Starting System Chrysler PT Cruiser I

DESCRIPTION

The starting system consists of

1. Starter relay
2. Starter motor (including an integral starter solenoid)

Other components to be considered as part of starting system are

1. Battery
2. Battery cables
3. Ignition switch and key lock cylinder
4. Clutch pedal position switch (manual transmission)
5. Park/neutral position switch (automatic transmission)
6. Wire harnesses and connections.

The Battery, Starting, and Charging systems operate in conjunction with one another, and must be tested as a complete system. For correct operation of starting/charging systems, all components used in these 3 systems must perform within specifications. When attempting to diagnose any of these systems, it is important that you keep their interdependency in mind.

The diagnostic procedures used in each of these articles 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.

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.

For circuit descriptions and diagrams, refer to SYSTEM WIRING DIAGRAMS article.

INSPECTION

Before removing any unit from the starting system for repair or diagnosis, perform the following inspections

1. Battery - 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. Refer to the «BATTERY SYSTEM»(/chrysler/pt-cruiser/i-2000-2010/remont/charging-system/#battery-system) for more information.
2. Ignition Switch - Visually inspect the ignition switch for indications of physical damage and loose or corroded wire harness connections.
3. Transmission Range Sensor or Park/Neutral Switch - Visually inspect the transmission range sensor for indications of physical damage and loose or corroded wire harness connections.
4. Starter Relay - Visually inspect the starter relay for indications of physical damage and loose or corroded wire harness connections.
5. Starter Motor - Visually inspect the starter motor for indications of physical damage and loose or corroded wire harness connections.
6. Starter Solenoid - Visually inspect the starter solenoid for indications of physical damage and loose or corroded wire harness connections.
7. Wiring - Visually inspect the wire harness for damage. Repair or replace any faulty wiring, as required. Check for loose or corroded wire harness connections at main engine ground and remote jump post.
8. Power Distribution Center (PDC) - Visually inspect the B+ connections at the PDC for physical damage and loose or corroded harness connections.

STARTING SYSTEM DIAGNOSIS

DIAGNOSIS AND TESTING - CONTROL CIRCUIT TEST

The starter control circuit has

1. Starter motor with integral solenoid
2. Starter relay
3. Transmission range sensor, or Park/Neutral Position switch with automatic transmissions
4. Ignition switch
5. Battery
6. All related wiring and connections
7. Powertrain Control Module (PCM)

1. To 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

1. Verify battery condition. Battery must be in good condition with a full charge before performing any starter tests. Refer to «BATTERY SYSTEM»(/chrysler/pt-cruiser/i-2000-2010/remont/charging-system/#battery-system) .
2. Perform Starter Solenoid test BEFORE performing 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. If engine cranks, starter/starter solenoid is good. Go to the «RELAY TEST»(/chrysler/pt-cruiser/i-2000-2010/remont/starter/#starting-system__relay-test) . If engine does not crank or solenoid chatters, check wiring and connectors from starter relay to starter solenoid and from the battery positive terminal to starter post for loose or corroded connections. Particularly at starter terminals. Repeat test. If engine still fails to crank properly, trouble is within starter or starter mounted solenoid, and replace starter. Inspect the ring gear teeth.

STARTER RELAY

RELAY TEST

The starter relay is located in the Power Distribution 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 article 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 (electromagnet) 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»(/chrysler/pt-cruiser/i-2000-2010/remont/starter/#starting-system__relay-circuit-test) procedure. If not OK, replace the faulty relay.

Scheme 1

Scheme 2

Scheme 3

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 connected to the common feed terminal (30) in the energized 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»(/chrysler/pt-cruiser/i-2000-2010/remont/starter/#starting-system__ignition-switch) .
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 Neutral 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 interlock input and see near zero engine speed (RPM). To diagnose the Park Neutral switch of the trans range sensor, refer to «TRANSMISSION DIAGNOSTIC PROCEDURES»(/chrysler/pt-cruiser/i-2000-2010/remont/automatic-trans/#automatic-transmission-diagnostic-procedures) article. Check for continuity 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 automatic 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 TRANSMISSION DIAGNOSTIC PROCEDURES article for more information.

If equipped with Clutch Interlock/Upstop Switch, refer to DIAGNOSIS AND TESTING .

IGNITION SWITCH

After testing starter solenoid and relay, test ignition switch and wiring. Refer to the SYSTEM 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 BATTERY SYSTEM for procedures.

ALL RELATED WIRING AND CONNECTORS

Refer to SYSTEM WIRING DIAGRAMS and WIRING DIAGRAM INFORMATION for more information.

DIAGNOSIS AND TESTING - FEED CIRCUIT RESISTANCE TEST

Before proceeding with this operation, review Diagnostic Preparation and Starter Feed Circuit Tests. The following operation will require a voltmeter, accurate to 1/10 of a volt.

1. To disable the 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 proper relay location.
2. Gain access to battery terminals.
3. With all wiring harnesses and components properly connected, perform the following: 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 contact between cable clamp and post. Connect positive lead of the voltmeter to the battery positive post, and negative lead to the battery positive cable clamp. Rotate and hold the ignition switch key in the START position. Observe the voltmeter. If voltage is detected, correct poor contact between the cable clamp and post. 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 correcting 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. Connect the positive voltmeter lead to the battery positive terminal, and negative lead to battery 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. 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. (Scheme 4)

Scheme 4

1. Check battery before performing this test. Battery must be fully charged.
2. Connect a volt-ampere tester to the battery terminals. Refer to the operating instructions provided with the tester being used.
3. To disable the 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 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. (Scheme 4) If voltage reads above 9.6 volts, and amperage draw reads above 280 amps, check for engine seizing or faulty starter. If voltage reads 12.4 volts or greater and amperage reads 0 to 10 amps, check for corroded cables and/or bad connections. Voltage below 9.6 volts and amperage draw above 300 amps, the problem is the starter. Replace the starter refer to «REMOVAL»(/chrysler/pt-cruiser/i-2000-2010/remont/starter/#starting-system).
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 corrected.

TORQUE

TORQUE SPECIFICATIONS

Scheme 5

Scheme 6

Scheme 7

Scheme 8

1. Turn wheels to the left.
2. Remove air cleaner cover.
3. Disconnect the negative battery cable.
4. Raise vehicle and support.
5. Remove the exhaust manifold support bracket. (Scheme 5)
6. Disconnect the battery cable and solenoid electrical connectors from the starter. (Scheme 7)and (Scheme 6).
7. Push up the spring clip that holds the heat shield for the starter. (Scheme 8)
8. Remove the upper mounting bolts first.
9. Remove the lower mounting bolt.
10. Remove the starter through the wheel well. (Scheme 9)

Scheme 9

Scheme 10

Scheme 11

Scheme 12

1. Disconnect the negative battery cable.
2. Remove the front grill, refer to «INTERIOR/EXTERIOR»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior) for more information.
3. Remove the hood seal, refer to «INTERIOR/EXTERIOR»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior) for more information.
4. Remove the upper radiator crossmember.
5. Remove ambient temperature sensor.
6. Raise vehicle and support.
7. Drain radiator, refer to «COOLING»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) for more information.
8. Disconnect the electrical connector for the radiator fan.
9. Remove the underbody plate (skid plate), refer to «INTERIOR/EXTERIOR»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior) for more information.
10. Remove the lower radiator hose.
11. Remove the 2 lower bolts for the inner cooler mounting to radiator.
12. Lower vehicle.
13. Remove the upper radiator hose.
14. Remove the 4 upper bolts for the inner cooler mounting to radiator.
15. Remove inner cooler from radiator by lifting the inner cooler up off of the 2 lower mounting tabs and push it toward the front of vehicle. These tabs are on the bottom of the inner cooler and lock into the bottom of the radiator. (Scheme 10)
16. Remove the radiator from vehicle. (Scheme 11)
17. Disconnect the electrical connectors from the starter. (Scheme 12)
18. Disconnect the battery cable from the starter.
19. Remove the lower mounting bolt and ground cable.
20. Remove the upper mounting bolt.
21. Remove starter.

Scheme 13

Scheme 14

1. Open Hood.
2. Remove air cleaner box cover. Refer to Air Cleaner Box Removal and Installation in appropriate ENGINE article.
3. Disconnect and isolate the battery negative cable. (Scheme 13)
4. Raise vehicle on hoist.
5. Remove Engine Structural Collar. Refer to «STRUCTURAL COLLAR»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
6. Disconnect starter motor wiring. (Scheme 14) 1 - BOLT 2 - GROUND 3 - STARTER 4 - BOLT
7. Remove starter motor mounting bolts. (Scheme 14)
8. Remove starter motor from vehicle.

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

1. Disconnect the negative battery cable.
2. Remove the air cleaner box. Refer to appropriate ENGINE article.
3. Pushing the inner cooler hose up and out of the way and remove the upper starter bolt and ground wire. (Scheme 15)
4. Raise vehicle and support
5. Remove the inner cooler lower hose from the inner cooler. (Scheme 16)
6. Remove the nuts that hold the lower inner cooler tube. (Scheme 17) 1 - Lower Inner Cooler Tube 2 - Power Steering Line Brackets 3 - Studs
7. Remove the studs that hold the power steering lines. (Scheme 17)
8. Loosen and relocate the power steering lines. (Scheme 18) 1 - Lower Inner Cooler Tube 2 - Power Steering Lines 3 - Mounting Studs
9. Remove the Structural Collar, refer to «STRUCTURAL COLLAR»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine). (Scheme 19) 1-8 - BOLT TIGHTENING SEQUENCE 9 - TRANSAXLE 10 - COLLAR 11 - OIL PAN 12 - STRUT
10. Unlock and disconnect the solenoid electrical connector.
11. Disconnect and remove the positive battery cable.
12. Remove the lower starter bolt.
13. Remove starter. (Scheme 20)

Scheme 20

INSTALLATION - 1.6L

1. Install the starter through the wheel well. (Scheme 9)
2. Install the lower mounting bolt.
3. Install the upper mounting bolts.
4. Push the spring clip that holds the heat shield for the starter back on the starter solenoid. (Scheme 8)
5. Connect the battery cable and solenoid electrical connectors to the starter. (Scheme 7)and (Scheme 6).
6. Install the exhaust manifold support bracket. (Scheme 5)
7. Lower vehicle.
8. Connect the negative battery cable.
9. Install air cleaner cover.

INSTALLATION - 2.2L DIESEL

1. Install starter. (Scheme 11)
2. Install the upper mounting bolt.
3. Install the lower mounting bolt and ground cable.
4. Connect the battery cable to the starter. (Scheme 12)
5. Connect the electrical connectors to the starter. (Scheme 12)
6. Install the radiator to vehicle.
7. Install radiator to inner cooler, make sure the 2 lower mounting tabs lock into the radiator brackets. These tabs are on the bottom of the inner cooler and lock into the bottom of the radiator. (Scheme 10)
8. Install the 4 upper bolts for the inner cooler mounting to radiator.
9. Connect the electrical connector for the radiator fan.
10. Install the upper radiator hose.
11. Raise vehicle and support.
12. Install the 2 lower bolts for the inner cooler mounting to radiator.
13. Install the lower radiator hose.
14. Install the underbody plate (skid plate), refer to «INTERIOR/EXTERIOR»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior) for more information.
15. Lower vehicle.
16. Install ambient temperature sensor.
17. Install the upper radiator crossmember.
18. Install the hood seal, refer to «INTERIOR/EXTERIOR»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior) for more information.
19. Install the front grill, refer to «INTERIOR/EXTERIOR»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior) for more information.
20. Connect the negative battery cable.
21. Fill radiator, refer to «COOLING»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) for more information.

INSTALLATION - 2.0/2.4L

1. Reinstall starter motor into vehicle lower engine compartment.
2. Install starter motor mounting bolts and torque to 54 N.m (40 ft. lbs.).
3. Connect starter motor wiring. Torque solenoid battery cable nut to 10 N.m (90 in. lbs.).
4. Install Engine Structural Collar. Refer to «STRUCTURAL COLLAR»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine) . CAUTION: The torque procedure for the structural collar must be followed, as damage to the oil pan or collar could occur.
5. Lower vehicle from hoist.
6. Reconnect battery negative cable.
7. Reinstall air cleaner box cover. Refer to appropriate ENGINE article.
8. Verify operation of vehicle and systems.
9. Close hood and remove from hoist.

INSTALLATION - STARTER 2.4L TURBO

1. Install starter. (Scheme 20)
2. Install the lower starter bolt and tighten bolt to 54 N.m (40 ft. lbs.).
3. Connect the positive battery cable and tighten nut to 10 N.m (90 in. lbs.).
4. Connect and lock the solenoid electrical connector.
5. Install the Structural Collar, refer to «STRUCTURAL COLLAR»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine). (Scheme 19)
6. Locate the power steering lines.
7. Install the studs that hold the power steering lines and tighten to 61 N.m (45 ft. lbs.).
8. Tighten nuts that hold the inner cooler lower tube.
9. Install the inner cooler lower hose to the inner cooler and tighten clamp. (Scheme 17)
10. Lower vehicle.
11. Pushing the inner cooler hose up and out of the way and install the upper starter bolt and ground wire and tighten bolt to 54 N.m (40 ft. lbs.). (Scheme 15)
12. Install the air cleaner box. Refer to appropriate ENGINE article.
13. Tighten air cleaner hose clamp
14. Connect the negative battery cable.

See also:
• RESTRAINTS
• BATTERY SYSTEM
• IGNITION SWITCH
• WIRING DIAGRAM INFORMATION
• CLUTCH
• POWERTRAIN DIAGNOSTIC PROCEDURES
• TRANSMISSION DIAGNOSTIC PROCEDURES
• INTERIOR/EXTERIOR
• COOLING
• STRUCTURAL COLLAR
• DIAGNOSIS AND TESTING - FEED CIRCUIT RESISTANCE TEST
• RELAY TEST
• STARTER SOLENOID
• RELAY CIRCUIT TEST
• IGNITION SWITCH
• REMOVAL