Chrysler Stratus Convertible. Manual — part 231

STARTING SYSTEM TEST

For circuit descriptions and diagrams, refer to

8W-21, Starting System in Group 8W, Wiring Dia-
grams.

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.

•

Clutch Pedal Position Switch - Visually

inspect the clutch pedal position switch for indica-
tions 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 indi-

cations 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. Check for loose or corroded wire harness
connections at main engine ground.

• Power Distribution Center (PDC) Visually

inspect the B+ connections at the PDC for physical
damage and loose or corroded harness connections.

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.

JX

STARTING SYSTEMS

8B - 5

DIAGNOSIS AND TESTING (Continued)

CONDITION

POSSIBLE CAUSE

CORRECTION

STARTER
ENGAGES,
FAILS TO TURN
ENGINE.

1. BATTERY
DISCHARGED OR
FAULTY.
2. STARTING CIRCUIT
WIRING FAULTY.
3. STARTER ASSEMBLY
FAULTY.
4. ENGINE SEIZED.
5. LOOSE
CONNECTION AT
BATTERY, PDC,
STARTER, OR ENGINE
GROUND.

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.
5. INSPECT FOR LOOSE CONNECTIONS.

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.
5. FAULTY TEETH ON
RING GEAR.

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.
5. ROTATE FLYWHEEL 360°, AND INSPECT TEETH.

REMOVAL AND INSTALLATION

SAFETY SWITCHES

For Removal and Installation of the:
• Clutch Position Switch, refer to Group 6, Clutch.

• Park/Neutral Switch, refer to Group 21, Tran-

saxle.

STARTER

CAUTION: The generator output terminal must be
connected to the battery positive terminal of the
starter solenoid. For the charging and cranking sys-
tems to operate properly.

2.0L ENGINE WITH MANUAL TRANSAXLE

REMOVAL

(1) Disconnect the remote battery negative cable

from the terminal on shock tower (Fig. 6).

(2) Remove air cleaner resonator, refer to Group

14, Fuel.

(3) Remove the battery positive cable nut from

starter. Remove battery positive cable and generator
output wire from starter (Fig. 7).

(4) Disconnect push on solenoid connector. Unlock

the red locking tab and compress lock to release the
connector.

(5) Remove two bolts attaching starter to trans-

mission housing and remove starter from vehicle.

INSTALLATION

For installation, reverse the above procedures.

Clean

corrosion/dirt

from

wire

terminals

before

installing wiring to the solenoid.

2.0L ENGINE WITH AUTOMATIC TRANSAXLE AND
2.4L ENGINE

REMOVAL

(1) Disconnect battery negative cable from remote

negative terminal on shock tower (Fig. 6).

(2) Remove air cleaner resonator, refer to Group

14, Fuel.

8B - 6

STARTING SYSTEMS

JX

DIAGNOSIS AND TESTING (Continued)

(3) Remove three Transmission Control Module

(TCM) mounting screws. Move TCM to provide access
to top starter mounting bolt. DO NOT disconnect
TCM wiring.

(4) Remove top bolt attaching starter to transmis-

sion housing (Fig. 8).

(5) Raise vehicle.

(6) Remove battery positive cable nut from starter

and remove cable.

(7) Disconnect push on solenoid connector. Unlock

the red locking tab and compress lock to release the
connector (2.0L only).

(8) Remove the bottom bolt attaching starter to

transmission housing (Fig. 8).

(9) Remove starter from vehicle.

INSTALLATION

(1) With vehicle is raised, set starter face into

transmission housing.

(2) Lower vehicle.
(3) Install top starter mounting bolt but do not

tighten.

(4) Raise vehicle.
(5) Install

bottom

starter

mounting

bolt

and

tighten to 54 N·m (40 ft. lbs.) torque.

(6) Clean corrosion/dirt from wire terminals before

installing wiring to the solenoid.

(7) Connect battery positive cable to solenoid post

(Fig. 8).

(8) Connect the push-on solenoid connector.
(9) Lower vehicle.

Fig. 7 Wire Terminal Connection – 2.0L Engine

1 – GENERATOR OUTPUT WIRE
2 – PUSH ON SOLENOID CONNNECTOR

3 – BATTERY POSITIVE WIRE

Fig. 6 Remove Remote Battery Cable at Shock

Tower

JX

STARTING SYSTEMS

8B - 7

REMOVAL AND INSTALLATION (Continued)

(10) Tighten top starter bolt to 54 N·m (40 ft. lbs.)

torque.

(11) Install TCM and the mounting screws.
(12) Install air cleaner resonator, refer to Group

14, Fuel.

(13) Connect battery remote cable to the remote

terminal.

2.5L ENGINE

REMOVAL

(1) Disconnect battery negative cable from remote

negative terminal on shock tower (Fig. 6).

(2) Raise vehicle.
(3) Remove oil filter.
(4) Remove battery positive cable nut from starter

and remove cable (Fig. 9).

(5) Disconnect push on solenoid connector.
(6) Remove three bolts attaching starter to trans-

mission housing and remove starter from vehicle.

INSTALLATION

For installation, reverse the above procedures.

Clean

corrosion/dirt

from

wire

terminals

before

installing wiring to the solenoid.

STARTER RELAY

The relay is located in the Power Distribution Cen-

ter (PDC). Refer to the PDC cover for relay location.

SPECIFICATIONS

STARTER

Engine Amperage Draw Test . 150-280 Amps*
Engine should be up to operating temperature.

Extremely heavy oil or tight engine will increase
starter amperage draw.

TORQUE

DESCRIPTION

TORQUE

Starter Mounting Bolts . . . . . . . 54 N·m (40 ft. lbs.)
Starter Solenoid Battery Nut . . 10 N·m (90 in. lbs.)

Fig. 8 Wire Terminal Connection

1 – BATTERY POSITIVE WIRE
2 – PUSH ON SOLENOID CONNECTOR

Fig. 9 Wire Terminal Connection – 2.5L Engine

1 – PUSH ON SOLENOID CONNECTOR
2 – BATTERY POSITIVE WIRE

Manufacturer

BOSCH

MELCO

NIPPONDENSO

Engine

2.0L

2.5L

2.4L

Application

Power rating

0.95 Kw

1.2 Kw

1.4 Kw

Voltage

12

VOLTS

12

VOLTS

12 VOLTS

Brushes

4

4

4

Drive

Planetary Planetary

Offset Gear

Gear
Train

Gear
Train

Reduced

8B - 8

STARTING SYSTEMS

JX

REMOVAL AND INSTALLATION (Continued)