Chrysler Front Wheel Drive Cars 6-CYL 1988-1995 Repair Information

Starter

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TESTING



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 Figure 1


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

  1. Connect a volt-ampere tester (multimeter) to the battery terminals.
  2.  
  3. Disable the ignition system as follows:
    1. Vehicles (except for Premier and Monaco) with conventional distributors-Disconnect the ignition coil cable from the distributor cap. Connect a suitable jumper wire between the coil cable end-terminal and a good body ground.
    2.  
    3. Premier and Monaco with conventional distributors-Disconnect the electrical wiring harness at the Ignition Control Module (ICM).
    4.  
    5. Vehicles with Direct Ignition System (DIS)-Unplug the ignition coils electrical connector.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 1: Connect a jumper wire between the coil cable and a good ground to disable the conventional ignition system-except Premier and Monaco

  4.  
  5. Verify that all lights and accessories are Off, and the transaxle shift selector is in Park (automatic) or Neutral (manual). 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 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.
     

  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 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 1, 2, 3 and 4

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.


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

  1. Disable the ignition system as follows:
    1. Vehicles (except for Premier and Monaco) with conventional distributors-Disconnect the ignition coil cable from the distributor cap. Connect a suitable jumper wire between the coil cable end-terminal and a good body ground.
    2.  
    3. Premier and Monaco with conventional distributors-Disconnect the electrical wiring harness at the Ignition Control Module (ICM).
    4.  
    5. Vehicles with Direct Ignition System (DIS)-Unplug the ignition coils electrical connector.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 2: Bosch starter motor solenoid electrical terminals-Premier and Monaco engines and some 3.0L engines on other models



    Click image to see an enlarged view

    Fig. Fig. 3: Nippondenso starter solenoid wiring terminals-some 3.0L engines, except Premier and Monaco models



    Click image to see an enlarged view

    Fig. Fig. 4: Nippondenso starter solenoid wiring terminals-3.3L and 3.8L engines

  2.  
  3. With all wiring harnesses and components (except for the coils) 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.  

  4.  
  5. Remove the heater shield. 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 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.
    4.  
    5. If the resistance tests did not detect feed circuit failures, refer to the starter solenoid test.
    6.  

  6.  

Starter Solenoid
PREMIER AND MONACO

See Figure 2 in previous section and Figure 5.

  1. Connect a heavy jumper wire on the starter relay connector between the battery (D1-5) and the solenoid (D1-4) terminals. Check if the engine will crank over. Next, connect the jumper wire between terminal D1-4 and terminal D1-1. If the engine cranks when both series are connected with the jumper wire, the starter solenoid is good. Proceed to the starter relay test.
  2.  
  3. If the engine does not crank or the solenoid chatters, check the wiring and connectors from the relay to the starter for being loose or corroded, particularly at the starter terminals.
  4.  
  5. If the engine cranks when D1-5 and D1-4 are connected with the jumper wire, but not when D1-1 and D1-4 are connected, check the circuit between D1-1 and D1-4 for an open or grounded circuit.
  6.  
  7. Repeat the test. If the engine still fails to crank properly, the trouble is within the starter and it must be removed for bench testing.

    Click image to see an enlarged view

    Fig. Fig. 5: Connect terminals D1-4 and D1-5 with a heavy jumper wire to bypass the starter relay assembly-Premier and Monaco

  8.  

TC BY MASERATI

See Figure 6

  1. Connect a heavy jumper wire on the starter relay connector between the battery terminal (1) and the solenoid terminal (3). If the engine cranks over, the starter solenoid is good. Proceed to the starter relay test.

    Click image to see an enlarged view

    Fig. Fig. 6: Connect terminal 1 (battery) and terminal 3 (solenoid) when testing the starter solenoid-TC by Maserati

  2.  
  3. If the engine does not crank or the solenoid chatters, check the wiring and connectors from the relay to the starter for being loose or corroded, particularly at the starter terminals.
  4.  
  5. Repeat the test. If the engine still fails to crank properly, the trouble is within the starter and it must be removed for bench testing.
  6.  

EXCEPT PREMIER, MONACO AND TC BY MASERATI

See Figures 7, 8, 9 and 10

  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 (automatic) or Neutral (manual) 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.

    Click image to see an enlarged view

    Fig. Fig. 7: Starter relay location-New Yorker, Dynasty, Daytona, LeBaron coupe and convertible, Imperial and Fifth Ave. models



    Click image to see an enlarged view

    Fig. Fig. 8: Starter relay location-LeBaron sedan, Spirit, Acclaim, Sundance and Shadow models

  4.  
  5. Lower the vehicle.
  6.  
  7. Locate the starter relay as follows:

    On New Yorker, Dynasty, Daytona, LeBaron coupe and convertible, Imperial and Fifth Ave. models, the relay is located in the Power Distribution Center (PDC). This center is mounted near the front of the left front strut tower. The position of the starter relay within the center will be shown on the center cover
     
    On LeBaron sedan, Spirit, Acclaim, Sundance and Shadow models, the relay is located on the front of the left front strut tower
     

  8.  
  9. Remove the starter relay from the connector.
  10.  
  11. 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).

    Click image to see an enlarged view

    Fig. Fig. 9: The starter relay terminal identification-except Premier, Monaco and TC by Maserati



    Click image to see an enlarged view

    Fig. Fig. 10: Starter relay terminal and wiring schematic-except Premier, Monaco and TC by Maserati

  12.  
  13. 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
     

  14.  
  15. 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 bench test.
  16.  

Starter Relay
PREMIER AND MONACO

See Figure 2 in previous section

To perform this test, the starter relay must be in place and the relay will be backprobed to ground for the voltage readings. Do not pierce the wiring for backprobing, refer to Chassis Electrical for more information on circuit testing.


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

  1. Using a voltmeter check terminal 2 of the starter relay with the ignition switch on START .
    1. If the terminal exhibits battery voltage, continue to Step 2.
    2.  
    3. If the terminal shows anything but battery voltage, repair the circuit from the ignition switch for an open condition.
    4.  

  2.  
  3. Check terminal 1 of the starter relay with the ignition switch START .
    1. If the terminal shows 0 volts, proceed to Step 3.
    2.  
    3. If the terminal shows anything but 0 volts, repair the ground circuit.
    4.  

  4.  
  5. Perform the same procedure for terminal 5 of the starter relay as was done with terminal 1.
  6.  
  7. Check terminal 4 of the starter relay with the ignition switch on START .
    1. The terminal should show battery voltage. If it does, the relay is good.
    2.  
    3. If the terminal does not show battery voltage, the relay should be replaced with a new one.
    4.  

  8.  

TC BY MASERATI

See Figures 11 and 12

  1. Position the transaxle gear selector in the Neutral (manual) or Park (automatic) position.
  2.  
  3. Set the parking brake.
  4.  
  5. Do not remove the starter relay connector.

    Click image to see an enlarged view

    Fig. Fig. 11: Connect terminal 1 (battery) and terminal 4 (ignition switch) to test the starter relay-TC by Maserati



    Click image to see an enlarged view

    Fig. Fig. 12: Add a second heavy jumper wire if a bad ground is found-TC by Maserati

  6.  
  7. Check for battery voltage between the starter relay battery terminal (1) and ground with a test lamp.
  8.  
  9. Connect a jumper wire on the starter relay between the battery (1) and the ignition (4) terminals. If the engine cranks (turn the ignition switch to the START position) the relay is good.
  10.  
  11. If the engine does not crank, connect a second jumper wire to the starter relay between the ground terminal (5) and a good ground (such as the engine block). Repeat the test:

    Engine cranks-The starter relay is good. The transaxle linkage is, however, out of adjustment or the safety neutral switch is defective
     
    Engine does not crank-The starter relay is defective and must be replaced with a new one.
     

  12.  

EXCEPT PREMIER, MONACO AND TC BY MASERATI

See Figures 7, 8, 9 and 10

  1. Before performing this test, complete the battery, circuit and solenoid tests.
  2.  
  3. Locate the starter relay as follows:
    1. On New Yorker, Dynasty, Daytona, LeBaron coupe and convertible, Imperial and Fifth Ave. bodies-The relay is located in the Power Distribution Center (PDC). This center is mounted near the front of the left front strut tower. The position of the starter relay within the center will be shown on the center cover.
    2.  
    3. On LeBaron sedan, Spirit, Acclaim, Sundance and Shadow bodies-The relay is located on the front of the left front strut tower.
    4.  

  4.  
  5. Remove the starter relay from the connector.
  6.  
  7. Connect a jumper wire between the positive (+) battery post and terminal 87 on the relay connector. Try to crank the engine over with the ignition switch:
    1. Engine does not crank: refer to the previous solenoid test.
    2.  
    3. Engine cranks: continue to Step 5.
    4.  

  8.  
  9. With the relay remove and the ignition switch ON , check for 12 volts at terminal 30 of the relay connector:
    1. 12 volts is NOT present: check for an open circuit. Refer to Chassis Electrical for the vehicle wiring diagrams.
    2.  
    3. 12 volts is present: the circuit is OK. Continue to Step 6.
    4.  

  10.  
  11. With the relay still removed, check for 12 volts at terminal 86 with the ignition switch in the START (cranking) position:
    1. 12 volts is present: skip to Step 8.
    2.  
    3. 12 volts is NOT present: go to Step 7.
    4.  

  12.  
  13. Depending on the transaxle in the vehicle, refer to the following procedures:
    1. Automatic transaxle: the circuit from the ignition switch is open. Refer to Chassis Electrical for the vehicle wiring diagrams. Do not continue to Step 8.
    2.  
    3. Manual transaxle: unplug the wiring connector from the clutch pedal mounted interlock switch. Connect a jumper wire across the two terminals of this connector. If 12 volts is now present at terminal 86 (with ignition switch in the cranking position), the switch may be out of adjustment or bad. Refer to Drive Train for the clutch procedures. Otherwise, if the 12 volts is still not present at terminal 86, the circuit is open somewhere. Refer to Chassis Electrical for vehicle wiring diagrams and procedures for checking circuits. Do not continue to Step 8.
    4.  

  14.  
  15. With the relay still removed, check for a ground circuit at terminal 85 of the starter relay connector. If the vehicle is equipped with an automatic transaxle, ground should only be present with the shifter in the Park or Neutral positions only. If the vehicle is equipped with a manual transaxle, a ground must be present at all times.
    1. Manual transaxle: If the ground is not present, the circuit is open or short-circuited. Refer to Chassis Electrical for the vehicle wiring diagrams. However, if the ground is present, refer to Step 8.
    2.  
    3. Automatic transaxle: If the ground is not present when the shifter is in the Park or Neutral positions, check the neutral safety switch continuity to ground. Refer to Chassis Electrical for the vehicle wiring diagrams and Drive Train for removal and installation procedures of the neutral safety switch. However, if the ground is present, refer to Step 8.
    4.  

  16.  
  17. If all the preceding circuit tests checked out OK, replace the starter relay with a new one.
  18.  

Starter Solenoid Bench Test

See Figures 13 and 14

  1. Disconnect the field coil wire from the field coil terminal.
  2.  
  3. Check for continuity between the solenoid terminal and field coil terminal with a continuity tester. Continuity (resistance) should be present.
  4.  
  5. Check for continuity between the solenoid terminal and solenoid housing. Continuity should be detected. If continuity is detected, the solenoid is good.
  6.  
  7. If continuity is not detected in either test, the solenoid has an open circuit and is defective. Repairs depend on the type of starter the vehicle has (use the starter solenoid terminal illustrations to determine the starter manufacturer):

    Bosch starter (some 3.0L engines)-Replace the solenoid with a new one
     
    Nippondenso starter (3.3L, 3.8L and some 3.0L engines)-Replace the entire starter motor assembly with a new one
     



    Click image to see an enlarged view

    Fig. Fig. 13: Bosch starter motor solenoid electrical terminals-Premier and Monaco engines and some 3.0L engines on other models



    Click image to see an enlarged view

    Fig. Fig. 14: Nippondenso starter solenoid wiring terminals-all 3.3L and 3.8L engines and some 3.0L engines from the non-Premier and Monaco vehicles

  8.  
  9. Connect the field coil wire to the field coil terminal.
  10.  

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

See Figures 15, 16 and 17



Click image to see an enlarged view

Fig. Fig. 15: These three attaching bolts hold the starter motor to the engine/transaxle assembly-all models

  1. Disconnect the negative (-) battery cable. Raise and safely support the front of the vehicle on jackstands. Remove the engine undercovers, if so equipped.
  2.  
  3. Remove the 3 bolts attaching the starter to the engine/transaxle.
  4.  


CAUTION
Be careful when removing the starter motor mounting bolts, the motor can be quite heavy. Personal injury could result if the starter motor falls from its mounting position.

  1. Remove the heat shield and its clamp, if so equipped.
  2.  
  3. Remove the two electrical wire connector terminal nuts and remove the wiring connector from the starter.
  4.  
  5. Remove the starter from the vehicle.
  6.  

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 80 inch lbs. (9 Nm) and the solenoid wire-to-starter nut to 55 inch lbs. (6 Nm).
  4.  
  5. Install the heat shield if one was removed.
  6.  
  7. Hold the starter motor in place, then secure in place with the 3 attaching bolts. Tighten the bolts to 40 ft. lbs. (54 Nm) for all vehicles except Premier and Monaco. Tighten the attaching bolts to 20 ft. lbs. (27 Nm) for Premier and Monaco.
  8.  
  9. Install any undercovers which were removed from the vehicle.
  10.  
  11. Lower the vehicle.
  12.  
  13. Connect the negative (-) battery cable.
  14.  



Click image to see an enlarged view

Fig. Fig. 16: After disconnecting the starter's electrical wiring, remove the 3 mounting bolts ...



Click image to see an enlarged view

Fig. Fig. 17: ... then the starter motor can be lowered from the underside of the vehicle

SOLENOID REPLACEMENT
Bosch Starter Motors

See Figures 18 and 19

Only the Bosch starter motors have procedures for replacing the solenoids. The Nippondenso starter motors need to be replaced with new ones if the solenoid is found to be faulty.

  1. Remove the starter as previously outlined.
  2.  
  3. Disconnect the field coil wire from the solenoid by removing the nut and pulling the connector off. Make certain to retain the nut and washer for reassembly.
  4.  
  5. Remove the 3 solenoid mounting screws.
  6.  
  7. Remove the solenoid by working the plunger stem off the shift fork.
  8.  



Click image to see an enlarged view

Fig. Fig. 18: Remove the field terminal nut, washer and the field terminal itself-Bosch starter motors



Click image to see an enlarged view

Fig. Fig. 19: Remove the solenoid mounting screws to separate the solenoid from the starter motor housing

To install:
  1. Install the solenoid onto the starter motor, making sure that the plunger correctly engages the solenoid.
  2.  
  3. Install and tighten the 3 solenoid-to-starter motor mounting screws.
  4.  
  5. Slide the field terminal onto the field terminal stud, then install the washer and nut. Tighten the nut to 55 inch lbs. (6 Nm).
  6.  
  7. Install the starter motor onto the vehicle.
  8.  

STARTER GEAR AND CLUTCH REPLACEMENT
Bosch Starter Motors

See Figures 20, 21, 22 and 23



Click image to see an enlarged view

Fig. Fig. 20: Remove the solenoid from the starter motor housing

  1. Remove the starter motor from the engine/transaxle assembly.
  2.  
  3. Remove the solenoid assembly from the starter motor. Refer to the previous procedure.
  4.  
  5. Remove the two through-bolts securing the starter drive end housing to the motor housing. Separate the two housings.

    Click image to see an enlarged view

    Fig. Fig. 21: Remove the two through-bolts, then separate the drive end housing and the motor housing

  6.  
  7. Remove the rubber seal from the drive end housing.
  8.  
  9. Pull the gear and clutch assembly from the drive end housing. Take note of the positions of any related components to ease installation.
  10.  

To Install:
  1. Insert the new gear and clutch into the drive end housing, making sure that the shift lever and bushing are installed in the same position as when they were removed.

    Click image to see an enlarged view

    Fig. Fig. 22: Remove the rubber seal from the drive end housing; make sure to note the positions of the various components



    Click image to see an enlarged view

    Fig. Fig. 23: Remove the starter drive gear train from the drive end housing

  2.  
  3. Install a new (or the old one if still in good shape) rubber seal into the drive end housing.
  4.  
  5. Assemble the two housings, and secure together with the two through-bolts.
  6.  
  7. Install the solenoid onto the starter motor assembly, then install the starter motor in the vehicle.
  8.  

Nippondenso Starter Motors

See Figures 24, 25, 26 and 27

  1. Remove the starter motor from the vehicle.
  2.  
  3. Remove the two gear housing attaching screws and separate the gear housing from the solenoid housing. The pinion gear, pinion gear bearing and rive gear will be loose between the solenoid housing and gear housing. Note the position of the various bearings and gears.
  4.  
  5. Remove the starter gear and clutch assembly from the solenoid housing. Note any related components' positions to ease reinstallation.
  6.  

To install:
  1. Wipe the pinion gear and bearing with a clean rag and coat them with a film of lightweight high temperature wheel bearing grease.
  2.  
  3. Install the clutch assembly and starter gear into the solenoid housing.
  4.  
  5. Place the lubricated bearing and gear over the bearing shaft in the gear housing.
  6.  
  7. Assemble the gear housing and the solenoid housing and secure with the two gear attaching screws.
  8.  
  9. Install the starter motor into the vehicle.
  10.  

OVERHAUL

Overhaul procedures for the starter motors utilized on the vehicles covered in this repair guide are not provided by Chrysler. If any fault is found with the starter motor, except for a bad starter gear and clutch or the solenoid on Bosch starter motors, the entire starter motor should be replaced with either a new or professionally rebuilt unit. This is also the most cost and time effective method.



Click image to see an enlarged view

Fig. Fig. 24: Remove the gear housing attaching screws to separate the two housings-Nippondenso starter motors



Click image to see an enlarged view

Fig. Fig. 25: Remove the pinion gear, pinion gear bearing and the drive gear from the housing



Click image to see an enlarged view

Fig. Fig. 26: Make sure, upon installation, that the drive gear, pinion gear and pinion gear bearing are correctly positioned



Click image to see an enlarged view

Fig. Fig. 27: Slide the new gear and clutch assembly into the housing as shown

 
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