Chrysler New Yorker. Manual — part 56
• Ignition switch
• Battery
• All related wiring and connections
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 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.
(3) Raise the vehicle.
(4) Perform a visual inspection of the starter/
starter solenoid for corrosion, loose connections or
faulty wiring.
(5) Lower the vehicle.
(6) Locate and remove the starter relay from the
Power Distribution Center (PDC). Refer to the PDC
label for relay identification and location.
(7) 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 or solenoid chatters, check
wiring and connectors from starter relay to starter
solenoid for loose or corroded connections. Particu-
larly 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.
STARTER RELAY
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN THE PARK POSITION/NEUTRAL
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.
Remove
the
starter
relay
from
the
PDC
as
described in this group 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 3. If not OK, replace the faulty relay.
(2) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 75
65 ohms. If OK, go to Step
4. 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 procedure. If not OK, replace the faulty
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 3. 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 4.
(3) The relay normally open terminal (87) is con-
nected to the common feed terminal (30) in the ener-
gized 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 5. 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
CAV
COLOR
FUNCTION
30 (B)
RD
B (+)
85 (C)
TN
P/N POSITION SW.SENSE
(AUTO)
86 (A)
YL
IGNITION SWITCH
OUTPUT
87 (D)
LG
STARTER RELAY OUTPUT
Starter Relay Pinout
8B - 2
STARTING
300M
DIAGNOSIS AND TESTING (Continued)
the ignition switch is held in the Start position. On
vehicles with a manual transmission, the clutch
pedal must be fully depressed for this test. Check for
battery voltage at the cavity for relay terminal 86
with the ignition switch in the Start position, and no
voltage when the ignition switch is released to the
On position. If OK, go to Step 6. If not OK with an
automatic transmission, 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 Test procedure in this group. If not
OK with a manual transmission, check the circuit
between the relay and the clutch pedal position
switch for an open or a short. If the circuit is OK, see
the Clutch Pedal Position Switch Test procedure in
this group.
(5) The coil ground terminal (85) is connected to
the electromagnet in the relay. On vehicles with an
automatic transmission, it is grounded through the
park/neutral position switch only when the gearshift
selector lever is in the Park or Neutral positions. On
vehicles with a manual transmission, it is grounded
at all times. Check for continuity to ground at the
cavity for relay terminal 85. If not OK with an auto-
matic transmission, check for an open or short circuit
to the park/neutral position switch and repair, if
required. If the circuit is OK, see the Park/Neutral
Position Switch Test procedure in this group. If not
OK with a manual transmission, repair the circuit to
ground as required.
SAFETY SWITCHES
For
diagnostics
of
the
Park/Neutral
Position
Switch, refer to Group 21, Transaxle.
IGNITION SWITCH
After testing starter solenoid and relay, test igni-
tion switch and wiring. Refer to Group 8D, Ignition
Systems or Group 8W, Wiring Diagrams. Check all
wiring for opens or shorts, and all connectors for
being loose or corroded.
BATTERY
Refer to Group 8A, Battery for proper procedures.
ALL RELATED WIRING AND CONNECTORS
Refer to Group 8W, Wiring Diagrams.
FEED CIRCUIT RESISTANCE TEST
Before proceeding with this operation, review Diag-
nostic Preparation and Starter Feed Circuit Tests.
The following operation will require a voltmeter,
accurate to 1/10 of a volt.
CAUTION:
Ignition and Fuel systems must be dis-
abled to prevent engine start while performing the
following tests.
(1) 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.
(2) Remove the air cleaner assembly for access to
battery terminals. Refer to Group 14, Fuel for service
procedures.
(3) With all wiring harnesses and components
properly connected, perform the following:
(a) 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 con-
tact between cable clamp and post.
(b) Connect positive lead of the voltmeter to the
battery positive post, and negative lead to the bat-
tery positive cable clamp. Rotate and hold the igni-
tion switch key in the START position. Observe the
voltmeter. If voltage is detected, correct poor con-
tact between the cable clamp and post.
(c) 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 correct-
ing 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.
(a) Connect the positive voltmeter lead to the
battery positive terminal, and negative lead to bat-
tery 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.
(b) If resistance tests do not detect feed circuit
failures, replace the starter motor.
300M
STARTING
8B - 3
DIAGNOSIS AND TESTING (Continued)
FEED CIRCUIT TEST
The following procedure will require a suitable
volt-ampere tester (Fig. 2).
CAUTION:
Before performing any starter tests, the
ignition and fuel systems must be disabled.
(1) Connect a volt-ampere tester to the battery ter-
minals. Refer to the operating instructions provided
with the tester being used.
(2) 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.
(3) 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.
(4) Rotate and hold the ignition switch in the
START position. Observe the volt-ampere tester (Fig.
2).
• 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.
(5) 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.
STARTING SYSTEM TEST
For circuit descriptions and diagrams, refer to
Group 8W, Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS,
REFER
TO
GROUP
8M
-
PASSIVE
RESTRAINT
SYSTEMS
BEFORE
ATTEMPTING
STEERING
WHEEL,
STEERING
COLUMN,
OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
INSPECTION
Before removing any unit from the starting system
for repair or diagnosis, perform the following inspec-
tions:
• Battery - Visually inspect the battery for indi-
cations 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 Group 8A, Battery
for more information.
• Ignition Switch - Visually inspect the ignition
switch for indications of physical damage and loose
or corroded wire harness connections.
• Park/Neutral Position Switch - Visually
inspect the park/neutral position switch for indica-
tions of physical damage and loose or corroded wire
harness connections.
• Starter Relay - Visually inspect the starter
relay for indications of physical damage and loose or
corroded wire harness connections.
• Starter - Visually inspect the starter for indica-
tions of physical damage and loose or corroded wire
harness connections.
• Starter Solenoid - Visually inspect the starter
solenoid for indications of physical damage and loose
or corroded wire harness connections.
• Wiring - Visually inspect the wire harness for
damage. Repair or replace any faulty wiring, as
required.
Fig. 2 Volt Ampere Tester
8B - 4
STARTING
300M
DIAGNOSIS AND TESTING (Continued)
STARTING SYSTEM DIAGNOSIS
CONDITION
POSSIBLE CAUSE
CORRECTION
STARTER FAILS TO
ENGAGE.
1. BATTERY DISCHARGED OR
FAULTY.
2. STARTING CIRCUIT WIRING
FAULTY.
3. STARTER RELAY FAULTY.
4. IGNITION SWITCH FAULTY.
5. PARK/NEUTRAL POSITION
SWITCH (AUTO TRANS) FAULTY
OR MIS-ADJUSTED.
6. CLUTCH PEDAL POSITION
SWITCH (MAN TRANS) FAULTY.
7. STARTER SOLENOID FAULTY.
8. STARTER ASSEMBLY FAULTY.
1. REFER TO GROUP 8A , BATTERY. CHARGE
OR REPLACE BATTERY, IF REQUIRED.
2. REFER TO FEED CIRCUIT RESISTANCE
TEST AND FEED CIRCUIT TEST IN THIS
SECTION.
3. REFER TO RELAY TEST, IN THIS SECTION.
REPLACE RELAY, IF NECESSARY.
4. REFER TO IGNITION SWITCH TEST, IN
GROUP 8D IGNITION SYSTEM OR GROUP
8W, WIRING DIAGRAMS. REPLACE SWITCH,
IF NECESSARY.
5. REFER PARK/NEUTRAL POSITION SWITCH
TEST, IN GROUP 21, TRANSAXLE. REPLACE
SWITCH, IF NECESSARY.
6. REFER TO CLUTCH PEDAL POSITION
SWITCH TEST, IN GROUP 6, CLUTCH.
REPLACE SWITCH, IF NECESSARY.
7. REFER TO SOLENOID TEST, IN THIS
SECTION. REPLACE STARTER ASSEMBLY, IF
NECESSARY.
8. IF ALL OTHER STARTING SYSTEM
COMPONENTS AND CIRCUITS CHECK OK,
REPLACE STARTER ASSEMBLY.
STARTER ENGAGES,
FAILS TO TURN
ENGINE.
1. BATTERY DISCHARGED OR
FAULTY.
2. STARTING CIRCUIT WIRING
FAULTY.
3. STARTER ASSEMBLY FAULTY.
4. ENGINE SEIZED.
1. REFER TO GROUP 8A, BATTERY. CHARGE
OR REPLACE BATTERY AS NECESSARY.
2. REFER TO THE FEED CIRCUIT
RESISTANCE TEST AND THE FEED CIRCUIT
TEST IN THIS SECTION. REPAIR AS
NECESSARY.
3. IF ALL OTHER STARTING SYSTEM
COMPONENTS AND CIRCUITS CHECK OK,
REPLACE STARTER ASSEMBLY.
4. REFER TO GROUP 9 ENGINE, FOR
DIAGNOSTIC AND SERVICE PROCEDURES.
STARTER ENGAGES,
SPINS OUT BEFORE
ENGINE STARTS.
1. BROKEN TEETH ON STARTER
RING GEAR.
2. STARTER ASSEMBLY FAULTY.
1. REMOVE STARTER. INSPECT RING GEAR
AND REPLACE IF NECESSARY.
2. IF ALL OTHER STARTING SYSTEM
COMPONENTS AND CIRCUITS CHECK OK,
REPLACE STARTER ASSEMBLY.
STARTER DOES NOT
DISENGAGE.
1. STARTER IMPROPERLY
INSTALLED.
2. STARTER RELAY FAULTY.
3. IGNITION SWITCH FAULTY.
4. STARTER ASSEMBLY FAULTY.
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
GROUP 8D, IGNITION SYSTEM. REPLACE
SWITCH, IF NECESSARY.
4. IF ALL OTHER STARTING SYSTEM
COMPONENTS AND CIRCUITS CHECK OK,
REPLACE STARTER ASSEMBLY.
300M
STARTING
8B - 5
DIAGNOSIS AND TESTING (Continued)
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