positive battery cable with a new one.
  2.  
  3. If the resistance tests did not detect feed circuit failures, replace the starter motor.
  4.  



Click image to see an enlarged view

Fig. Fig. 6: Connect the positive (+) voltmeter lead to the positive battery terminal, and the negative lead to the battery cable terminal on the starter solenoid

Starter Solenoid

See Figure 7

  1. Battery and circuit tests must be performed before this test. Perform this test before the starter relay test.
  2.  


WARNING
Check to ensure that the transaxle is in Park with the parking brake applied.

  1. Raise and safely support the front of the vehicle on jackstands.
  2.  
  3. Perform a visual inspection of the starter/starter solenoid for corrosion, loose connections or faulty wiring.
  4.  
  5. Lower the vehicle.
  6.  
  7. Locate and remove the starter relay in the Power Distribution Center (PDC).
  8.  
  9. Connect a remote starter switch or a jumper wire between the battery positive (+) post and terminal 87 on the starter relay connector (see the illustration).
  10.  



Click image to see an enlarged view

Fig. Fig. 7: Starter relay terminal labeling

  1. Try to crank the engine over with the ignition switch:

    If the engine now cranks, the starter/solenoid is good. Refer to the starter relay test.
     
    If the engine does not crank with this test, or the solenoid chatters, check the wiring and connectors from the starter relay to the starter solenoid for loose or corroded connections. Particularly at the starter terminals.
     

  2.  
  3. Repeat the test. If the engine still fails to crank properly, trouble is within the starter or starter mounted solenoid. The starter must be removed and bench tested, refer to the starter motor test.
  4.  

Starter Solenoid

  1. Check the battery condition, it must be in good condition with a full charge before performing this test.
  2.  

Perform the starter solenoid test before performing the starter relay test.

  1. Raise and support the vehicle.
  2.  
  3. Inspect the starter and solenoid for corrosion or looses connections.
  4.  
  5. Lower the vehicle.
  6.  
  7. Remove the starter relay from the PDC. Connect a remote starter switch or a jumper wire between the remove battery positive post and terminals 87 of the starter relay connector.
  8.  
  9. If the engine cranks, the starter and solenoid are OK.
  10.  
  11. If the engine does not crank, or the solenoid chatters, check the wiring and connectors from the relay to the solenoid for loose or corroded connections. Particularly the starter terminals.
  12.  
  13. Repeat the test. If the engine still fails to crank properly, trouble is within the starter or solenoid.
  14.  

Starter Relay

See Figure 8

The starter relay is located in the Power Distribution Center (PDC).



Click image to see an enlarged view

Fig. Fig. 8: The starter relay is located in the Power Distribution Center #8

  1. Before performing this test, complete the battery, circuit and solenoid tests.
  2.  
  3. Remove the starter relay from the connector.
  4.  
  5. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If this is OK, go to the next step. If not replace the faulty relay.
  6.  
  7. Resistance between terminals 85 and 86 should be 70-80 ohms. If this is OK, go to the next step, if not replace the relay.
  8.  
  9. Connect the battery B+ lead to terminals 86 and a ground lead terminal 85 to energize the relay. The relay should click. Also test for continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If they are OK, refer to the relay circuit test. If not, replace the relay.
  10.  

Relay Circuit

  1. The relay common feed terminal cavity 30 is connected to battery voltage and should be hot at all times. If this is OK, proceed to the next step. If not, repair the open circuit to the PDC fuse as needed.
  2.  
  3. The relay normally closed terminal 87A is connected to terminal 30 in the de-energized position, but is used for this application. Go to the next step.
  4.  
  5. The relay normally open terminal 87 is connected to the common feed terminal 30 in the energized position. This terminal supplies battery voltage to the starter solenoid field coils. There should be continuity between the cavity for relay terminal 87 and the starter solenoid at all times. If this is OK, go to the next step, if not, repair the open circuit to the solenoid.
  6.  
  7. The coil battery terminal 86 is connected to the electromagnet in the relay. It is energized when the ignition switch is held in the start position. Check the battery voltage at the cavity for relay terminal 86 with the ignition switch in the start position, and no voltage when the ignitions switch is released to the ON position. If this is OK, go to the next step. If not, check for an open or short to the ignition switch and repair if needed.
  8.  
  9. The coil ground terminal 85 is connected to the electromagnet in the relay. It is grounded the the neutral safety switch only when the gearshift is in the P or N positions. Check the continuity to ground at the cavity for relay terminal 85. If this is not OK, check for an open or short circuit to the neutral safety switch and repair it.
  10.  
  11. If all the preceding circuit tests checked out OK, replace the starter relay with a new one.
  12.  

Starter Motor

With the starter motor removed from the engine, the pinion gear should be tested for freedom of operation by turning it on the screw shaft. The armature should be tested for freedom of rotation by prying the pinion gear with a prytool to engage it with the shaft.

Tight bearings, a bent armature or driveshaft, or a bent frame will cause the armature to catch and not rotate freely.

If the shafts do not rotate freely, the motor should be replaced with either a professionally rebuilt or new motor. Chrysler does not provide disassembly procedures for anything other than solenoid removal (Bosch starters) and gear removal.

No rotation and high current flow conditions indicate one or more of the following:



Connecting terminal or armature windings shorted to ground.
 
Seized bearings (this should have been determined by rotating the armature by hand).
 

No rotation and no current flow conditions indicate one or more of the following:



Open armature windings (inspect the commutator for badly burned commutator bars, if disassembled).
 
Broken brush springs, worn brushes, protruding insulation between commutator bars, or other causes could prevent good contact between brushes and commutator.
 

REMOVAL & INSTALLATION



3.3L Engine

See Figures 9, 10 and 11

  1. Disconnect the negative - battery cable. Raise and safely support the front of the vehicle on jackstands.
  2.  



Click image to see an enlarged view

Fig. Fig. 9: Disconnect the negative battery cable

  1. Remove the three bolts attaching the starter to the engine/transaxle.
  2.  



Click image to see an enlarged view

Fig. Fig. 10: Remove the three starter mounting bolts

  1. Remove the starter from the the transmission housing. Position the starter to gain access to the wiring connectors.
  2.  
  3. Remove the battery positive cable nut from the starter and remove the cable.
  4.  



Click image to see an enlarged view

Fig. Fig. 11: Remove the battery positive cable nut from the starter and remove the cable

  1. Disconnect the push on solenoid connector.
  2.  
  3. Remove the starter from the vehicle.
  4.  

To install:
  1. Clean all wire terminals of dirt, grease or corrosion.
  2.  
  3. Attach the electrical wire connectors and secure with the mounting nuts. Tighten the starter solenoid B+ nut to 90 inch lbs. (10 Nm) and the solenoid wire-to-starter nut to 55 inch lbs. (6 Nm).
  4.  
  5. Hold the starter motor in place, then secure in place with the 3 attaching bolts. Tighten the bolts to 40 ft. lbs. (54 Nm).
  6.  
  7. Lower the vehicle.
  8.  
  9. Connect the negative - battery cable.
  10.  

3.5L Engine

See Figures 9 and 12

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. For easier servicing, do not remove the wiring from the starter motor at this time.
  6.  
  7. Remove the three bolts attaching the starter to the engine.
  8.  



Click image to see an enlarged view

Fig. Fig. 12: Remove the three bolts attaching the starter to the engine

  1. Remove the starter solenoid assembly from the transfer housing. Position the starter to gain access to the wiring connectors.
  2.  
  3. Remove the battery positive cable nut from starter and remove the cable.
  4.  
  5. Disconnect the push on solenoid connector.
  6.  
  7. Remove the starter from the vehicle.
  8.  

To install:
  1. Clean all wire terminals of dirt, grease or corrosion.
  2.  
  3. Attach the electrical wire connectors and secure with the mounting nuts. Tighten the starter solenoid B+ nut to 90 inch lbs. (10 Nm) and the solenoid wire-to-starter nut to 55 inch lbs. (6 Nm).
  4.  
  5. Hold the starter motor in place, then secure in place with the 3 attaching bolts. Tighten the bolts to 40 ft. lbs. (54 Nm).
  6.  
  7. Lower the vehicle.
  8.  
  9. Connect the negative battery cable.
  10.  

 
label.common.footer.alt.autozoneLogo