Starter Chrysler LeBaron II

DESCRIPTION

Chrysler Corp. models equipped with 1.6L engines use a Mitsubishi direct drive starter motor with an overrunning clutch. Chrysler Corp. models equipped with 2.2L engines use either a Bosch or Nippondenso direct drive starter motor with an overrunning clutch. Chrysler Corp. models with 2.6L engines and A-470 automatic transaxles use a Nippondenso reduction gear starter motor. Although structure of the starter motors differs, the electrical wiring is similar.

TROUBLE SHOOTING

Note. See the TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section.

TESTING (ON-VEHICLE)

Note. The following tests are specifically for starters used on the Chrysler Corp.1.6L, 2.2L and 2.6L engines.

AMPERAGE DRAW TEST

Note. Tests are performed with a Battery-Starter tester which incorporates a carbon pile rheostat. Engine should be at normal operating temperature and battery should be at full charge.

1. Connect Battery-Starter tester and remote starter switch. Turn control knob to "Off" position and set voltmeter selector to 16 volt position.
2. Turn function selector to Starter System Test (0-500 amp scale). Connect positive voltmeter lead to positive battery terminal and negative voltmeter lead to negative battery terminal.
3. Connect positive ammeter lead to positive battery terminal and negative ammeter lead to negative battery terminal. Disconnect coil wire from distributor cap and attach to a good ground to prevent engine from starting.
4. Crank engine. Note EXACT reading on voltmeter. Stop cranking engine. Turn tester control knob until EXACT reading is obtained on the voltmeter.
5. Observe ammeter reading. Ammeter should indicate starter amperage draw.

1. Make sure battery is at full charge. Disconnect positive battery cable at battery. Connect an ammeter (0-300 scale) between disconnected battery lead and battery terminal.
2. Connect a voltmeter, graduated in tenths, between positive battery post and starter relay terminal on starter solenoid.
3. Crank engine and check reading on voltmeter and ammeter. Voltage reading should not exceed .3 volt.
4. A reading higher than .3 volt indicates a high resistance caused by loose circuit connections, defective cable, burned starter relay or solenoid switch contacts.
5. If current is high and starter cranks slowly, starter is defective and should be removed and repaired.

INSULATED CIRCUIT TEST

1. Make sure battery is at full charge. Set voltmeter selector to 4 volt position. Disconnect coil wire at distributor cap.
2. Connect voltmeter positive lead to positive battery terminal. Connect voltmeter negative lead to solenoid connector that connects to starter field coils. NOTE: It will be necessary to peel back rubber boot to gain access to connector. Also, the voltmeter will read off scale until engine is cranked over.
3. Crank engine with a remote starter switch. Check voltmeter reading. A voltage drop of .3 volt or less indicates voltage drop is normal.
4. If voltmeter reads more than .3 volt, high resistance is indicated in starter insulated circuit.
5. Disconnect negative voltmeter lead from solenoid connector. Reconnect negative voltmeter lead to the following points and repeat test at each connection. Solenoid starter terminal. Solenoid battery terminal. Solenoid battery cable terminal. Starter relay. Battery cable connection.
6. A small change will occur each time a portion of the circuit is removed from test. A definite change in voltmeter reading indicates the last part eliminated in test is at fault.

1. Connect voltmeter positive lead to starter housing. Connect voltmeter negative lead to battery negative terminal. Crank engine with a remote starter switch.
2. Voltmeter reading should not exceed .2 volt. A reading less than .2 volt indicates a voltage loss in ground cable which is normal.
3. A voltage loss of more than .2 volt indicates excessive voltage loss in starter ground circuit.
4. Disconnect voltmeter. Reconnect to the following points and repeat test at each connection. Starter drive housing. Cable terminal at engine. Battery cable clamp.
5. A small change will occur each time a portion of the circuit is removed from test. A definite change in voltmeter indicates last part eliminated in test is at fault.

NO LOAD TEST

1. Place starter in a vise. Use a fully charged 12 volt battery. Connect an ammeter (0 - 100 scale) and a carbon pile rheostat in series with battery positive terminal and starter terminal. Connect a voltmeter (16 volt scale) across starter.
2. Rotate rheostat to full resistance position. Connect battery cable from negative battery terminal to starter housing. Adjust rheostat until voltage shown on voltmeter is 11 volts. Check specifications for maximum amperage draw and minimum RPM.

CHECKING ARMATURE FOR SHORT CIRCUIT

Place armature in a growler and hold a thin steel blade parallel and just above core while rotating armature slowly. If armature is shorted, blade will vibrate and be attracted to the core. Replace shorted armature.

CHECKING ARMATURE FOR GROUND

Use test lamp and touch one lead to armature shaft and other lead to each commutator bar. see scheme 1 If lamp lights, armature is grounded. Replace armature.

CHECKING FIELD COILS FOR GROUND

Use test lamp and touch one probe to series field coil lead and other probe to field frame. see scheme 2 If lamp lights, replace field coil housing assembly.

CHECKING BRUSH HOLDERS FOR GROUND

1. Touch each of brush holders with one probe, while holding other probe against brush plate. Two brush holders are grounded 180° apart and should cause test lamp to light.
2. Other 2 brush holders should not cause lamp to light, as they are insulated. If these brush holders are grounded, replace brush plate assembly.

Chrysler Corp. (Except 2.6L)

1. Disconnect field coil wire from solenoid terminal. Remove mounting screws and work solenoid off shift fork. Remove solenoid. On Bosch and Nippondenso, remove end shield bearing cap, "C" washer, flat washer, through bolts and starter end shield. (Nippondenso uses a spring between "C" washer and flat washer.)
2. On Mitsubishi starters, remove through bolts, starter-to-engine bracket, brush plate mounting screws and remove starter end shield. Pry retaining springs back and remove field brushes. Remove brush plate and slide field frame off starter over armature. Remove rubber seal from drive end housing.
3. Remove armature and clutch assembly. Remove clutch shift lever retainer, spring or bolt and remove clutch shift lever from drive end housing. With socket press stop collar off snap ring. Remove snap ring, stop collar and clutch assembly from armature.

Scheme 1

1. Remove rubber boot from field coil terminal. Remove nut and terminal lead from field coil terminal stud. Remove through bolts, and then screws from starter end shield. Remove upper left solenoid screw. (Holding field coil wire retainer.) Remove retainer. (Scheme 1): View of Nippondenso Starter for Chrysler Corp. 2.6L Engine
2. Remove starter end shield. Slide field brushes from brush holders, by prying back on retaining springs. Remove brush plate and slide armature out of field frame. Remove field frame from gear housing.
3. Remove gear housing-to-solenoid screws and separate housing from solenoid, using a soft mallet if necessary. Remove reduction gear pinion roller retainer, reduction gear and clutch assembly from gear housing. Remove pinion gear, pinion gear rollers, solenoid ball and spring.
4. Remove solenoid cover screws, solenoid cover, and plunger.

CLEANING

Clean armature, field coils, and brush end plate by wiping with a clean cloth. Grease dissolving solvent will damage insulation. Clean drive clutch using a brush moistened with solvent. Immersing drive clutch will wash lubricant out of assembly. Wash other parts in solvent.

REASSEMBLY

To reassemble, reverse disassembly procedures, noting the following: A battery cable pulling tool should be used to pull clutch stop ring over snap ring on Chrysler models. On Nippondenso 2.6L engine starters, coat pinion rollers with grease before installing in roller retainer.

SPECIFICATIONS

BOSCH, MITSUBISHI & NIPPONDENSO STARTER SPECIFICATIONS

See also:
• TROUBLE SHOOTING - BASIC PROCEDURES