battery location CHRYSLER CARAVAN 2005 User Guide

²System diagnostics - diagnosis and error han-
dling (sensors, display, module).
²Data exchange over the Programmable Commu-
nication Interface (PCI) data bus.
OPERATION
The module has a number of functions:
²Supply voltage to the sensors and display.
²Disconnection of the display with bus idle and
over voltage Vmax.
²Triggering the sensors.
²Analyze echo delay times and calculate obstacle
distances.
²Bi-directional data communication to the display
for diagnosis.
²System diagnostics - diagnosis and error han-
dling (sensors, display, module).
²Data exchange over the Programmable Commu-
nication Interface (PCI) data bus.
The system detection length from the rear of the
vehicle is 0.3 meters to 1.5 meters. This area extends
around the rear side of the vehicle. The system detec-
tion height from the ground is 0.2 meters to about
1.5 meters. The radio mutes when the system acti-
vates its audible tone.When the driver selects Reverse, the system scans
for objects behind the vehicle using four sensors
located in the rear bumper. Objects can be detected
from up to 1.5 meters. A warning display above the
rear window provides both visible and audible warn-
ings indicating the range of the object.
The system is active only when the vehicle is in
reverse for vehicle speeds less than 16 Km/h (10
mph). If the vehicles Parking/Emergency Brake is
applied, the system is deactivated.
The display contains two sets of yellow and red
Light Emitting Diode's (LED's) that the driver can
see as they look over their shoulder while backing
up. Each side of the vehicle has its own warning
LED's. The system provides a visual warning by illu-
minating one or more yellow LED's as the vehicle
gets closer to the object. As the vehicle continues to
approaches the object, one red LED is illuminated
and the system emits a series of short beeps. The
tone will remain constant and both red LED's are
illuminated once the vehicle is within 12 inches (30.5
cm) of the object.
The system can be turned ON or OFF through the
Electronic Vehicle Information Center (EVIC) when
the vehicle is in PARK. If the park assist system is
turned OFF, a single chime will sound and the EVIC
will display the following message ªREAR PARK
ASSIST OFFº, when the vehicle is in reverse.
²Ensure that the rear bumper is free of dirt and
debris to keep the system operating properly.
²Jackhammers, large trucks, and other vibrations
could affect the performance of the system.
²Ensure that the parking brake is not applied.
If ªService Park Assist Systemº appears in the
EVIC after making sure the rear bumper is clean,
proceed to diagnose the system using a scan tool and
the appropriate diagnostic information.
To diagnose the Park Assist Module, use a scan
tool and the appropriate body diagnostic information.
REMOVAL
(1) Open hood.
(2)
Disconnect and isolate the battery negative cable.
(3) Remove the left quarter trim panel (Refer to 23
- BODY/INTERIOR/QUARTER TRIM PANEL -
REMOVAL).
Fig. 3 PARK ASSIST MODULE - LOCATION
1 - RETAINING SCREW J-CLIPS
2 - LEFT QUARTER PANEL/C-PILLAR
3 - MODULE RETAINING SCREWS
4 - PARK ASSIST MODULE
RSCHIME/BUZZER8B-5
PARK ASSIST MODULE (Continued)

(4) Disconnect the Park Assist Module electrical
connector (Fig. 4).
(5) Remove the two attaching screws and separate
the module from vehicle (Fig. 3).
INSTALLATION
(1) Position the Park Assist Module and install the
two attaching screws (Fig. 3). Torque screws to 3.5
N´m (30 in. lbs.).
(2) Connect the Park Assist Module electrical con-
nector (Fig. 4).
(3) Install the left quarter trim panel (Refer to 23 -
BODY/INTERIOR/QUARTER TRIM PANEL -
INSTALLATION).
(4) Connect the battery negative cable.
(5) Close hood.
(6) Verify vehicle and system operation.
PARK ASSIST SENSOR
DESCRIPTION
The Park Assist Sensors are located in the rear
bumper fascia mounted equally apart (Fig. 5). The
sensors generate ultrasonic pulses when triggered by
the park assist module when an obstacle is detected.
The sensors then signal the module when reflected
ultrasonic pulses are received.
The sensors detect objects with an ultrasonic pulse
that reflects off the object and then is sent to the
module to determine the distance of the object.
OPERATION
The Park Assist Sensors:
²Generate ultrasonic pulses when triggered by
the Park Assist Module.
²Reception/filtering of ultrasonic energy received.
²Signalling the module of received ultrasonic
pulses that meet threshold criteria.
The sensors are supplied power by the module. The
sensor supply is enabled when the sensor function is
necessary.
The sensors detection length from the rear of the
vehicle is 0.3 meters to 1.5 meters. This area extends
around the rear side of the vehicle. The sensor detec-
tion height from the ground is 0.2 meters to about
1.5 meters.
²Ensure that the rear bumper (sensors) is free of
dirt and debris to keep the system operating prop-
erly.
²Jackhammers, large trucks, and other vibrations
could affect the performance of the system.
²Ensure that the parking brake is not applied.
If ªService Park Assist Systemº appears in the
EVIC after making sure the rear bumper is clean,
proceed to diagnose the system using a scan tool and
the appropriate diagnostic information.
REMOVAL
(1) Open hood.
(2) Disconnect and isolate the battery negative
cable.
(3) Remove rear fascia (Refer to 13 - FRAME &
BUMPERS/BUMPERS/REAR FASCIA - REMOVAL).
(4) Unsnap Park Assist Sensor from the retaining
housing and remove from fascia.
INSTALLATION
(1)Position the Park Assist Sensor over the retain-
ing housing and firmly snap into housing in rear fascia.
(2) Install the rear fascia (Refer to 13 - FRAME &
BUMPERS/BUMPERS/REAR FASCIA - INSTALLA-
TION).
(3) Connect the battery negative cable.
(4) Close hood.
(5) Verify vehicle and system operation.
Fig. 4 PARK ASSIST MODULE ELECTRICAL
CONNECTOR
1 - MODULE ELECTRICAL CONNECTOR
2 - PARK ASSIST MODULE
Fig. 5 PARK ASSIST SENSOR LOCATION
8B - 6 CHIME/BUZZERRS
PARK ASSIST MODULE (Continued)

(1) Plug the DRBIIItscan tool into the diagnostic
connector. The connector is located under the instru-
ment panel.
(2) Go to the Transmission screen.
(3) Go to the Miscellaneous screen.
(4) Select Quick Learn Procedure. Follow the
instructions of the DRBIIItto perform the Quick
Learn Procedure.
REMOVAL
REMOVAL - SBEC CONTROLLER
(1) Disconnect the negative battery cable.
(2) Remove the battery shield, refer to the Battery
section for more information.
(3) Remove the 2 upper PCM bracket bolts (Fig.
11).
(4) Remove the 2 PCM connectors.
(5) Remove the headlamp, refer to the Lamps sec-
tion for more information.
(6) Remove the lower PCM mounting bolt (Fig. 12).
(7) Remove PCM.
REMOVAL - NGC CONTROLLER
The PCM engine control strategy prevents reduced
idle speeds until after the engine operates for 320 km
(200 miles). If the PCM is replaced after 320 km (200
miles) of usage, update the mileage and vehicle iden-
tification number (VIN) in the new PCM. Use the
DRBIIItscan tool to change the millage and VIN in
the PCM. If this step is not done a Diagnostic Trou-
ble Code (DTC) may be set. Refer to the appropriate
Powertrain Diagnostic Manual and the DRBIIItscan
tool.
Fig. 11 PCM
1 - Attaching Bolts
Fig. 12 PCM LOWER BOLT
NGC CONTROLLER LOCATION
8E - 16 ELECTRONIC CONTROL MODULESRS
POWERTRAIN CONTROL MODULE (Continued)

ENGINE SYSTEMS
TABLE OF CONTENTS
page page
BATTERY SYSTEM......................... 1
CHARGING.............................. 21STARTING............................... 31
BATTERY SYSTEM
TABLE OF CONTENTS
page page
BATTERY SYSTEM
DESCRIPTION..........................1
OPERATION............................2
DIAGNOSIS AND TESTING
BATTERY SYSTEM.....................2
CLEANING.............................5
INSPECTION...........................5
SPECIFICATIONS
BATTERY............................6
SPECIAL TOOLS
BATTERY SYSTEM SPECIAL TOOLS.......7
BATTERY
DESCRIPTION..........................7
OPERATION............................9
DIAGNOSIS AND TESTING
BATTERY............................9
STANDARD PROCEDURE
SPIRAL PLATE BATTERY CHARGING......10
CONVENTIONAL BATTERY CHARGING....11
OPEN-CIRCUIT VOLTAGE TEST..........13IGNITION-OFF DRAW TEST.............13
CHECKING BATTERY ELECTROLYTE
LEVEL..............................14
MICRO 420 BATTERY TESTER...........15
REMOVAL - BATTERY...................16
INSTALLATION.........................16
BATTERY HOLDDOWN
REMOVAL.............................16
INSTALLATION.........................16
BATTERY CABLES
DESCRIPTION.........................16
OPERATION...........................17
DIAGNOSIS AND TESTING
BATTERY CABLES....................17
REMOVAL.............................19
INSTALLATION.........................19
BATTERY TRAY
DESCRIPTION.........................19
REMOVAL.............................19
INSTALLATION.........................20
BATTERY SYSTEM
DESCRIPTION
This vehicle is equipped with a single 12-volt bat-
tery. All of the components of the battery system are
located within the engine compartment. The battery
system for this vehicle contains the following related
components:
²Battery- The storage battery provides a reli-
able means of storing a renewable source of electrical
energy within the vehicle.
²Battery Cable- The battery cables connect the
battery terminal posts to the vehicle electrical sys-
tem.²Battery Holddown- The battery holddown
hardware secures the battery in the battery tray in
the engine compartment.
²Battery Thermowrap- The battery thermow-
rap insulates the battery to protect it from engine
compartment temperature extremes.
²Battery Tray- The battery tray provides a
secure mounting location in the vehicle for the bat-
tery and an anchor point for the battery holddown
hardware.
RSENGINE SYSTEMS8F-1

(2) Wearing safety glasses, look through the bat-
tery cell cap holes to determine the level of the elec-
trolyte in the battery. The electrolyte should be above
the hooks inside the battery cells (Fig. 10).
(3)Add only distilled wateruntil the electrolyte
is above the hooks inside the battery cells (Fig. 10).
MICRO 420 BATTERY TESTER
Always use the Micro 420 Instruction Manual that
was supplied with the tester as a reference. If the
Instruction Manual is not available the following pro-
cedure can be used:
WARNING: ALWAYS WEAR APPROPRIATE EYE
PROTECTION AND USE EXTREME CAUTION WHEN
WORKING WITH BATTERIES.
BATTERY TESTING
(1) If testing the battery OUT-OF-VEHICLE, clean
the battery terminals with a wire brush before test-
ing. If the battery is equipped with side post termi-
nals, install and tighten the supplied lead terminal
stud adapters. Do not use steel bolts. Failure to prop-
erly install the stud adapters, or using stud adapters
that are dirty or worn-out may result in false test
readings.
(2) If testing the battery IN-THE-VEHICLE, make
certain all of the vehicle accessory loads are OFF,
including the ignition.The preferred test positionis at the battery terminal. If the battery is not
accessible, you may test using both the positive and
negative jumper posts. Select TESTING AT JUMPER
POST when connecting to that location.
(3) Connect the tester to the battery or jumper
posts, the red clamp to positive (+) and the black
clamp to negative (±).
NOTE: Multiple batteries connected in parallel must
have the ground cable disconnected to perform a
battery test. Failure to disconnect may result in
false battery test readings.
(4) Using the ARROW key selectinoroutof vehi-
cle testing and press ENTER to make a selection.
(5) If not selected, choose the Cold Cranking Amp
(CCA) battery rating. Or select the appropriate bat-
tery rating for your area (see menu). The tester will
then run its self programmed test of the battery and
display the results. Refer to the test result table
noted below.
CAUTION: If REPLACE BATTERY is the result of the
test, this may mean a poor connection between the
vehicle's cables and battery exists. After discon-
necting the vehicle's battery cables from the bat-
tery, retest the battery using the OUT-OF-VEHICLE
test before replacing.
(6) While viewing the battery test result, press the
CODE button and the tester will prompt you for the
last 4 digits of the VIN. Use the UP/DOWN arrow
buttons to scroll to the correct character; then press
ENTER to select and move to the next digit. Then
Fig. 10 HOOK INSIDE BATTERY CELLS - LOW-
MAINTENANCE BATTERY ONLY
1 - TOP OF BATTERY
2 - HOOK INSIDE BATTERY CELLS
Fig. 11 Micro 420 Battery Tester
RSBATTERY SYSTEM8F-15
BATTERY (Continued)

are installed at the open end of the female battery
terminal clamp. Large eyelet type terminals are
crimped onto the opposite end of the battery cable
wire and then solder-dipped. The battery positive
cable wires have a red insulating jacket to provide
visual identification and feature a larger female bat-
tery terminal clamp to allow connection to the larger
battery positive terminal post. The battery negative
cable wires have a black insulating jacket and a
smaller female battery terminal clamp.
The battery cables cannot be repaired and, if dam-
aged or faulty they must be replaced. Both the bat-
tery positive and negative cables are available for
service replacement only as a unit with the battery
wire harness, which may include portions of the wir-
ing circuits for the generator and other components
on some vehicles. Refer to the appropriate wiring
information for complete circuit schematic or connec-
tor pin-out information.
OPERATION
The battery cables connect the battery terminal
posts to the vehicle electrical system. These cables
also provide a path back to the battery for electrical
current generated by the charging system for restor-
ing the voltage potential of the battery. The female
battery terminal clamps on the ends of the battery
cable wires provide a strong and reliable connection
of the battery cable to the battery terminal posts.
The terminal pinch bolts allow the female terminal
clamps to be tightened around the male terminal
posts on the top of the battery. The eyelet terminals
secured to the opposite ends of the battery cable
wires from the female battery terminal clamps pro-
vide secure and reliable connection of the battery
cables to the vehicle electrical system.
The battery positive cable terminal clamp is
attached to the ends of two wires. One wire has an
eyelet terminal that connects the battery positive
cable to the B(+) terminal stud of the Integrated
Power Module (IPM), and the other wire has an eye-
let terminal that connects the battery positive cable
to the B(+) terminal stud of the engine starter motor
solenoid. The battery negative cable terminal clamp
is also attached to the ends of two wires. One wire
has an eyelet terminal that connects the battery neg-
ative cable to the vehicle powertrain through a stud
on the left side of the engine cylinder block. The
other wire has an eyelet terminal that connects the
battery negative cable to the vehicle body through a
ground screw on the left front fender inner shield,
near the battery.
DIAGNOSIS AND TESTING
BATTERY CABLES
A voltage drop test will determine if there is exces-
sive resistance in the battery cable terminal connec-
tions or the battery cable. If excessive resistance is
found in the battery cable connections, the connec-
tion point should be disassembled, cleaned of all cor-
rosion or foreign material, then reassembled.
Following reassembly, check the voltage drop for the
battery cable connection and the battery cable again
to confirm repair.
When performing the voltage drop test, it is impor-
tant to remember that the voltage drop is giving an
indication of the resistance between the two points at
which the voltmeter probes are attached.EXAM-
PLE:When testing the resistance of the battery pos-
itive cable, touch the voltmeter leads to the battery
positive cable terminal clamp and to the battery pos-
itive cable eyelet terminal at the starter solenoid
B(+) terminal stud. If you probe the battery positive
terminal post and the battery positive cable eyelet
terminal at the starter solenoid B(+) terminal stud,
you are reading the combined voltage drop in the
battery positive cable terminal clamp-to-terminal
post connection and the battery positive cable.
VOLTAGE DROP TEST
The following operation will require a voltmeter
accurate to 1/10 (0.10) volt. Before performing this
test, be certain that the following procedures are
accomplished:
²The battery is fully-charged and load tested.
(Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BAT-
TERY - STANDARD PROCEDURE - BATTERY
CHARGING) for the proper battery charging and
load test procedures.
²Fully engage the parking brake.
²If the vehicle is equipped with an automatic
transmission, place the gearshift selector lever in the
Park position. If the vehicle is equipped with a man-
ual transmission, place the gearshift selector lever in
the Neutral position and block the clutch pedal in the
fully depressed position.
²Verify that all lamps and accessories are turned
off.
²To prevent the engine from starting, remove the
Automatic Shut Down (ASD) relay. The ASD relay is
located in the Intelligent Power Module (IPM), in the
engine compartment. See the fuse and relay layout
label affixed to the underside of the IPM cover for
ASD relay identification and location.
RSBATTERY SYSTEM8F-17
BATTERY CABLES (Continued)

CONDITION POSSIBLE CAUSE CORRECTION
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.
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. THIS MAY RESULT IN
PERSONAL INJURY OR DEATH.
(1) Verify battery condition. Battery must be in
good condition with a full charge before performing
any starter tests. Refer to Battery Tests.
RSSTARTING8F-33
STARTING (Continued)

(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 and from the battery positive ter-
minal to starter post for loose or corroded connec-
tions. 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. THIS MAY
RESULT IN PERSONAL INJURY OR DEATH.
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.
Remove the starter relay from the PDC as
described in this group to perform the following tests:
(1) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 2. If not OK, replace the faulty relay.
(2) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 75  5 ohms. If OK, go to Step
3. If not OK, replace the faulty relay.
(3) Connect a battery B+ lead to terminals 85 and
a ground lead to terminal 86 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 OK, refer to Relay
Circuit Test procedure. If not OK, replace the faulty
relay.
CAV FUNCTION
30 B (+)
85 IGNITION SWITCH OUTPUT
86
PCM-CONTROLLED GROUND
87 STARTER RELAY OUTPUT
87A NO CONNECT
Starter Relay Pinout
Starter Relay Pinout
Starter Relay Pinout
8F - 34 STARTINGRS
STARTING (Continued)

RELAY CIRCUIT TEST
(1) The relay common feed terminal cavity (30) is
connected to battery voltage and should be hot at all
times. If OK, go to Step 2. If not OK, repair the open
circuit to the PDC fuse as required.
(2) The relay normally closed terminal (87A) is
connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3.
(3) The relay normally open terminal (87) is con-
nected to the common feed terminal (30) in the ener-
gized 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 terminal at all times. If OK,
go to Step 4. If not OK, repair the open circuit to the
starter solenoid as required.
(4) The coil battery terminal (85) is connected to
the electromagnet in the relay. It is energized when
the ignition switch is held in the Start position and
the clutch pedal is depressed (manual trans). Check
for battery voltage at the cavity for relay terminal 86
with the ignition switch in the Start position and the
clutch pedal is depressed (manual trans), and no
voltage when the ignition switch is released to the
On position. If OK, go to Step 5. If not OK, check for
an open or short circuit to the ignition switch and
repair, if required. If the circuit to the ignition switch
is OK, see the Ignition Switch Test procedure in this
group.
(5) The coil ground terminal (86) is connected to
the electromagnet in the relay. It is grounded by the
PCM if the conditions are right to start the car. For
automatic trans. cars the PCM must see Park Neu-
tral switch low and near zero engine speed (rpm).
For manual trans. cars the PCM only needs to see
near zero engine speed (rpm) and low clutch inter-
lock input and see near zero engine speed (rpm). To
diagnose the Park Neutral switch of the trans range
sensor refer to the transaxle section. Check for conti-
nuity to ground while the ignition switch is in the
start position and if equipped the clutch pedal
depressed. If not OK and the vehicle has an auto-
matic trans. verify Park Neutral switch operation. If
that checks OK check for continuity between PCM
and the terminal 86. Repair open circuit as required.
Also check the clutch interlock switch operation if
equipped with a manual transmission. If OK, the
PCM may be defective.
SAFETY SWITCHES
For diagnostics of the Transmission Range Sensor,
refer to the Transaxle section for more information.
If equipped with Clutch Interlock/Upstop Switch,
refer to Diagnosis and Testing in the Clutch section.
IGNITION SWITCH
After testing starter solenoid and relay, test igni-
tion switch and wiring. Refer to the Ignition Section
or Wiring Diagrams for more information. Check all
wiring for opens or shorts, and all connectors for
being loose or corroded.
BATTERY
For battery diagnosis and testing, refer to the Bat-
tery section for procedures.
ALL RELATED WIRING AND CONNECTORS
Refer to Wiring Diagrams for more information.
DIAGNOSIS AND TESTING - FEED CIRCUIT
RESISTANCE TEST
Before proceeding with this operation, review Diag-
nostic Preparation and Starter Feed Circuit Tests.
The following operation will require a voltmeter,
accurate to 1/10 of a volt.
CAUTION: Ignition and Fuel systems must be dis-
abled to prevent engine start while performing the
following tests.
(1) To disable the Ignition and Fuel systems, dis-
connect the Automatic Shutdown Relay (ASD). The
ASD relay is located in the Power Distribution Cen-
ter (PDC). Refer to the PDC cover for proper relay
location.
(2) Gain access to battery terminals.
(3) With all wiring harnesses and components
properly connected, perform the following:
(a) Connect the negative lead of the voltmeter to
the battery negative post, and positive lead to the
battery negative cable clamp. Rotate and hold the
ignition switch in the START position. Observe the
voltmeter. If voltage is detected, correct poor con-
tact between cable clamp and post.
(b) Connect positive lead of the voltmeter to the
battery positive post, and negative lead to the bat-
tery positive cable clamp. Rotate and hold the igni-
tion switch key in the START position. Observe the
voltmeter. If voltage is detected, correct poor con-
tact between the cable clamp and post.
(c) Connect negative lead of voltmeter to battery
negative terminal, and positive lead to engine
block near the battery cable attaching point.
Rotate and hold the ignition switch in the START
position. If voltage reads above 0.2 volt, correct
poor contact at ground cable attaching point. If
voltage reading is still above 0.2 volt after correct-
ing poor contacts, replace ground cable.
(4) Connect positive voltmeter lead to the starter
motor housing and the negative lead to the battery
negative terminal. Hold the ignition switch key in
RSSTARTING8F-35
STARTING (Continued)

the START position. If voltage reads above 0.2 volt,
correct poor starter to engine ground.
(a) Connect the positive voltmeter lead to the
battery positive terminal, and negative lead to bat-
tery cable terminal on starter solenoid. Rotate and
hold the ignition switch in the START position. If
voltage reads above 0.2 volt, correct poor contact at
battery cable to solenoid connection. If reading is
still above 0.2 volt after correcting poor contacts,
replace battery positive cable.
(b) If resistance tests do not detect feed circuit
failures, replace the starter motor.
DIAGNOSIS AND TESTING - FEED CIRCUIT
TEST
NOTE: The following results are based upon the
vehicle being at room temperature.
The following procedure will require a suitable
volt-ampere tester (Fig. 1).
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.(1) Check battery before performing this test. Bat-
tery must be fully charged.
(2) Connect a volt-ampere tester to the battery ter-
minals. Refer to the operating instructions provided
with the tester being used.
(3) To disable the ignition and fuel systems, dis-
connect the Automatic Shutdown Relay (ASD). The
ASD relay is located in the Power Distribution Cen-
ter (PDC). Refer to the PDC cover for proper relay
location.
(4) Verify that all lights and accessories are OFF,
and the transmission shift selector is in the PARK
and SET parking brake.
CAUTION: Do not overheat the starter motor or
draw the battery voltage below 9.6 volts during
cranking operations.
(5) Rotate and hold the ignition switch in the
START position. Observe the volt-ampere tester (Fig.
1).
²If voltage reads above 9.6 volts, and amperage
draw reads above 280 amps, check for engine seizing
or faulty starter.
²If voltage reads 12.4 volts or greater and amper-
age reads 0 to 10 amps, check for corroded cables
and/or bad connections.
²Voltage below 9.6 volts and amperage draw
above 300 amps, the problem is the starter. Replace
the starter refer to starter removal.
(6) After the starting system problems have been
corrected, verify the battery state-of-charge and
charge battery if necessary. Disconnect all testing
equipment and connect ASD relay. Start the vehicle
several times to assure the problem has been cor-
rected.
SPECIFICATIONS
Torques
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Starter Mounting Bolts 47.4 35
Starter Solenoid Battery
Nut11.3 8.3 100
Fig. 1 Volt Ampere Tester
8F - 36 STARTINGRS
STARTING (Continued)