Circuit Test - Chrysler Dodge Caravan 2002 Manual

RS
STARTING (Continued)
CONDITION
STARTER 1. BROKEN TEETH ON
ENGAGES, STARTER RING GEAR.
SPINS OUT
BEFORE
ENGINE
STARTS.
2. STARTER ASSEMBLY
FAULTY.
STARTER DOES 1. STARTER
NOT IMPROPERLY
DISENGAGE. INSTALLED.
2. STARTER RELAY
FAULTY.
3. IGNITION SWITCH
FAULTY.
4. STARTER ASSEMBLY
FAULTY.
5. FAULTY TEETH ON
RING GEAR.
DIAGNOSIS AND TESTING - CONTROL

CIRCUIT TEST

The starter control circuit has:
• Starter motor with integral solenoid
• Starter relay
• Transmission range sensor, or Park/Neutral
Position switch with automatic transmissions
• Ignition switch
• Battery
• All related wiring and connections
• Powertrain Control Module (PCM)
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
• 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
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN THE PARK POSITION WITH THE
PARKING BRAKE APPLIED.
(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 per-
forming the starter relay test.
POSSIBLE CAUSE
1. REMOVE STARTER. INSPECT RING GEAR AND REPLACE
IF NECESSARY.
2. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
1. INSTALL STARTER. TIGHTEN STARTER MOUNTING
HARDWARE TO CORRECT TORQUE SPECIFICATIONS.
2. REFER TO RELAY TEST, IN THIS SECTION. REPLACE
RELAY, IF NECESSARY.
3. REFER TO IGNITION SWITCH TEST, IN THE STEERING
SECTION. REPLACE SWITCH, IF NECESSARY.
4. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
5. ROTATE FLYWHEEL 360°, AND INSPECT TEETH AND RING
GEAR REPLACED IF DAMAGED.
(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.
(a) If engine cranks, starter/starter solenoid is
good. Go to the Starter Relay Test.
(b) If engine does not crank or solenoid chatters,
check wiring and connectors from starter relay to
starter solenoid for loose or corroded connections.
Particularly at starter terminals.
(c) Repeat test. If engine still fails to crank prop-
erly, trouble is within starter or starter mounted
solenoid, and replace starter. Inspect the ring gear
teeth.
STARTER RELAY
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN THE PARK/NEUTRAL POSITION
WITH THE PARKING BRAKE APPLIED.
RELAY TEST
The starter relay is located in the Power Distribu-
tion Center (PDC) in the engine compartment. Refer
to the PDC label for relay identification and location.
STARTING
CORRECTION
8F - 31