Starting System: Diagnosis Chrysler Voyager IV

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 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 - 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 - Visually inspect the starter 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.

Scheme 8

Scheme 9

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)
8. 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.

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 to perform the following tests

Scheme 10

Scheme 11

Scheme 12

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 86 and a ground lead to terminal 85 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»(ref-189540-S04397937772005091000000) . If not OK, replace the faulty relay.

STARTER RELAY CAVITIES FUNCTION REFERENCES

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 (86) 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»(ref-189540-S25493728762005091000000) Test procedure.
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 cavity for relay terminal 85. If not OK with an automatic transmission, check for an open or short circuit to the transmission range sensor and repair. 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 and near zero engine rpm. For manual trans. cars the PCM only needs to see near zero engine rpm. To diagnose the Park Neutral switch of the trans range sensor refer to transaxle for more information. Check for continuity to ground while the ignition switch is in the start position. 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 85. Repair open circuit as required. If OK, the PCM may be defective.

DIAGNOSIS AND TESTING - FEED CIRCUIT RESISTANCE TEST

Before proceeding with this operation, review DIAGNOSIS AND TESTING - FEED CIRCUIT TEST . 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 13)

Scheme 13

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.
5. Rotate and hold the ignition switch in the START position. Observe the volt-ampere tester (Scheme 13) 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 «STARTER MOTOR»(ref-189540-S02683030772005091000000).
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.