PT Cruiser 2006-2007

Starter

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Removal & Installation



Non-Turbo Models
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    The negative battery cable
     
    The air cleaner box cover
     
    The engine structural collar
     
    The starter electrical connectors
     
    The starter

    Click image to see an enlarged view

    Fig. Removal of the starter motor mounting

     

  4.  

To install:

  1. Install the starter and torque the bolts to 40 ft. lbs. (54 Nm).
  2.  
  3. Attach the starter electrical connectors.
  4.  
  5. Install the engine structural collar on models with an automatic transaxle as follows, refer to the illustration for bolt locations:
    1. Place the collar in position and hand tighten the collar to transaxle bolt.
    2.  
    3. Position the power steering hose support bracket and install the collar to oil pan bolt.
    4.  
    5. Place the bending strut in place and hand start the bolt.
    6.  
    7. Install the bolt through the strut and collar and hand tighten.
    8.  
    9. Place the power steering hose support bracket in position and install and hand tighten the remaining bolts.
    10.  
    11. Tighten the collar-to-transaxle bolts to 75 ft. lbs. (101 Nm).
    12.  
    13. Install the bolts through the strut and into the block.
    14.  
    15. Tighten the remaining bolts to 45 ft. lbs. (61 Nm).
    16.  

  6.  
  7. Install the engine structural collar on models with a manual transaxle as follows, refer to the illustration for bolt locations:
    1. Place the collar in position and hand tighten the collar to transaxle bolt.
    2.  
    3. Position the power steering hose support bracket and install the collar to oil pan bolt.
    4.  
    5. Position the clutch slave cylinder into position and hand start the bolts.
    6.  
    7. Tighten bolts (1) to 75 ft. lbs. (101 Nm).
    8.  
    9. Tighten bolts (2 and 5) to 45 ft. lbs. (61 Nm).
    10.  
    11. Tighten bolts (3 and 4) to 20 ft. lbs. (28 Nm).

      Click image to see an enlarged view

      Fig. Structural collar assembly-automatic transaxle



      Click image to see an enlarged view

      Fig. Structural collar assembly-manual transaxle

    12.  

  8.  
  9. Install the air cleaner box cover.
  10.  
  11. Connect the negative battery cable.
  12.  

Turbo Models
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    The negative battery cable
     
    The air cleaner box cover
     
    The upper starter bolt by pushing the inner cooler up and out of the way
     
    The inner cooler lower hose from the inner cooler
     
    The nuts retaining the inner cooler tube
     
    The studs retaining the power steering lines
     
    Position the power steering lines aside
     
    The engine structural collar
     
    The starter electrical connectors
     
    The starter

    Click image to see an enlarged view

    Fig. Removal of the starter motor mounting

     

  4.  

To install:

  1. Install the starter and torque the bolts to 40 ft. lbs. (54 Nm). Attach the starter electrical connectors.
  2.  
  3. Install the engine structural collar on models with an automatic transaxle as follows; refer to the illustration for bolt locations:
    1. Place the collar in position and hand tighten the collar to transaxle bolt.
    2.  
    3. Position the power steering hose support bracket and install the collar to oil pan bolt.
    4.  
    5. Place the bending strut in place and hand start the bolt.
    6.  
    7. Install the bolt through the strut and collar and hand tighten.
    8.  
    9. Place the power steering hose support bracket in position and install and hand tighten the remaining bolts.
    10.  
    11. Tighten the collar-to-transaxle bolts to 75 ft. lbs. (101 Nm).
    12.  
    13. Install the bolts through the strut and into the block.
    14.  
    15. Tighten the remaining bolts to 45 ft. lbs. (61 Nm).
    16.  

  4.  
  5. Install the engine structural collar on models with a manual transaxle as follows, refer to the illustration for bolt locations:
    1. Place the collar in position and hand tighten the collar to transaxle bolt.
    2.  
    3. Position the power steering hose support bracket and install the collar to oil pan bolt.
    4.  
    5. Position the clutch slave cylinder into position and hand start the bolts.
    6.  
    7. Tighten bolts (1) to 75 ft. lbs. (101 Nm).
    8.  
    9. Tighten bolts (2 and 5) to 45 ft. lbs. (61 Nm).
    10.  
    11. Tighten bolts (3 and 4) to 20 ft. lbs. (28 Nm).
    12.  

  6.  
  7. Install or connect the following:

    The power steering lines aside
     
    The studs retaining the power steering lines and tighten to 45 ft. lbs. (61 Nm)
     
    The nuts retaining the inner cooler tube
     
    The inner cooler lower hose to the inner cooler
     
    The upper starter bolt by pushing the inner cooler up and out of the way. Tighten to 40 ft. lbs. (54 Nm).
     
    The sir cleaner box cover
     
    The negative battery cable
     

  8.  

Testing & Troubleshooting



Cold Cranking Test

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

  1. Connect a volt-ampere tester to the battery terminals. See instructions provided by manufacturer of volt-ampere tester being used. 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 transaxle, place gearshift selector lever in Neutral position and block clutch pedal in fully depressed position. If equipped with automatic transaxle, place gearshift selector lever in Park position.
  6.  
  7. Verify that all lamps and accessories are turned OFF.
  8.  
  9. To prevent engine from starting, remove the Automatic Shut Down (ASD) relay. The relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC cover for the relay location.`
  10.  
  11. Rotate and hold ignition switch in START position.
    NOTE
    Cranking voltage and current (amperage) draw readings are shown on the volt-ampere tester.


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



    If the voltage reads below 9.6 volts, refer to Starter Motor test. If the starter motor is not OK, replace the 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 the high-amperage feed circuit.

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

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

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



The battery is fully-charged and load-tested
 
The parking brake is fully engaged
 
If equipped with a manual transaxle, place the gearshift selector lever in the Neutral position and block the clutch pedal in a fully depressed position. If equipped with an automatic transaxle, place the gearshift selector lever in the Park position.
 
Verify that all lamps and accessories are turned OFF.
 
To prevent the engine from starting, remove the Automatic Shut Down (ASD) relay. The relay is located in Power Distribution Center (PDC). Refer to label on PDC cover for relay location.
 

  1. Connect the positive lead of the voltmeter to the negative battery cable terminal post. Connect the negative lead of the voltmeter to the 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.
  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.
  8.  
  9. 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.
  10.  
  11. 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.
  12.  
  13. 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.

    If reading is above 0.2 volt, correct poor starter to engine block ground contact.
     
    If reading is above 0.2 volt, clean and tighten battery cables. Repeat test.
     
    If reading is still above 0.2 volt, replace faulty positive battery cable.
     

  14.  

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.


WARNING
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.  

Starter 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.
    1. If OK, go to Step 4.
    2.  
    3. If not OK, replace faulty starter motor.
    4.  

  6.  
  7. Check for continuity between solenoid terminal and solenoid case. There should be continuity. If not OK, replace faulty starter motor.
  8.  

 
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