Starting System Dodge Grand Caravan IV

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 groups 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 override safety that does not allow the starter to be engaged if the engine is already running.

For circuit descriptions and diagrams, refer to the Wiring Diagrams.

INSPECTION

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

Scheme 1

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 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.

Scheme 2

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 TESTS .
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 «STARTER RELAY»(/dodge/grand-caravan/iv-2000-2007/remont/starter/#starting-system__starter-relay) . 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 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»(/dodge/grand-caravan/iv-2000-2007/remont/starter/#starting-system__ignition-switch) procedure.
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 the TRANSAXLE . 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 the TRANSAXLE for more information.

If equipped with Clutch Interlock/Upstop Switch, refer to Diagnosis and Testing in CLUTCH article.

IGNITION SWITCH

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

ALL RELATED WIRING AND CONNECTORS

Refer to WIRING DIAGRAMS 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 3)

Scheme 3

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 3) 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»(/dodge/grand-caravan/iv-2000-2007/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

STARTER

STARTER SPECIFICATIONS

Engine should be up to operating temperature. Extremely heavy oil or tight engine will increase starter amperage draw.

Scheme 4

Scheme 5

Scheme 6

1. Release hood latch and open hood (Scheme 4)
2. Disconnect and isolate the battery negative cable.
3. Disconnect solenoid wire connector from terminal (Scheme 5)
4. Remove nut holding B+ wire to terminal.
5. Disconnect solenoid and B+ wires from starter terminals.
6. Remove the lower bolt.
7. Remove the upper bolt and ground wire (Scheme 6)
8. Remove starter.

Scheme 7

Scheme 8

Scheme 9

1. Release hood latch and open hood.
2. Disconnect and isolate the battery negative cable.
3. Hoist and support vehicle on safety stands.
4. Remove nut holding B+ terminal to starter solenoid (Scheme 7)
5. Disconnect solenoid connector from starter.
6. Remove bolts holding starter to transaxle bell-housing (Scheme 8)
7. Remove starter from bellhousing (Scheme 9)
8. Separate starter spacer from transaxle bell-housing.

INSTALLATION - 2.4L

1. Place starter in position on vehicle.
2. Install the lower bolts to hold starter to transaxle bellhousing.
3. Install the upper bolt and ground wire (Scheme 6)
4. Place solenoid and B+ wires in position on starter terminals (Scheme 5)
5. Install nut to hold B+ wire to terminal.
6. Connect solenoid wire connector onto terminal.
7. Connect battery negative cable.
8. Verify starter operation.

INSTALLATION - 3.3/3.8L

1. Place starter spacer in position on transaxle bellhousing, flange toward flywheel.
2. Place starter in position on bellhousing.
3. Install bolts and ground wire (Scheme 6) to hold starter to transaxle bellhousing.
4. Connect solenoid connector into starter.
5. Install nut to hold B+ terminal to starter solenoid.
6. Lower vehicle.
7. Connect battery negative cable.
8. Verify starter operation.

See also:
• AIR BAG RESTRAINT SYSTEMS
• STARTER RELAY
• IGNITION SWITCH
• STARTER MOTOR