PT Cruiser, 2001 - 2005

Testing

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Cold Cranking Test



The battery must be fully charged and load-tested before proceeding.

  1. Connect volt-ampere tester to battery terminals . See instructions provided by manufacturer of volt-ampere tester being used. Note: Certain diesel equipped models use dual batteries. If equipped with dual battery system, tester should be connected to battery on left side of vehicle only. Also, tester current reading must be taken from positive battery cable lead that connects to starter motor.
  2.  
  3. Fully engage parking brake.
  4.  
  5. If equipped with manual transmission, place gearshift selector lever in Neutral position and block clutch pedal in fully depressed position. If equipped with automatic transmission, place gearshift selector lever in Park position.
  6.  
  7. Verify that all lamps and accessories are turned off.
  8.  
  9. To prevent a gasoline engine from starting, remove Automatic ShutDown (ASD) relay. To prevent a diesel engine from starting, remove Fuel Pump Relay. These relays are located in Power Distribution Center (PDC). Refer to label on PDC cover for relay location.
    WARNING
    If equipped with a diesel engine, attempt to start the engine a few times before proceeding with the following step.

  10.  
  11. Rotate and hold ignition switch in START position.
    NOTE
    Cranking voltage and current (amperage) draw readings shown on volt-ampere tester.


    NOTE
    A cold engine will increase starter current (amperage) draw reading, and reduce battery voltage reading.



    If voltage reads below 9.6 volts, refer to Starter Motor test. If starter motor is not OK, replace faulty starter motor.
     
    If voltage reads above 9.6 volts and current (amperage) draw reads below specifications, refer to Feed Circuit Test.
     
    If voltage reads 12.5 volts or greater and starter motor does not turn, refer to Control Circuit Testing.
     
    If voltage reads 12.5 volts or greater and starter motor turns very slowly, refer to Feed Circuit Test.
     

  12.  

Feed Circuit Test



The starter feed circuit test (voltage drop method) will determine if there is excessive resistance in high-amperage feed circuit.

When performing these tests, it is important to remember that voltage drop is giving an indication of resistance between two points at which voltmeter probes are attached. Example: When testing resistance of positive battery cable, touch voltmeter leads to positive battery cable clamp and cable connector at starter solenoid.

If you probe positive battery terminal post and cable connector at starter solenoid, you are reading combined voltage drop in positive battery cable clamp-to terminal post connection and positive battery cable.

The following operation will require a voltmeter accurate to 0.10 volt. Before performing tests, be certain that following procedures are accomplished:



Battery is fully-charged and load-tested.
 
Fully engage parking brake.
 
If equipped with manual transmission, place gearshift selector lever in Neutral position and block clutch pedal in fully depressed position. If equipped with automatic transmission, place gearshift selector lever in Park position.
 
Verify that all lamps and accessories are turned off.
 
To prevent a gasoline engine from starting, remove Automatic Shut Down (ASD) relay. To prevent a diesel engine from starting, remove Fuel Pump Relay. These relays are located in Power Distribution Center (PDC). Refer to label on PDC cover for relay location.
 

  1. Connect positive lead of voltmeter to negative battery cable terminal post. Connect negative lead of voltmeter to negative battery cable clamp .
  2.  
  3. Rotate and hold ignition switch in START position.
  4.  
  5. Observe voltmeter. If voltage is detected, correct poor contact between cable clamp and terminal post.
    NOTE
    Certain diesel equipped models use dual batteries. If equipped with dual battery system, procedure must be performed twice, once for each battery.

  6.  
  7. Connect positive lead of voltmeter to positive battery terminal post. Connect negative lead of voltmeter to battery positive cable clamp . Rotate and hold ignition switch in START position. Observe voltmeter. If voltage is detected, correct poor contact between cable clamp and terminal post. Note: Certain diesel equipped models use dual batteries.
  8.  
  9. If equipped with dual battery system, this procedure must be performed twice, once for each battery.
  10.  
  11. Connect voltmeter to measure between battery positive terminal post and starter solenoid battery terminal stud . Rotate and hold ignition switch in START position. Observe voltmeter. If reading is above 0.2 volt, clean and tighten battery cable connection at solenoid. Repeat test. If reading is still above 0.2 volt, replace faulty positive battery cable.
    NOTE
    Certain diesel equipped models use dual batteries. If equipped with dual battery system, this procedure must be performed on driver side battery only.

  12.  
  13. Connect voltmeter to measure between negative battery terminal post and a good clean ground on engine block . Rotate and hold ignition switch in START position. Observe voltmeter. If reading is above 0.2 volt, clean and tighten negative battery cable attachment on engine block. Repeat test. If reading is still above 0.2 volt, replace faulty negative battery cable. Note: Certain diesel equipped models use dual batteries. If equipped with dual battery system, this procedure must be performed twice, once for each battery.
  14.  
  15. Connect positive lead of voltmeter to starter housing. Connect negative lead of voltmeter to negative battery terminal post . Rotate and hold ignition switch in START position. Observe voltmeter.
    NOTE
    Certain diesel equipped models use dual batteries. If equipped with dual battery system, this procedure must be performed on driver side battery only.



    If reading is above 0.2 volt, correct poor starter to engine block ground contact.
     

  16.  
  17. If equipped with dual battery system (certain diesel equipped models), connect positive lead of voltmeter to positive battery cable clamp on battery located on left side of vehicle. Connect negative lead of voltmeter to positive battery terminal post on battery located on right side of vehicle. Rotate and hold ignition switch in START position. Observe voltmeter.

    If reading is above 0.2 volt, clean and tighten battery cables at both batteries. Repeat test.
     
    If reading is still above 0.2 volt, replace faulty positive battery cable.
     

  18.  

Solenoid



This test can only be performed with starter motor removed from vehicle.

  1. Remove the starter motor from vehicle.
  2.  
  3. Disconnect wire from solenoid field coil terminal.
  4.  
  5. Check for continuity between the solenoid terminal and solenoid field coil terminal with a continuity tester. There should be continuity. If OK, go to Step 4. If not OK, replace faulty starter motor.
  6.  
  7. Check for continuity between solenoid terminal and solenoid case. There should be continuity. If not OK, replace faulty starter motor
  8.  

Starter Motor



Correct starter motor operation can be confirmed by performing the following free running bench test. This test can only be performed with starter motor removed from vehicle.


CAUTION
Permanent magnets are used in the starter. Permanent magnet starters are highly sensitive to hammering, shocks, external pressure and reverse polarity. This starter motor must never be clamped in a vise by starter field frame. The starter should only be clamped by mounting flange. Do not reverse battery cable connections to starter motor when testing. The permanent magnets may be damaged and starter rendered unserviceable if it is subjected to any of these conditions.

  1. Remove the starter motor from vehicle.
  2.  
  3. Mount starter motor securely in a soft-jawed bench vise. The vise jaws should be clamped on the mounting flange of starter motor. Never clamp on starter motor by field frame.
  4.  
  5. Connect a suitable volt-ampere tester and a 12-volt battery to starter motor in series, and set ammeter to 100 ampere scale. See instructions provided by manufacturer of volt-ampere tester being used.
  6.  
  7. Install jumper wire from solenoid terminal to solenoid battery terminal. The starter motor should operate. If starter motor fails to operate, replace faulty starter motor assembly.
  8.  
  9. Adjust carburetor on pile load of tester to obtain free running test voltage.
  10.  
  11. Note reading on ammeter and compare reading to free running test maximum amperage draw.
  12.  
  13. If ammeter reading exceeds maximum amperage draw specification, replace faulty starter motor assembly.
  14.  

 
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