transmission oil DODGE TOWN AND COUNTRY 2001 Owner's Manual

TRANSMISSION
TABLE OF CONTENTS
page page
TRANSMISSION
DIAGNOSIS AND TESTING.................36
TRANS OIL COOLER FLOW TESTING.......36
STANDARD PROCEDURE..................37
FLUSHING COOLERS AND TUBES.........37
TRANS COOLER
DESCRIPTION...........................38REMOVAL..............................38
CLEANING..............................38
INSPECTION............................38
INSTALLATION...........................38
TRANS COOLER LINES
REMOVAL..............................38
INSTALLATION...........................39
TRANSMISSION
DIAGNOSIS AND TESTING - TRANSMISSION
OIL COOLER FLOW
To determine proper transmission oil flow through
the oil cooler perform the following procedure:
(1) Disconnect the hose from the ªcooler returnº
fitting on the transmission. (Refer to 7 - COOLING/
TRANSMISSION/TRANS COOLER LINES -
REMOVAL)
(2) Using Special Tool adaptors 6906-1-3 with a 9
mm (3/8 in.) transmission hose attached to oneadapter, connect Special Tool 8392 flow meter in-se-
ries with the oil cooler flow circuit (Fig. 1).
(3) Start engine and run at curb idle speed.
Observe the flow meter gauge. Refer to the following
chart for specifications.
COOLER FLOW SPECIFICATION (Min.)
2.6 LPM (0.7 GPM)
(4) If oil flow is below minimum specifications, fur-
ther diagnosis must be performed.
(a) Perform Oil Pump Volume Check. (Refer to
21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
Fig. 1 TRANS COOLER FLOW TEST
1 - SPECIAL TOOL 8392 4 - TRANS HOSE-9mm(3/89I.D.)
2 - SPECIAL TOOL 6906-1-3 5 - FROM COOLER
3 - TO TRANS
7 - 36 TRANSMISSIONRS
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- 31TH/OIL PUMP - STANDARD PROCEDURE)
(Refer to 21 - TRANSMISSION/TRANSAXLE/AU-
TOMATIC - 41TE/OIL PUMP - STANDARD PRO-
CEDURE)
(b) If oil pump volume is within specification, a
possible restriction in the cooler lines or cooler has
occurred.
(c) If oil pump volume is not within specification,
possible internal transmission restrictions, compo-
nent wear or damage has occurred. (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC -
31TH - DIAGNOSIS AND TESTING) (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC -
41TE - DIAGNOSIS AND TESTING)
(d) If an oil cooler restriction is suspected, per-
form further inspections and flow meter testing by
isolating components (i.e. lines, coolers).
(e) After a restriction is isolated, perform cooler
flush procedure. (Refer to 7 - COOLING/TRANS-
MISSION - STANDARD PROCEDURE)
(f) Re-test cooler flow. If cooler flow does not
exceed minimum specification, replace compo-
nent(s) as necessary.
STANDARD PROCEDURE - FLUSHING
COOLERS AND TUBES
The recommended procedure for cooler flushing is
to use Tool 6906 Cooler Flusher.
WARNING:
WEAR PROTECTIVE EYEWEAR THAT MEETS THE
REQUIREMENTS OF OSHA AND ANSI Z87.1±1968.
WEAR STANDARD INDUSTRIAL RUBBER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
(1) Remove cover plate filler plug on Tool 6906.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Use MopartTransmission Cooler Flush (MS-552) or
equivalent solution conforming to MS-552. Flushing
solvents are petroleum based solutions generally
used to clean automatic transmission components.
DO NOTuse solvents containing acids, water, gaso-
line, or any other corrosive liquids.
(2) Reinstall filler plug on Tool 6906.
(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
(4) Connect the BLUE pressure line to the OUT-
LET (From) cooler line.
(5) Connect the CLEAR return line to the INLET
(To) cooler line
(6) Turn pump ON for two to three minutes to
flush cooler and lines.
(7) Turn pump OFF.
(8) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(9) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF.
(10) Place CLEAR suction line into a one quart
container of MopartATF+4 (Automatic Transmission
FluidÐType 9602).
(11) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. This
purges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.
(12) Disconnect alligator clips from battery. Recon-
nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
RSTRANSMISSION7-37
TRANSMISSION (Continued)
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TRANS COOLER
DESCRIPTION
The transmission oil cooler is an external oil-to-air
type cooler is mounted between the front of the radi-
ator and back side of the A/C condensor (Fig. 3). Use
only approved transmission oil cooler hoses that are
molded to fit the space available.
REMOVAL
(1) Remove the radiator. (Refer to 7 - COOLING/
ENGINE/RADIATOR - REMOVAL)
(2) Disconnect lines from oil cooler (Fig. 2).
(3) Remove oil cooler attaching screws (Fig. 3).
(4) Remove the oil cooler.
CLEANING
Check the external cooler for debris on the cooling
fin surfaces. Clean as necessary. For internal clean-
ing/flushing procedures, (Refer to 7 - COOLING/
TRANSMISSION - STANDARD PROCEDURE).
INSPECTION
Inspect all hoses, tubes, clamps and connections for
leaks, cracks, or damage. Replace as necessary. Use
only approved transmission oil cooler hoses that are
molded to fit the space available.
Inspect external coolers for leaks, loose mounts, or
damage. Replace as necessary.
INSTALLATION
(1) Install transaxle oil cooler and mounting
screws (Fig. 3).
NOTE: When replacing the transmission oil cooler,
the cooler hoses must be replaced.
(2) Connect the new cooler hoses and install
clamps (Fig. 2).
(3) Install the radiator. (Refer to 7 - COOLING/
ENGINE/RADIATOR - INSTALLATION)
(4) Start engine. Check and adjust the fluid level
as necessary.
TRANS COOLER LINES
REMOVAL
(1) Using appropriate hose clamp pliers, release
tension on clamps and move off fittings.
NOTE: When the transaxle cooler lines are removed
from the rolled-groove type fittings at the cooler
and transaxle, damage to the inner wall of hose will
occur. To prevent potential leakage, the cooler
hoses must be replaced.
(2) Remove the hoses (Fig. 4) or (Fig. 5).
Fig. 2 TRANSMISSION COOLER HOSES
1 - TRANSAXLE COOLER HOSES
2 - FITTING - COOLER OUTLET
3 - FITTING - COOLER INLET
Fig. 3 Transmission Oil Cooler
1 - TRANSAXLE OIL COOLER
2 - SCREWS
3 - A/C CONDENSOR (REAR SIDE)
7 - 38 TRANSMISSIONRS
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INSTALLATION
NOTE: When the transaxle cooler lines are removed
from the rolled-groove type fittings at the cooler
and transaxle, damage to the inner wall of hose willoccur. To prevent potential leakage, the cooler
hoses must be replaced.
(1) Connect hoses to cooler and transaxle fittings
(Fig. 4) or (Fig. 5).
(2) Using appropriate pliers, position clamps over
fittings and release tension.
(3) Start engine and check transaxle fluid level.
Adjust fluid level as necessary.
Fig. 4 TRANS OIL COOLER LINES - 41TE
1 - FITTING - COOLER RETURN
2 - FITTING - COOLER SUPPLY
3 - HOSES - TRANSAXLE COOLER
4 - FITTING - COOLER OUTLET
5 - FITTING - COOLER INLET
Fig. 5 TRANSAXLE OIL COOLER LINES - 31TH
1 - FITTING - COOLER RETURN
2 - FITTING - COOLER SUPPLY
3 - HOSES - TRANSAXLE COOLER
4 - FITTING - COOLER OUTLET
5 - FITTING - COOLER INLET
RSTRANSMISSION7-39
TRANS COOLER LINES (Continued)
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²Throttle Position Sensor
²Torque Management Input (From TCM)
²Transaxle Control Module (TCM)
²Transaxle Gear Engagement (From TCM)
²Vehicle Speed (from transmission control mod-
ule)
NOTE: PCM Outputs:
²Air Conditioning Clutch Relay
²Automatic Shut Down (ASD) and Fuel Pump
Relays
²Data Link Connector (PCI and SCI Transmit)
²Double Start Override
²EGR Solenoid
²Fuel Injectors
²Generator Field
²High Speed Fan Relay
²Idle Air Control Motor
²Ignition Coils
²Leak Detection Pump
²Low Speed Fan Relay
²MTV Actuator
²Proportional Purge Solenoid
²SRV Valve
²Speed Control Relay
²Speed Control Vent Relay
²Speed Control Vacuum Relay
²8 Volt Output
²5 Volt Output
Based on inputs it receives, the powertrain control
module (PCM) adjusts fuel injector pulse width, idle
speed, ignition timing, and canister purge operation.
The PCM regulates the cooling fans, air conditioning
and speed control systems. The PCM changes gener-
ator charge rate by adjusting the generator field.
The PCM adjusts injector pulse width (air-fuel
ratio) based on the following inputs.
²Battery Voltage
²Intake Air Temperature Sensor
²Engine Coolant Temperature
²Engine Speed (crankshaft position sensor)
²Exhaust Gas Oxygen Content (heated oxygen
sensors)
²Manifold Absolute Pressure
²Throttle Position
The PCM adjusts engine idle speed through the
idle air control motor based on the following inputs.
²Brake Switch
²Engine Coolant Temperature
²Engine Speed (crankshaft position sensor)
²Park/Neutral (transmission gear selection)
²Transaxle Gear Engagement
²Throttle Position
²Vehicle Speed (from Transmission Control Mod-
ule)The PCM adjusts ignition timing based on the fol-
lowing inputs.
²Intake Air Temperature
²Engine Coolant Temperature
²Engine Speed (crankshaft position sensor)
²Knock Sensor
²Manifold Absolute Pressure
²Park/Neutral (transmission gear selection)
²Transaxle Gear Engagement
²Throttle Position
The automatic shut down (ASD) and fuel pump
relays are mounted externally, but turned on and off
by the powertrain control module through the same
circuit.
The camshaft and crankshaft signals are sent to
the powertrain control module. If the PCM does not
receive both signals within approximately one second
of engine cranking, it deactivates the ASD and fuel
pump relays. When these relays are deactivated,
power is shut off to the fuel injectors, ignition coils,
fuel pump and the heating element in each oxygen
sensor.
The PCM contains a voltage converter that
changes battery voltage to a regulated 8.0 volts. The
8.0 volts power the camshaft position sensor, crank-
shaft position sensor and vehicle speed sensor. The
PCM also provides a 5.0 volts supply for the engine
coolant temperature sensor, intake air temperature
sensor, manifold absolute pressure sensor and throt-
tle position sensor.
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 in new PCM. Use
the DRB scan tool to change the mileage in the PCM.
Refer to the appropriate Powertrain Diagnostic Man-
ual and the DRB scan tool.
DIAGNOSTIC TROUBLE CODE
DESCRIPTION
A Diagnostic Trouble Code (DTC) indicates the
PCM has recognized an abnormal condition in the
system.
Remember that DTC's are the results of a sys-
tem or circuit failure, but do not directly iden-
tify the failed component or components.
NOTE: For a list of DTC's, refer to the charts in this
section.
RSELECTRONIC CONTROL MODULES8E-9
POWERTRAIN CONTROL MODULE (Continued)
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(M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
(G) Generator Lamp Illuminated
GENERIC SCAN
TOOL CODEDRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE
P0461 Fuel Level Unit No Changeover
TimeNo level of fuel level sender detected.
P0462 Fuel Level Sending Unit Volts Too
LowFuel level sensor input below acceptable voltage.
P0463 Fuel Level Sending Unit Volts Too
HighFuel level sensor input above acceptable voltage.
P0500 (M) No Vehicle Speed Sensor Signal No vehicle speed sensor signal detected during road load
conditions.
P0505 (M) Idle Air Control Motor Circuits Replace
P0508 Idle Air Control Motor Circuit Low Idle Air Control Motor Circuit input below acceptable current
P0509 Idle Air Control Motor Circuit High Idle Air Control Motor Circuit input above acceptable current
P0522 Oil Pressure Sens Low Oil pressure sensor input below acceptable voltage.
P0523 Oil Pressure Sens High Oil pressure sensor input above acceptable voltage.
P0551 (M) Power Steering Switch Failure Incorrect input state detected for the power steering switch
circuit. PL: High pressure seen at high speed.
P0600 (M) PCM Failure SPI Communications No communication detected between co-processors in the
control module.
P0601 (M) Internal Controller Failure Internal control module fault condition (check sum) detected.
P0604 Internal Trans Controller Transmission control module RAM self test fault detected.
-Aisin transmission.
P0605 Internal Trans Controller Transmission control module ROM self test fault detected
-Aisin transmission.
P0622 (G) Generator Field Not Switching
ProperlyAn open or shorted condition detected in the generator field
control circuit.
P0645 A/C Clutch Relay Circuit An open or shorted condition detected in the A/C clutch relay
control circuit.
P0700 (M) EATX Controller DTC Present This SBEC III or JTEC DTC indicates that the EATX or Aisin
controller has an active fault and has illuminated the MIL via
a CCD (EATX) or SCI (Aisin) message. The specific fault
must be acquired from the EATX via CCD or from the Aisin
via ISO-9141.
P0703 (M) Brake Switch Stuck Pressed or
ReleasedIncorrect input state detected in the brake switch circuit.
(Changed from P1595).
P0711 Trans Temp Sensor, No Temp Rise
After StartRelationship between the transmission temperature and
overdrive operation and/or TCC operation indicates a failure
of the Transmission Temperature Sensor. OBD II Rationality.
P0712 Trans Temp Sensor Voltage Too Low Transmission fluid temperature sensor input below
acceptable voltage.
P0713 Trans Temp Sensor Voltage Too
HighTransmission fluid temperature sensor input above
acceptable voltage.
P0720 Low Output SPD Sensor RPM,
Above 15 MPHThe relationship between the Output Shaft Speed Sensor
and vehicle speed is not within acceptable limits.
8E - 14 ELECTRONIC CONTROL MODULESRS
POWERTRAIN CONTROL MODULE (Continued)
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2:1. In direct drive (3rd gear), the gear ratio changes
to 1:1. The gear ratio changes as clutches are applied
and released. By monitoring the length of time it
takes for the gear ratio to change following a shift
request, the TCM can determine the volume of fluid
used to apply or release a friction element.
The volume of transmission fluid needed to apply
the friction elements are continuously updated for
adaptive controls. As friction material wears, the vol-
ume of fluid need to apply the element increases.Certain mechanical problems within the clutch
assemblies (broken return springs, out of position
snap rings, excessive clutch pack clearance, improper
assembly, etc.) can cause inadequate or out-of-range
clutch volumes. Also, defective Input/Output Speed
Sensors and wiring can cause these conditions. The
following chart identifies the appropriate clutch vol-
umes and when they are monitored/updated:
CLUTCH VOLUMES
ClutchWhen Updated
Proper Clutch
Volume
Shift Sequence Oil Temperature Throttle Angle
L/R2-1 or 3-1 coast
downshift>70É <5É 35to83
2/4 1-2 shift
> 110É5 - 54É20 to 77
OD 2-3 shift 48 to 150
UD 4-3 or 4-2 shift > 5É 24 to 70
SHIFT SCHEDULES
As mentioned earlier, the TCM has programming
that allows it to select a variety of shift schedules.
Shift schedule selection is dependent on the follow-
ing:
²Shift lever position
²Throttle position²Engine load
²Fluid temperature
²Software level
As driving conditions change, the TCM appropri-
ately adjusts the shift schedule. Refer to the follow-
ing chart to determine the appropriate operation
expected, depending on driving conditions.
Schedule Condition Expected Operation
Extreme ColdOil temperature at start-up below
-16É FPark, Reverse, Neutral and 2nd
gear only (prevents shifting which
may fail a clutch with frequent
shifts)
ColdOil temperature at start-up above
-12É F and below 36É F± Delayed 2-3 upshift
(approximately 22-31 mph)
± Delayed 3-4 upshift (45-53 mph)
± Early 4-3 costdown shift
(approximately 30 mph)
± Early 3-2 coastdown shift
(approximately 17 mph)
± High speed 4-2, 3-2, 2-1 kickdown
shifts are prevented
± No EMCC
WarmOil temperature at start-up above
36É F and below 80 degree F± Normal operation (upshift,
kickdowns, and coastdowns)
± No EMCC
8E - 26 ELECTRONIC CONTROL MODULESRS
TRANSMISSION CONTROL MODULE (Continued)
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Schedule Condition Expected Operation
HotOil temperature at start-up above
80É F± Normal operation (upshift,
kickdowns, and coastdowns)
± Full EMCC, no PEMCC except to
engage FEMCC (except at closed
throttle at speeds above 70-83 mph)
OverheatOil temperature above 240É F or
engine coolant temperature above
244É F± Delayed 2-3 upshift (25-32 mph)
± Delayed 3-4 upshift (41-48 mph)
± 3rd gear FEMCC from 30-48 mph
± 3rd gear PEMCC from 27-31 mph
Super OverheatOil temperature above 260É F ± All9Overheat9shift schedule
features apply
± 2nd gear PEMCC above 22 mph
± Above 22 mph the torque
converter will not unlock unless the
throttle is closed or if a wide open
throttle 2nd PEMCC to 1 kickdown
is made
STANDARD PROCEDURE - PINION FACTOR
SETTING
NOTE: This procedure must be performed if the
Transmission Control Module (TCM) has been
replaced with a NEW or replacement unit. Failure to
perform this procedure will result in an inoperative
or improperly calibrated speedometer.
The vehicle speed readings for the speedometer are
taken from the output speed sensor. The TCM must
be calibrated to the different combinations of equip-
ment (final drive and tires) available. Pinion Factor
allows the technician to set the Transmission Control
Module initial setting so that the speedometer read-
ings will be correct. To properly read and/or reset the
Pinion Factor, it is necessary to use a DRB scan tool.
(1) Plug the DRB scan tool into the diagnostic con-
nector located under the instrument panel.
(2) Select the Transmission menu.
(3) Select the Miscellaneous menu.
(4) Select Pinion Factor. Then follow the instruc-
tions on the DRB scan tool screen.
STANDARD PROCEDURE - QUICK LEARN
PROCEDURE
The quick learn procedure requires the use of the
DRB scan tool. This program allows the electronic
transaxle system to recalibrate itself. This will pro-
vide the best possible transaxle operation.NOTE: The quick learn procedure should be per-
formed if any of the following procedures are per-
formed:
²Transaxle Assembly Replacement
²Transmission Control Module Replacement
²Solenoid/Pressure Switch Assembly Replacement
²Clutch Plate and/or Seal Replacement
²Valve Body Replacement or Recondition
To perform the Quick Learn Procedure, the follow-
ing conditions must be met:
²The brakes must be applied
²The engine speed must be above 500 rpm
²The throttle angle (TPS) must be less than 3
degrees
²The shift lever position must stay until
prompted to shift to overdrive
²The shift lever position must stay in overdrive
after the Shift to Overdrive prompt until the DRB
indicates the procedure is complete
²The calculated oil temperature must be above
60É and below 200É
(1) Plug the DRB scan tool into the diagnostic con-
nector. The connector is located under the instrument
panel.
(2) Go to the Transmission screen.
(3) Go to the Miscellaneous screen.
(4) Select Quick Learn Procedure. Follow the
instructions of the DRB to perform the Quick Learn
Procedure.
RSELECTRONIC CONTROL MODULES8E-27
TRANSMISSION CONTROL MODULE (Continued)
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(5) The coil ground terminal (85) is connected to
the electromagnet in the relay. It is grounded
through the transmission range sensor only when the
gearshift selector lever is in the Park or Neutral
positions. Check for continuity to ground at the cav-
ity for relay terminal 85. If not OK with an auto-
matic transmission, check for an open or short circuit
to the transmission range sensor and repair.
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.
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) Remove the air cleaner assembly for access to
battery terminals. Refer to the Fuel section for ser-
vice procedures.
(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
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.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. 2).
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
Fig. 2 Volt Ampere Tester
RSSTARTING8F-31
STARTING (Continued)
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(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.
2).
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 testingequipment and connect ASD relay. Start the vehicle
several times to assure the problem has been cor-
rected.
SPECIFICATIONS
STARTER
MANUFACTURER NIPPONDENSO
Engine Application 2.4L /3.3/3.8L
Power rating 1.2 Kw
Voltage 12 VOLTS
No. of Fields 4
No. of Poles 4
Brushes 4
Drive Conventional Gear Train
Free running Test
Voltage 11
Amperage Draw 73 Amp
Minimum Speed 3401 RPM
SolenoidClosing Voltage 7.5 Volts
Cranking Amperage Draw
test150 - 200 Amps.
Engine should be up to operating temperature.
Extremely heavy oil or tight engine will increase
starter amperage draw.
Torques
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Starter Mounting Bolts 47.4 35
Starter Solenoid Battery
Nut11.3 8.3 100
8F - 32 STARTINGRS
STARTING (Continued)
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