Starting System Chrysler Crossfire I final

An electrically operated engine starting system is standard factory-installed equipment on this model. The starting system is designed to provide the vehicle operator with a convenient, efficient and reliable means of cranking and starting the internal combustion engine used to power the vehicle and all of its accessory systems from within the safe and secure confines of the passenger compartment. See the owner's manual for more information and instructions on the recommended use and operation of the factory-installed starting system.

The starting system consists of the following components

1. Battery
2. Starter Motor
3. Starter Solenoid
4. Ignition Switch
5. Wire harnesses and connections (including the battery cables).

This article provides complete service information for the starter motor. Complete service information for the other starting system components can be located as follows

1. Refer to «DESCRIPTION»(/chrysler/crossfire/i-final-2008-2008/remont/charging-system/#battery-system) .
2. Refer to «DESCRIPTION»(/chrysler/crossfire/i-final-2008-2008/remont/ignition-system/#ignition-system-electrical-diagnostics) .
3. See «OPERATION»(/chrysler/crossfire/i-final-2008-2008/remont/starter/#starting-system) for complete service information and circuit diagrams for the starting system wiring components. See «SYSTEM WIRING DIAGRAMS»(ref-291823) article.

The battery, starting, and charging systems in the vehicle operate with one another, and must be tested as a complete system. In order for the vehicle to start and charge properly, all of the components that are used in these systems must perform within specifications.

The diagnostic procedures used in each of these systems include the most basic conventional diagnostic methods, to the more sophisticated On-Board Diagnostics (OBD) built into the Powertrain Control Module (PCM). Use of an induction-type milliampere ammeter, volt/ohmmeter, battery charger, carbon pile rheostat (load tester), and 12-volt test lamp may be required.

All OBD-sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for any failure it detects. Refer to On-Board Diagnostic Test For Charging System in DIAGNOSIS AND TESTING .

The starting system components form two separate circuits. A high-amperage feed circuit that feeds the starter motor between 150 and 350 amperes, and a low-amperage control circuit that operates on less than 20 amperes. The high-amperage feed circuit components include the battery, the battery cables, the contact disc portion of the starter solenoid, and the starter motor. The low-amperage control circuit components include the ignition switch, the pulse module, the electromagnetic windings of the starter solenoid, and the connecting wire harness components.

Battery voltage is supplied through the low-amperage control circuit to the pulse module when the ignition switch is turned to the momentary Start position. When the starter solenoid coil windings are energized, the solenoid pull-in coil pulls in the solenoid plunger. The solenoid plunger pulls the shift lever in the starter motor. This engages the starter overrunning clutch and pinion gear with the starter ring gear on the flywheel.

As the solenoid plunger reaches the end of its travel, the solenoid contact disc completes the high-amperage starter feed circuit and energizes the solenoid plunger hold-in coil. Current now flows between the solenoid battery terminal and the starter motor, energizing the starter.

When the solenoid plunger hold-in coil is de-energized, the solenoid plunger return spring returns the plunger to its relaxed position. This causes the contact disc to open the starter feed circuit, and the shift lever to disengage the overrunning clutch and pinion gear from the starter ring gear.

Once the engine starts, the pulse module prevents starter motor damage by only allowing the starter to be engaged until the engine is running. Once the engine fires and achieves an RPM threshold that the Powertrain Control Module (PCM) defines as "engine running", the starter motor is automatically disengaged by the PCM through the pulse module. The pulse module further prevents starter motor damage by not allowing the starter motor to be engaged if the engine is already running.

The battery, starting, and charging systems operate with one another, and must be tested as a complete system. In order for the vehicle to start and charge properly, all of the components involved in these systems must perform within specifications.

The diagnostic procedures used includes most conventional diagnostic methods. The use of an induction-type milliampere ammeter, volt/ohmmeter, battery charger, carbon pile rheostat (load tester), and 12-volt test lamp may be required.

INSPECTION

For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS article. Before removing any unit from the starting system for repair or diagnosis, perform the following inspections

1. Visually inspect the battery for indications 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. For complete service information for the battery, refer to «DESCRIPTION»(/chrysler/crossfire/i-final-2008-2008/remont/charging-system/#battery-system) .
2. Visually inspect the ignition switch for indications of physical damage and loose or corroded wire harness connections. For complete service information for the ignition switch. refer to «DESCRIPTION»(/chrysler/crossfire/i-final-2008-2008/remont/ignition-system/#ignition-system-service-information) .
3. Visually inspect the starter motor for indications of physical damage and loose or corroded wire harness connections.
4. Visually inspect the starter solenoid for indications of physical damage and loose or corroded wire harness connections.
5. Visually inspect the wire harnesses for damage. Repair or replace any faulty wiring, as required. Refer to «SYSTEM WIRING DIAGRAMS»(ref-291823) article for complete service information and circuit diagrams for the starting system wiring components. Refer to «DESCRIPTION»(/chrysler/crossfire/i-final-2008-2008/remont/body-electrical/#wiring-diagram-information) .

COLD CRANKING TEST

For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS article . The battery must be fully-charged and load-tested before proceeding. Refer to BATTERY SYSTEM article.

Scheme 1

1. Connect a suitable volt-ampere tester (3) to the battery terminals (1,2). See the instructions provided by the manufacturer of the volt-ampere tester being used.
2. Fully engage the parking brake.
3. Place the automatic transmission gearshift selector lever in the Park position or place the manual transmission gearshift selector in the Neutral position.
4. Verify that all lamps and accessories are turned off.
5. Prevent the engine from starting.
6. Rotate and hold the ignition switch in the Start position. Note the cranking voltage and current (amperage) draw readings shown on the volt-ampere tester. If the voltage reads below 9.6 volts, refer to «DIAGNOSIS AND TESTING»(/chrysler/crossfire/i-final-2008-2008/remont/starter/#starting-system) . If the starter motor is OK, refer to «DIAGNOSIS AND TESTING»(ref-306563-S22198515912008121700000) . If the starter motor is not OK, replace the faulty starter motor. If the voltage reads above 9.6 volts and the current (amperage) draw reads below specifications, refer to «FEED CIRCUIT TEST»(/chrysler/crossfire/i-final-2008-2008/remont/starter/#starting-system__feed-circuit-test) . If the voltage reads 12.5 volts or greater and the starter motor does not turn, refer to «CONTROL CIRCUIT TESTING»(/chrysler/crossfire/i-final-2008-2008/remont/starter/#starting-system__control-circuit-testing) . If the voltage reads 12.5 volts or greater and the starter motor turns very slowly, refer to «FEED CIRCUIT TEST»(/chrysler/crossfire/i-final-2008-2008/remont/starter/#starting-system__feed-circuit-test) .

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

FEED CIRCUIT TEST

The starter feed circuit test (voltage drop method) will determine if there is excessive resistance in the high-amperage feed circuit. For complete wiring diagrams, refer to DESCRIPTION .

When performing these tests, it is important to remember that the voltage drop is giving an indication of the resistance between the two points at which the voltmeter probes are attached.

Example: When testing the resistance of the battery positive cable, touch the voltmeter leads to the battery positive cable clamp and the cable connector at the starter solenoid. If you probe the battery positive terminal post and the cable connector at the starter solenoid, you are reading the combined voltage drop in the battery positive cable clamp-to-terminal post connection and the battery positive cable.

The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing the tests, be certain that the following procedures are accomplished

1. Battery is fully-charged and load-tested. Refer to «DIAGNOSIS AND TESTING»(/chrysler/crossfire/i-final-2008-2008/remont/charging-system/#battery-system) .
2. Fully engage the parking brake.
3. Place the automatic transmission gearshift selector lever in the Park position or place the manual transmission gearshift selector in the Neutral position.
4. Verify that all lamps and accessories are turned off.
5. Prevent the engine from starting.

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

1. Connect the positive lead of the voltmeter (1) to the battery (2) negative terminal post. Connect the negative lead of the voltmeter (1) to the battery (2) negative cable clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor contact between the cable clamp and the terminal post.
2. Connect the positive lead of the voltmeter (1) to the battery (2) positive terminal post. Connect the negative lead of the voltmeter (1) to the battery (2) positive cable clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor contact between the cable clamp and the terminal post.
3. Connect the voltmeter (2) to measure between the battery (1) positive terminal post and the starter (3) solenoid battery terminal stud. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery cable connection at the solenoid. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery positive cable.
4. Connect the voltmeter (1) to measure between the battery (2) negative terminal post and a good clean ground on the engine block (3). Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery negative cable attachment on the engine block. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery negative cable.
5. Connect the positive lead of the voltmeter (3) to the starter (1) housing. Connect the negative lead of the voltmeter to the battery (2) negative terminal post. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, correct the poor starter to engine block ground contact.

If the resistance tests detect no feed circuit problems, refer to DIAGNOSIS AND TESTING .

CONTROL CIRCUIT TESTING

The starter control circuit components should be tested in the order in which they are listed, as follows

1. Starter Solenoid - Refer to «DIAGNOSIS AND TESTING»(/chrysler/crossfire/i-final-2008-2008/remont/starter/#starting-system) .
2. Ignition Switch - Refer to «DESCRIPTION»(/chrysler/crossfire/i-final-2008-2008/remont/ignition-system/#ignition-system-electrical-diagnostics) .
3. Wire harnesses and connections - Refer to «DESCRIPTION»(/chrysler/crossfire/i-final-2008-2008/remont/body-electrical/#wiring-diagram-information) .

Scheme 7

SPECIFICATIONS - TORQUE

TORQUE SPECIFICATIONS

STARTER MOTOR RATING

Scheme 8

The starter motor (2) is mounted with two bolts to the transmission housing and is located on the right side of the engine. The starter motor incorporates several features to create a reliable, efficient, compact, lightweight and powerful unit. The electric motor of the starter features electromagnetic field coils wound around pole shoes, and brushes contact the motor commutator. The starter motor is serviced only as a unit and cannot be repaired. The entire starter motor (2) and starter solenoid unit (1) must be replaced if either component is faulty or damaged.

OPERATION - STARTER MOTOR

The starter motor is equipped with a planetary gear reduction system. The planetary gear reduction system consists of a gear that is integral to the output end of the electric motor armature shaft that is in continual engagement with a larger gear that is splined to the input end of the starter pinion gear shaft. This feature makes it possible to reduce the dimensions of the starter. At the same time, it allows higher armature rotational speed and delivers increased torque through the starter pinion gear to the starter ring gear.

The starter motor is activated by an integral heavy duty starter solenoid switch mounted to the overrunning clutch housing. This electromechanical switch connects and disconnects the feed of battery voltage to the starter motor and actuates a shift fork that engages and disengages the starter pinion gear with the starter ring gear.

STARTER MOTOR TESTING

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

1. Remove the starter motor from the vehicle. Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/starter/#starting-system) and «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/starter/#starting-system) .
2. Mount the starter motor securely in a soft-jawed bench vise. The vise jaws should be clamped on the mounting flange of the starter motor. Never clamp on the starter motor by the field frame.
3. Connect a suitable volt-ampere tester and a 12-volt battery to the starter motor in series, and set the ammeter to the 100 ampere scale. See the instructions provided by the manufacturer of the volt-ampere tester being used.
4. Install a jumper wire from the solenoid terminal to the solenoid battery terminal. The starter motor should operate. If the starter motor fails to operate, replace the faulty starter motor assembly.
5. Adjust the carbon pile load of the tester to obtain the free running test voltage. Refer to «SPECIFICATIONS»(/chrysler/crossfire/i-final-2008-2008/remont/starter/#starting-system) .
6. Note the reading on the ammeter and compare this reading to the free running test maximum amperage draw. Refer to «SPECIFICATIONS»(/chrysler/crossfire/i-final-2008-2008/remont/starter/#starting-system) .
7. If the ammeter reading exceeds the maximum amperage draw specification, replace the faulty starter motor assembly.

STARTER SOLENOID

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

Scheme 9

Scheme 10

1. Remove the starter motor from the vehicle. See «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/starter/#starting-system) .
2. Disconnect the wire from the solenoid field coil terminal.
3. Check the solenoid (1) for continuity between the solenoid terminal (2) and the solenoid field coil terminal (4) with a continuity tester (3). There should be continuity. If OK, go to Step 4. If not OK, replace the faulty starter motor assembly.
4. Using a continuity tester (3), check for continuity between the solenoid terminal (2) and the solenoid case (1). There should be continuity. If not OK, replace the faulty starter motor assembly.

Scheme 11

1. Disconnect the negative battery cable.
2. Raise and support the vehicle.
3. Remove the lower engine panel.
4. Disconnect the right O2 sensor electrical connector.
5. Remove the right side exhaust pipe from the exhaust manifold to the rear exhaust system. Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/exhaust/#exhaust-system__removal) .
6. Remove the starter bolts (1) and reposition the starter to access the starter electrical cables.
7. Remove the starter positive cable protective plastic cap (3).
8. Disconnect the starter cables by removing the ground cable nut (2) and the positive cable nut.
9. Remove the starter (4) from the vehicle.

INSTALLATION - STARTER MOTOR

1. Install the starter (4).
2. Connect the starter cable and the ground cable with the nuts. Tighten the starter positive cable nut to 14 N.m (10 ft. lbs.). Tighten the starter ground cable nut (2) to 6 N.m (52 in. lbs.)
3. Install the starter positive cable protective plastic cap (3).
4. Install the starter bolts (1). Tighten to 42 N.m (31 ft. lbs.).
5. Install the right side exhaust pipe. Refer to «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/exhaust/#exhaust-system__installation) .
6. Connect the right side O2 sensor.
7. Install the lower engine panel.
8. Lower the vehicle.
9. Connect the negative battery cable.

See also:
• DESCRIPTION
• DESCRIPTION
• DIAGNOSIS AND TESTING
• COLUMN
• AUTOMATIC - NAG1 SERVICE INFORMATION
• RESTRAINTS - SERVICE INFORMATION
• DESCRIPTION
• DESCRIPTION
• REMOVAL
• INSTALLATION
• OPERATION
• FEED CIRCUIT TEST
• CONTROL CIRCUIT TESTING