steering wheel CHRYSLER CARAVAN 2002 Workshop Manual
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 2002, Model line: CARAVAN, Model: CHRYSLER CARAVAN 2002Pages: 2399, PDF Size: 57.96 MB
Page 330 of 2399
REMOTE SWITCHES
DESCRIPTION
A remote radio control switch option is available on
some models. Two rocker-type switches are mounted
on the back (instrument panel side) of the steering
wheel spokes (Fig. 10). The switch on the left spoke
is the seek switch and has seek up, seek down, and
preset station advance functions. The switch on the
right spoke is the volume control switch and has vol-
ume up, and volume down functions. The switch on
the right spoke also includes a ªmodeº control that
allows the driver to sequentially select AM radio, FM
radio, cassette player, CD player or CD changer (if
equipped).
OPERATION
These switches are resistor multiplexed units that
are hard-wired to the Body Control Module (BCM)
through the clockspring. The BCM sends the proper
messages on the Programmable Communications
Interface (PCI) data bus network to the radio
receiver. For diagnosis of the BCM or the PCI data
bus, the use of a DRB IIItscan tool and the proper
Diagnostic Procedures manual are recommended. For
more information on the operation of the remote
radio switch controls, refer to the owner's manual in
the vehicle glove box.
DIAGNOSIS AND TESTING - REMOTE
SWITCHES
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
Any diagnosis of the Audio system should
begin with the use of the DRB IIItdiagnostic
tool. For information on the use of the DRB
IIIt, refer to the appropriate Diagnostic Service
Manual.
Refer to the appropriate wiring information. The
wiring information includes wiring diagrams, proper
wire and connector repair procedures, details of wire
harness routing and retention, connector pin-out
information and location views for the various wire
harness connectors, splices and grounds.
(1) Disconnect and isolate the battery negative
cable. Wait two minutes for the airbag system capac-
itor to discharge before further service.
(2) Remove the remote radio switch(es) from the
steering wheel. (Refer to 8 - ELECTRICAL/AUDIO/
REMOTE SWITCHES - REMOVAL).
(3) Use an ohmmeter to check the switch resis-
tance as shown in the Remote Radio Switch Test
table (Fig. 11).
Fig. 10 Remote Radio Switch Operational View
1 - PRESET SEEK
2 - SEEK UP
3 - VOLUME UP
4 - MODE
5 - VOLUME DOWN
6 - SEEK DOWN
Fig. 11 Remote Radio Switches
1 - WHITE REAR SWITCH
2 - BLACK REAR SWITCH
RSAUDIO8A-11
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REMOTE RADIO SWITCH TEST
SWITCH POSITION RESISTANCE
VOLUME UP 7320 OHMS
VOLUME DOWN 1210 OHMS
SEEK UP 4530 OHMS
SEEK DOWN 2050 OHMS
PRE-SET STATION ADVANCE 10 OHMS
NOTE: The right remote radio switch back is white
in color. The left switch back is black in color. The
right/left remote radio switch orientation is with the
steering wheel installed, and driver in drivers seat.
(4) If the switch resistance checks OK, go to Step
5. If not OK, replace the faulty switch.
(5) Check for continuity between the ground cir-
cuit cavity of the switch wire harness connector and
a good ground. There should be continuity. If OK, go
to Step 6. If not OK, repair the open circuit as
required.
(6) Unplug the 24-way white wire harness connec-
tor from the Body Control Module (BCM). Check for
continuity between the radio control circuit cavity of
the remote radio switch wire harness connector and a
good ground. There should be no continuity. If OK, go
to Step 7. If not OK, repair the short circuit as
required.
(7) Check for continuity between the radio control
circuit cavities of the remote radio switch wire har-
ness connector and the BCM wire harness connector.
There should be continuity. If OK, refer to the proper
Diagnostic Procedures manual to test the BCM and
the PCI data bus. If not OK, repair the open circuit
as required.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable. Wait two minutes for the airbag system capac-
itor to discharge before further service.
(2) Remove the driver side airbag module from the
vehicle. Refer to ELECTRICAL/RESTRAINTS/
DRIVER AIR BAG.(3) Remove the steering wheel from the steering
column. Refer to STEERING/COLUMN/STEERING
WHEEL.
(4) Unplug the wire harness connector from the
remote radio switch (s).
(5) Remove three screws securing steering wheel
rear cover.
(6) Remove the remote radio switch from the steer-
ing wheel by depressing tabs on each side of each
switch.
NOTE: The right remote radio switch back is white
in color. The left switch back is black in color. The
right/left remote radio switch orientation is with the
steering wheel installed, and driver in drivers seat.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1)
Install remote radio switch to the steering wheel.
(2) Install three screws securing steering wheel
rear cover.
(3) Connect the wire harness to the remote radio
switch.
(4) Install the steering wheel. Refer to STEERING/
COLUMN/STEERING WHEEL.
(5) Install the driver side airbag module. Refer to
ELECTRICAL/RESTRAINTS/DRIVER AIRBAG.
(6) Connect the battery negative cable.
SPEAKER
DIAGNOSIS AND TESTING - SPEAKER
WARNING: DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE AIRBAG SYSTEM CAPACI-
TOR TO DISCHARGE BEFORE PERFORMING FUR-
THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
SURE WAY TO DISABLE THE AIRBAG SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT AND POSSIBLE PERSONAL INJURY.
8A - 12 AUDIORS
REMOTE SWITCHES (Continued)
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CHIME/BUZZER
TABLE OF CONTENTS
page page
CHIME/BUZZER
DESCRIPTION..........................1
OPERATION............................1
WARNING.............................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - CHIME
SYSTEM.............................1
DIAGNOSIS AND TESTING - DOME LAMP
ON CHIME............................2
DIAGNOSIS AND TESTING - ENGINE
TEMPERATURE CRITICAL CHIME..........2
DIAGNOSIS AND TESTING - EXTERIOR
LAMPS ON CHIME.....................2
DIAGNOSIS AND TESTING - KEY-IN
IGNITION CHIME.......................2DIAGNOSIS AND TESTING - LOW OIL
PRESSURE CHIME.....................3
DIAGNOSIS AND TESTING - SEAT BELT
CHIME...............................3
DIAGNOSIS AND TESTING - SEAT BELT
LAMP...............................3
DIAGNOSIS AND TESTING - TIRE
PRESSURE MONITOR..................3
DIAGNOSIS AND TESTING - TURN SIGNAL
ON CHIME............................3
DIAGNOSIS AND TESTING - WARNING
LAMP ANNOUNCEMENT CHIME...........4
CHIME/BUZZER
DESCRIPTION
The chime/buzzer system provides the driver with
warning chimes for:
²Seat Belt
²Exterior Lamps ON
²Key-In Ignition
²Engine Temperature Critical
²Turn Signals ON
²Dome Lamp ON
²Low Oil Pressure
²High Speed Warning
²Warning Lamp Announcement
²Key-In Accessory
²Low/High Tire Pressure
²Service Tire Pressure Monitor (TPM)
HIGH SPEED WARNING - EXPORT
The chime will sound, acting as a warning to the
driver that the vehicle speed has exceeded 120 3
kph (75 2 mph).
OPERATION
The Chime/Buzzer Warning System is diagnosed
using a DRB llltscan tool. Refer to the proper Body
Diagnostic Procedures Manual.
HIGH SPEED WARNING - EXPORT
When the vehicle speed sensor sees 120 3kph
(75 2 mph), it sends a PCI data bus message to the
Body Control Module (BCM). The BCM then turns onthe chime to let the driver know that the vehicle has
reached a speed greater than 120 3kph(75 2
mph). This audible message will continue until the
vehicle is slowed below the predetermined speed.
WARNING
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - CHIME SYSTEM
NO TONE WHEN IGNITION SWITCH IS TURNED ON
AND DRIVER'S SEAT BELT IS NOT BUCKLED.
(1) Using a DRB llltscan tool, actuate chime
(BCM actuates).
(2) Using a voltmeter, check for voltage:
RSCHIME/BUZZER8B-1
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STARTING
TABLE OF CONTENTS
page page
STARTING
DESCRIPTION.........................28
OPERATION...........................28
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - STARTING
SYSTEM TEST.......................28
DIAGNOSIS AND TESTING - CONTROL
CIRCUIT TEST........................31
DIAGNOSIS AND TESTING - FEED CIRCUIT
RESISTANCE TEST....................33
DIAGNOSIS AND TESTING - FEED CIRCUIT
TEST...............................33SPECIFICATIONS
STARTER ...........................34
Torques.............................34
STARTER MOTOR
REMOVAL
REMOVAL - 2.4L......................35
REMOVAL - 3.3/3.8L...................36
INSTALLATION
INSTALLATION - 2.4L..................36
INSTALLATION - 3.3/3.8L................36
STARTING
DESCRIPTION
The starting system has (Fig. 1):
²Ignition switch
²Starter relay
²Transmission Range Sensor or Park/Neutral
Switch
²Wiring harness
²Battery
²Starter motor with an integral solenoid
²Powertrain Control Module (PCM)
OPERATION
These components form two separate circuits. A
high amperage circuit that feeds the starter motor up
to 300+ amps, and a control circuit that operates on
less than 20 amps.
The PCM controls a double start over-ride safety
that does not allow the starter to be engaged if the
engine is already running.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - STARTING
SYSTEM TEST
For circuit descriptions and diagrams, refer to the
Wiring Diagrams.WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO THE PASSIVE RESTRAINT SYS-
TEMS BEFORE ATTEMPTING STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
INSPECTION
Before removing any unit from the starting system
for repair or diagnosis, perform the following inspec-
tions:
²Battery- Visually inspect the battery for indi-
cations of physical damage and loose or corroded
cable connections. Determine the state-of-charge and
cranking capacity of the battery. Charge or replace
the battery, if required. Refer to the Battery section
for more information.
²Ignition Switch- Visually inspect the ignition
switch for indications of physical damage and loose
or corroded wire harness connections.
²Transmission Range Sensor- Visually inspect
the transmission range sensor for indications of phys-
ical damage and loose or corroded wire harness con-
nections.
²Starter Relay- Visually inspect the starter
relay for indications of physical damage and loose or
corroded wire harness connections.
8F - 28 STARTINGRS
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STARTING SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSE CORRECTION
STARTER FAILS
TO ENGAGE.1. BATTERY
DISCHARGED OR
FAULTY.1. REFER TO THE BATTERY SECTION FOR MORE
INFORMATION. CHARGE OR REPLACE BATTERY, IF
REQUIRED.
2. STARTING CIRCUIT
WIRING FAULTY.2. REFER TO FEED CIRCUIT RESISTANCE TEST AND FEED
CIRCUIT TEST IN THIS SECTION.
3. STARTER RELAY
FAULTY.3. REFER TO RELAY TEST, IN THIS SECTION. REPLACE
RELAY, IF NECESSARY.
4. IGNITION SWITCH
FAULTY.4. REFER TO IGNITION SWITCH TEST, IN THE STEERING
SECTION OR 8 WIRING DIAGRAMS. REPLACE SWITCH, IF
NECESSARY.
5. PARK/NEUTRAL
POSITION SWITCH
(AUTO TRANS) FAULTY
OR MIS-ADJUSTED.5. REFER PARK/NEUTRAL POSITION SWITCH TEST, IN THE
TRANSAXLE. SECTION FOR MORE INFORMATION. REPLACE
SWITCH, IF NECESSARY.
6. CLUTCH PEDAL
POSITION SWITCH
(MAN TRANS) FAULTY.6. REFER TO CLUTCH PEDAL POSITION SWITCH TEST, IN
THE CLUTCH. SECTION. REPLACE SWITCH, IF NECESSARY.
7. STARTER SOLENOID
FAULTY.7. REFER TO SOLENOID TEST, IN THIS SECTION. REPLACE
STARTER ASSEMBLY, IF NECESSARY.
8. STARTER ASSEMBLY
FAULTY.8. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
9. FAULTY TEETH ON
RING GEAR.9. ROTATE FLYWHEEL 360É, AND INSPECT TEETH AND RING
GEAR REPLACED IF DAMAGED.
10. PCM DOUBLE
START OVERRIDE
OUTPUT FAILURE.10. REFER TO PCM DIAGNOSTIC. CHECK FOR CONTINUITY
BETWEEN PCM AND TERMINAL 85. REPAIR OPEN CIRCUIT
AS REQUIRED. IF OK, PCM MAY BE DEFECTIVE.
STARTER
ENGAGES,
FAILS TO TURN
ENGINE.1. BATTERY
DISCHARGED OR
FAULTY.1. REFER TO THE BATTERY SECTION FOR MORE
INFORMATION. CHARGE OR REPLACE BATTERY AS
NECESSARY.
2. STARTING CIRCUIT
WIRING FAULTY.2. REFER TO THE FEED CIRCUIT RESISTANCE TEST AND
THE FEED CIRCUIT TEST IN THIS SECTION. REPAIR AS
NECESSARY.
3. STARTER ASSEMBLY
FAULTY.3. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
4. ENGINE SEIZED. 4. REFER TO THE ENGINE SECTION, FOR DIAGNOSTIC AND
SERVICE PROCEDURES.
5. LOOSE
CONNECTION AT
BATTERY, PDC,
STARTER, OR ENGINE
GROUND.5. INSPECT FOR LOOSE CONNECTIONS.
6. FAULTY TEETH ON
RING GEAR.6. ROTATE FLYWHEEL 360É, AND INSPECT TEETH AND RING
GEAR REPLACED IF DAMAGED.
8F - 30 STARTINGRS
STARTING (Continued)
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CONDITION POSSIBLE CAUSE CORRECTION
STARTER
ENGAGES,
SPINS OUT
BEFORE
ENGINE
STARTS.1. BROKEN TEETH ON
STARTER RING GEAR.1. REMOVE STARTER. INSPECT RING GEAR AND REPLACE
IF NECESSARY.
2. STARTER ASSEMBLY
FAULTY.2. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
STARTER DOES
NOT
DISENGAGE.1. STARTER
IMPROPERLY
INSTALLED.1. INSTALL STARTER. TIGHTEN STARTER MOUNTING
HARDWARE TO CORRECT TORQUE SPECIFICATIONS.
2. STARTER RELAY
FAULTY.2. REFER TO RELAY TEST, IN THIS SECTION. REPLACE
RELAY, IF NECESSARY.
3. IGNITION SWITCH
FAULTY.3. REFER TO IGNITION SWITCH TEST, IN THE STEERING
SECTION. REPLACE SWITCH, IF NECESSARY.
4. STARTER ASSEMBLY
FAULTY.4. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
5. FAULTY TEETH ON
RING GEAR.5. ROTATE FLYWHEEL 360É, AND INSPECT TEETH AND RING
GEAR REPLACED IF DAMAGED.
DIAGNOSIS AND TESTING - CONTROL
CIRCUIT TEST
The starter control circuit has:
²Starter motor with integral solenoid
²Starter relay
²Transmission range sensor, or Park/Neutral
Position switch with automatic transmissions
²Ignition switch
²Battery
²All related wiring and connections
²Powertrain Control Module (PCM)
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
²To disable ignition and fuel systems, disconnect
the Automatic Shutdown Relay (ASD). The ASD relay
is located in the Power Distribution Center (PDC).
Refer to the PDC cover for the proper relay location.
STARTER SOLENOID
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN THE PARK POSITION WITH THE
PARKING BRAKE APPLIED.
(1) Verify battery condition. Battery must be in
good condition with a full charge before performing
any starter tests. Refer to Battery Tests.
(2) Perform Starter Solenoid test BEFORE per-
forming the starter relay test.(3) Perform a visual inspection of the starter/
starter solenoid for corrosion, loose connections or
faulty wiring.
(4) Locate and remove the starter relay from the
Power Distribution Center (PDC). Refer to the PDC
label for relay identification and location.
(5) Connect a remote starter switch or a jumper
wire between the remote battery positive post and
terminal 87 of the starter relay connector.
(a) If engine cranks, starter/starter solenoid is
good. Go to the Starter Relay Test.
(b) If engine does not crank or solenoid chatters,
check wiring and connectors from starter relay to
starter solenoid for loose or corroded connections.
Particularly at starter terminals.
(c) Repeat test. If engine still fails to crank prop-
erly, trouble is within starter or starter mounted
solenoid, and replace starter. Inspect the ring gear
teeth.
STARTER RELAY
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN THE PARK/NEUTRAL POSITION
WITH THE PARKING BRAKE APPLIED.
RELAY TEST
The starter relay is located in the Power Distribu-
tion Center (PDC) in the engine compartment. Refer
to the PDC label for relay identification and location.
RSSTARTING8F-31
STARTING (Continued)
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Page 439 of 2399
(5) Connect the push-in field wire connector to
back of generator.
(6) Install the EVAP Purge solenoid to its bracket.
(7) Install the Air Box, refer to the Engine/Air
Cleaner for more information.
(8) Connect the Inlet Air Temperature sensor.
(9) Connect battery negative cable.
INSTALLATION - 2.5L
(1) Install generator.
(2) Install the 2 lower mounting Bolts (Fig. 8).
(3) Install the Air Cleaner Box (Fig. 7).
(4) Install the upper support bracket (Fig. 6).
(5) Install the wiring harness on upper generator
bracket (Fig. 6).
(6) Connect the field connection (Fig. 5).
(7) Connect the generator battery connection (Fig.
5).
(8) Raise vehicle and support.
(9) Install the generator drive belt (Fig. 4).
(10) Install the right front splash shield (Fig. 3).
(11) Lower vehicle.
(12) Install the engine cover (Fig. 2).
(13) Connect the negative battery cable (Fig. 1).
INSTALLATION - 3.3/3.8L
(1) Roll and place generator in position on vehicle
(Fig. 10).
(2) Install upper bolts to hold generator in place.
(3) Lubricate the o-ring. Install oil dip stick tube.
(4) Install the upper oil dip stick tube bolt.
(5) Place B+ terminal in position on generator.
(6) Install nut to hold B+ wire terminal to back of
generator.
(7) Connect the push-in field wire connector into
back of generator.
(8) Raise vehicle and support.
(9) Install the lower mounting bolt and tighten.
(10) Install the lower oil dip stick tube bolt and
tighten (Fig. 9).
(11) Install accessory drive belt, refer to the Cool-
ing System section for proper procedures.
(12) Install the right front lower splash shield.
(13) Lower vehicle.
(14) Install wiring harness to the oil dip stick tube
(15) Connect battery negative cable.
(16) Verify generator output rate.
INSTALLATION - 3.5L
(1) Install generator (Fig. 16) and the 3 mounting
bolts and tighten.
(2) Connect the generator positive battery cable
(Fig. 15).
(3) Connect the field connector and lock the con-
nector (Fig. 15).
(4) Install the axle shaft to the transmission.(5) Install axle to steering knuckle (Fig. 13).
(6) Install the 2 upper clevies bolts and tighten,
refer to the Suspension section.
(7) Install axle nut and tighten, refer to the Differ-
ential and Driveline section.
(8) Relocate the ABS sensor wiring to bracket (Fig.
12).
(9) Install the accessory drive belt (Fig. 14), refer
to the Cooling section.
(10) Install the right front splash shield.
(11) Install the right front tire, refer to the Wheels
and Tires section.
(12) Lower vehicle.
(13) Connect the negative battery cable.
GENERATOR DECOUPLER
PULLEY
DESCRIPTION
The Generator Decoupler is a one way clutch (Fig.
17). It is attached to the generator and replaces the
standard pulley. It is a non-serviceable item and is to
be replaced as an assembly. It is a dry operation (no
grease or lubricants). The operation of it is not tem-
perature sensitive and has a low sensitivity to elec-
trical load.
OPERATION
The generator decoupler is a one way clutch and
should be replaced as an assembly. It is designed to
help reduce belt tension fluctuation, reduce fatigue
loads, improve belt life, reduce hubloads on compo-
nents, and reduce noise.
Fig. 17 GENERATOR DECOUPLER 3.3/3.8L
8Fa - 28 CHARGINGRG
GENERATOR (Continued)
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STARTING
TABLE OF CONTENTS
page page
STARTING
DESCRIPTION.........................31
OPERATION...........................31
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - STARTING
SYSTEM TEST.......................31
DIAGNOSIS AND TESTING - CONTROL
CIRCUIT TEST........................34
DIAGNOSIS AND TESTING - FEED CIRCUIT
RESISTANCE TEST....................36
DIAGNOSIS AND TESTING - FEED CIRCUIT
TEST...............................36
SPECIFICATIONS
STARTER ...........................37Torques.............................37
STARTER MOTOR
REMOVAL
REMOVAL - 2.4L......................38
REMOVAL - 3.3/3.8L...................39
REMOVAL - 3.5L......................39
REMOVAL - 2.5L......................40
INSTALLATION
INSTALLATION - 2.4L..................41
INSTALLATION - 3.3/3.8L................41
INSTALLATION - 3.5L..................41
INSTALLATION - 2.5L..................41
STARTING
DESCRIPTION
The starting system has (Fig. 1):
²Ignition switch
²Starter relay
²Transmission Range Sensor or Park/Neutral
Switch
²Wiring harness
²Battery
²Starter motor with an integral solenoid
²Powertrain Control Module (PCM)
OPERATION
These components form two separate circuits. A
high amperage circuit that feeds the starter motor up
to 300+ amps, and a control circuit that operates on
less than 20 amps.
The PCM controls a double start over-ride safety
that does not allow the starter to be engaged if the
engine is already running.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - STARTING
SYSTEM TEST
For circuit descriptions and diagrams, refer to the
Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO THE PASSIVE RESTRAINT SYS-
TEMS BEFORE ATTEMPTING STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
RGSTARTING8Fa-31
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STARTING SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSE CORRECTION
STARTER FAILS
TO ENGAGE.1. BATTERY
DISCHARGED OR
FAULTY.1. REFER TO THE BATTERY SECTION FOR MORE
INFORMATION. CHARGE OR REPLACE BATTERY, IF
REQUIRED.
2. STARTING CIRCUIT
WIRING FAULTY.2. REFER TO FEED CIRCUIT RESISTANCE TEST AND FEED
CIRCUIT TEST IN THIS SECTION.
3. STARTER RELAY
FAULTY.3. REFER TO RELAY TEST, IN THIS SECTION. REPLACE
RELAY, IF NECESSARY.
4. IGNITION SWITCH
FAULTY.4. REFER TO IGNITION SWITCH TEST, IN THE STEERING
SECTION OR 8 WIRING DIAGRAMS. REPLACE SWITCH, IF
NECESSARY.
5. PARK/NEUTRAL
POSITION SWITCH
(AUTO TRANS) FAULTY
OR MIS-ADJUSTED.5. REFER PARK/NEUTRAL POSITION SWITCH TEST, IN THE
TRANSAXLE. SECTION FOR MORE INFORMATION. REPLACE
SWITCH, IF NECESSARY.
6. CLUTCH PEDAL
POSITION SWITCH
(MAN TRANS) FAULTY.6. REFER TO CLUTCH PEDAL POSITION SWITCH TEST, IN
THE CLUTCH. SECTION. REPLACE SWITCH, IF NECESSARY.
7. STARTER SOLENOID
FAULTY.7. REFER TO SOLENOID TEST, IN THIS SECTION. REPLACE
STARTER ASSEMBLY, IF NECESSARY.
8. STARTER ASSEMBLY
FAULTY.8. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
9. FAULTY TEETH ON
RING GEAR.9. ROTATE FLYWHEEL 360É, AND INSPECT TEETH AND RING
GEAR REPLACED IF DAMAGED.
10. PCM DOUBLE
START OVERRIDE
OUTPUT FAILURE.10. REFER TO PCM DIAGNOSTIC. CHECK FOR CONTINUITY
BETWEEN PCM AND TERMINAL 85. REPAIR OPEN CIRCUIT
AS REQUIRED. IF OK, PCM MAY BE DEFECTIVE.
STARTER
ENGAGES,
FAILS TO TURN
ENGINE.1. BATTERY
DISCHARGED OR
FAULTY.1. REFER TO THE BATTERY SECTION FOR MORE
INFORMATION. CHARGE OR REPLACE BATTERY AS
NECESSARY.
2. STARTING CIRCUIT
WIRING FAULTY.2. REFER TO THE FEED CIRCUIT RESISTANCE TEST AND
THE FEED CIRCUIT TEST IN THIS SECTION. REPAIR AS
NECESSARY.
3. STARTER ASSEMBLY
FAULTY.3. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
4. ENGINE SEIZED. 4. REFER TO THE ENGINE SECTION, FOR DIAGNOSTIC AND
SERVICE PROCEDURES.
5. LOOSE
CONNECTION AT
BATTERY, PDC,
STARTER, OR ENGINE
GROUND.5. INSPECT FOR LOOSE CONNECTIONS.
6. FAULTY TEETH ON
RING GEAR.6. ROTATE FLYWHEEL 360É, AND INSPECT TEETH AND RING
GEAR REPLACED IF DAMAGED.
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CONDITION POSSIBLE CAUSE CORRECTION
STARTER
ENGAGES,
SPINS OUT
BEFORE
ENGINE
STARTS.1. BROKEN TEETH ON
STARTER RING GEAR.1. REMOVE STARTER. INSPECT RING GEAR AND REPLACE
IF NECESSARY.
2. STARTER ASSEMBLY
FAULTY.2. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
STARTER DOES
NOT
DISENGAGE.1. STARTER
IMPROPERLY
INSTALLED.1. INSTALL STARTER. TIGHTEN STARTER MOUNTING
HARDWARE TO CORRECT TORQUE SPECIFICATIONS.
2. STARTER RELAY
FAULTY.2. REFER TO RELAY TEST, IN THIS SECTION. REPLACE
RELAY, IF NECESSARY.
3. IGNITION SWITCH
FAULTY.3. REFER TO IGNITION SWITCH TEST, IN THE STEERING
SECTION. REPLACE SWITCH, IF NECESSARY.
4. STARTER ASSEMBLY
FAULTY.4. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
5. FAULTY TEETH ON
RING GEAR.5. ROTATE FLYWHEEL 360É, AND INSPECT TEETH AND RING
GEAR REPLACED IF DAMAGED.
DIAGNOSIS AND TESTING - CONTROL
CIRCUIT TEST
The starter control circuit has:
²Starter motor with integral solenoid
²Starter relay
²Transmission range sensor, or Park/Neutral
Position switch with automatic transmissions
²Ignition switch
²Battery
²All related wiring and connections
²Powertrain Control Module (PCM)
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
²To disable ignition and fuel systems, disconnect
the Automatic Shutdown Relay (ASD). The ASD relay
is located in the Power Distribution Center (PDC).
Refer to the PDC cover for the proper relay location.
STARTER SOLENOID
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN THE PARK POSITION WITH THE
PARKING BRAKE APPLIED.
(1) Verify battery condition. Battery must be in
good condition with a full charge before performing
any starter tests. Refer to Battery Tests.
(2) Perform Starter Solenoid test BEFORE per-
forming the starter relay test.(3) Perform a visual inspection of the starter/
starter solenoid for corrosion, loose connections or
faulty wiring.
(4) Locate and remove the starter relay from the
Power Distribution Center (PDC). Refer to the PDC
label for relay identification and location.
(5) Connect a remote starter switch or a jumper
wire between the remote battery positive post and
terminal 87 of the starter relay connector.
(a) If engine cranks, starter/starter solenoid is
good. Go to the Starter Relay Test.
(b) If engine does not crank or solenoid chatters,
check wiring and connectors from starter relay to
starter solenoid for loose or corroded connections.
Particularly at starter terminals.
(c) Repeat test. If engine still fails to crank prop-
erly, trouble is within starter or starter mounted
solenoid, and replace starter. Inspect the ring gear
teeth.
STARTER RELAY
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN THE PARK/NEUTRAL POSITION
WITH THE PARKING BRAKE APPLIED.
RELAY TEST
The starter relay is located in the Power Distribu-
tion Center (PDC) in the engine compartment. Refer
to the PDC label for relay identification and location.
8Fa - 34 STARTINGRG
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