Chrysler PT Cruiser. Manual — part 486
battery cable to solenoid connection. If reading is
still above 0.2 volt after correcting poor contacts,
replace battery positive cable.
(b) 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 (Fig. 1).
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
(1) Check battery before performing this test. Bat-
tery must be fully charged.
(2) Connect a volt-ampere tester to the battery ter-
minals. Refer to the operating instructions provided
with the tester being used.
(3) To disable the ignition and fuel systems, dis-
connect the Automatic Shutdown Relay (ASD). The
ASD relay is located in the Power Distribution Cen-
ter (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 (Fig.
1).
• 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 amper-
age 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 removal.
(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 cor-
rected.
SPECIFICATIONS
TORQUE
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Starter Mounting Bolts
54
40
Starter Solenoid Battery
Nut
10
90
Fig. 1 Volt Ampere Tester
8F - 42
STARTING
PT
STARTING (Continued)
STARTER MOTOR
REMOVAL
REMOVAL - 1.6L
(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
(Fig. 2).
(6) Disconnect the battery cable (Fig. 4) and sole-
noid electrical connectors (Fig. 3) from the starter.
(7) Push up the spring clip that holds the heat
shield for the starter (Fig. 5).
(8) Remove the upper mounting bolts first.
(9) Remove the lower mounting bolt.
(10) Remove the starter through the wheel well
(Fig. 6).
REMOVAL - 2.2 DIESEL
(1) Disconnect the negative battery cable.
(2) Remove the front grill, refer to the Body sec-
tion for more information.
(3) Remove the hood seal, refer to the Body section
for more information.
(4) Remove the upper radiator crossmember.
(5) Remove ambient temperature sensor.
Fig. 2 EXHAUST BRACKET
Fig. 3 ELECTRICAL CONNECTIONS
Fig. 4 ELECTRICAL CONNECTIONS REMOVED
Fig. 5 STARTER HEAT SHIELD
PT
STARTING
8F - 43
(6) Raise vehicle and support.
(7) Drain radiator, refer to the Cooling section for
more information.
(8) Disconnect the electrical connector for the radi-
ator fan.
(9) Remove the underbody plate (skid plate), refer
to the Body section 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
(Fig. 7)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.
(16) Remove the radiator from vehicle (Fig. 8).
(17) Disconnect the electrical connectors from the
starter (Fig. 9).
(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.
REMOVAL - 2.0/2.4L
(1) Open Hood.
(2) Remove air cleaner box cover. Refer to Fuel
Delivery, Removal and Installation, Air Cleaner Box.
(3) Disconnect and isolate the battery negative
cable (Fig. 10).
Fig. 6 STARTER REMOVAL
Fig. 7 MOUNTING TABS
Fig. 8 STARTER LOCATION
8F - 44
STARTING
PT
STARTER MOTOR (Continued)
(4) Raise vehicle on hoist.
(5) Remove Engine Structural Collar. Refer to
Engine, Structural Collar Removal and Installation.
(6) Disconnect starter motor wiring (Fig. 11).
(7) Remove starter motor mounting bolts (Fig. 11).
(8) Remove starter motor from vehicle.
REMOVAL - 2.4L TURBO
(1) Disconnect the negative battery cable.
(2) Remove the air cleaner box.
(3) Pushing the inner cooler hose up and out of the
way and remove the upper starter bolt (Fig. 12) and
ground wire.
Fig. 9 ELECTRICAL CONNECTIONS
Fig. 10 Battery Negative Cable Remove/Install
Fig. 11 Starter Remove/Install
1 - BOLT
2 - GROUND
3 - STARTER
4 - BOLT
Fig. 12 UPPER STARTER BOLT - 2.4L TURBO
PT
STARTING
8F - 45
STARTER MOTOR (Continued)
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