Chrysler 300M, Dodge Interpid. Manual — part 71
INSTALLATION
INSTALLATION - 2.7L
(1) Install generator.
(2) Install pivot bolt, leave loose.
(3) Connect the generator field circuit plug.
(4) Install the B+ terminal nut and wire and
tighten to 9.8 N·m (85 ±15 in. lbs.).
(5) Install the generator drive belt. Refer to the
Cooling System section.
(6) Adjusting T-bolt and tighten belt.
(7) Remove jackstand from under radiator and
install lower radiator crossmember support.
(8) Reposition transmission cooler and tighten fas-
teners.
(9) Install lower plastic splash shield.
(10) Lower vehicle.
(11) Connect negative battery cable.
Tighten all fasteners to the proper torque. Refer to
the Torque Specifications chart in this section.
INSTALLATION - 3.5L
(1) Install generator.
(2) Install the pivot bolt.
(3) Install the lower mounting bolt.
(4) Connect the B+ wire and tighten nut and
tighten to 9.8 N·m (85 ±15 in. lbs.).
(5) Connect the generator field circuit connector.
(6) Install generator drive belt. Refer to the Cool-
ing System section.
(7) Tighten the pivot bolt.
(8) Tighten the lower mounting bolt.
(9) Install the upper radiator support and tighten
bolts.
(10) Connect the negative battery cable. Tighten
all fasteners to the proper torque. Refer to the
Torque Specifications chart in this section.
VOLTAGE REGULATOR
DESCRIPTION
The Electronic Voltage Regulator (EVR) is not a
separate component. It is actually a voltage regulat-
ing circuit located within the Powertrain Control
Module (PCM). The EVR is not serviced separately. If
replacement is necessary, the PCM must be replaced.
OPERATION
The amount of DC current produced by the gener-
ator is controlled by EVR circuitry contained within
the PCM. This circuitry is connected in series with
the generators second rotor field terminal and its
ground.
Voltage is regulated within the PCM on the NGC
vehicles, to control the strength of the rotor magnetic
field. The EVR circuitry monitors system line voltage
at the PDC and calculated battery temperature or
inlet air temperature sensor (refer to Inlet Air Tem-
perature Sensor, if equipped, for more information ).
It then determines a target charging voltage. If
sensed battery voltage is lower than the target volt-
age, the PCM feeds the field winding until sensed
battery voltage is at the target voltage. A circuit in
the PCM cycles the feed side of the generator field at
250 times per second (250Hz), but has the capability
to feed the field control wire 100% of the time (full
field) to achieve the target voltage. If the charging
rate cannot be monitored (limp-in), a duty cycle of
20% is used by the PCM in order to have some gen-
erator output. Also refer to Charging System Opera-
tion for additional information.
LH
CHARGING
8F - 21
GENERATOR (Continued)
STARTING
TABLE OF CONTENTS
page
page
STARTING
. . . . . . . . . . . . . . . . . . . . . . . . . 22
. . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DIAGNOSIS AND TESTING - STARTING
SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . 22
DIAGNOSIS AND TESTING - CONTROL
CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . . . 25
DIAGNOSIS AND TESTING - FEED CIRCUIT
RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . . . 27
STARTER MOTOR
. . . . . . . . . . . . . . . . . . . 28
. . . . . . . . . . . . . . . . . . . 28
. . . . . . . . . . . . . . . . . . . . 28
. . . . . . . . . . . . . . . . . . . . 28
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
. . . . . . . . . . . . . . . . . . . . . . . . . 28
STARTER MOTOR RELAY
. . . . . . . . . . . . . . . . . . . . . . . . . 29
. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DIAGNOSIS AND TESTING - STARTER RELAY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
STARTER SOLENOID
. . . . . . . . . . . . . . . . . . . . . . . . . 30
. . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DIAGNOSIS AND TESTING - STARTER
. . . . . . . . . . . . . . . . . . . . . . . . . . 30
STARTING
DESCRIPTION
The starting system consists of:
• Starter relay
• Starter motor (including an integral starter sole-
noid)
Other components to be considered as part of start-
ing system are:
• Battery
• Battery cables
• Ignition switch and key lock cylinder
• Clutch pedal position switch (manual transmis-
sion)
• Park/neutral position switch (automatic trans-
mission)
• Wire harnesses and connections.
The Battery, Starting, and Charging systems oper-
ate 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 Diag-
nostics (OBD) built into the Powertrain Control Mod-
ule (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 over-ride safety
that does not allow the starter to be engaged if the
engine is already running.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - STARTING
SYSTEM TEST
For circuit descriptions and diagrams, refer to the
Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO THE PASSIVE RESTRAINT SYS-
TEMS BEFORE ATTEMPTING STEERING WHEEL,
STEERING
COLUMN,
OR
INSTRUMENT
PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
8F - 22
STARTING
LH
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 the Battery section
for more information.
• Ignition Switch - Visually inspect the ignition
switch for indications of physical damage and loose
or corroded wire harness connections.
• Transmission Range Sensor or Park/Neu-
tral Switch - Visually inspect the transmission
range sensor for indications 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 Motor - Visually inspect the starter
motor for indications 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 and remote jump
post.
• 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.
1. REFER TO THE BATTERY SECTION FOR MORE
INFORMATION. CHARGE OR REPLACE BATTERY, IF
REQUIRED.
2. STARTING CIRCUIT
WIRING FAULTY.
2. REFER TO FEED CIRCUIT RESISTANCE TEST AND FEED
CIRCUIT TEST IN THIS SECTION.
3. STARTER RELAY
FAULTY.
3. REFER TO RELAY TEST, IN THIS SECTION. REPLACE
RELAY, IF NECESSARY.
4. IGNITION SWITCH
FAULTY.
4. REFER TO IGNITION SWITCH TEST, IN THE STEERING
SECTION OR 8 WIRING DIAGRAMS. REPLACE SWITCH, IF
NECESSARY.
5. PARK/NEUTRAL
POSITION SWITCH
(AUTO TRANS) FAULTY
OR MIS-ADJUSTED.
5. REFER PARK/NEUTRAL POSITION SWITCH TEST, IN THE
TRANSAXLE. SECTION FOR MORE INFORMATION. REPLACE
SWITCH, IF NECESSARY.
6. CLUTCH INTERLOCK
SWITCH (MAN TRANS)
FAULTY.
6. REFER TO CLUTCH PEDAL POSITION SWITCH TEST, IN
THE CLUTCH. SECTION. REPLACE SWITCH, IF NECESSARY.
7. STARTER SOLENOID
FAULTY.
7. REFER TO SOLENOID TEST, IN THIS SECTION. REPLACE
STARTER ASSEMBLY, IF NECESSARY.
8. STARTER ASSEMBLY
FAULTY.
8. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
9. FAULTY TEETH ON
RING GEAR.
9. ROTATE FLYWHEEL 360°, AND INSPECT TEETH AND RING
GEAR REPLACED IF DAMAGED.
10. PCM DOUBLE
START OVERRIDE
OUTPUT FAILURE.
10. REFER TO PCM DIAGNOSTIC. CHECK FOR CONTINUITY
BETWEEN PCM AND TERMINAL 85. REPAIR OPEN CIRCUIT
AS REQUIRED. IF OK, PCM MAY BE DEFECTIVE.
STARTER
ENGAGES,
FAILS TO TURN
ENGINE.
1. BATTERY
DISCHARGED OR
FAULTY.
1. REFER TO THE BATTERY SECTION FOR MORE
INFORMATION. CHARGE OR REPLACE BATTERY AS
NECESSARY.
LH
STARTING
8F - 23
STARTING (Continued)
CONDITION
POSSIBLE CAUSE
CORRECTION
2. STARTING CIRCUIT
WIRING FAULTY.
2. REFER TO THE FEED CIRCUIT RESISTANCE TEST AND
THE FEED CIRCUIT TEST IN THIS SECTION. REPAIR AS
NECESSARY.
3. STARTER ASSEMBLY
FAULTY.
3. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
4. ENGINE SEIZED.
4. REFER TO THE ENGINE SECTION, FOR DIAGNOSTIC AND
SERVICE PROCEDURES.
5. LOOSE
CONNECTION AT
BATTERY, PDC,
STARTER, OR ENGINE
GROUND.
5. INSPECT FOR LOOSE CONNECTIONS.
6. FAULTY TEETH ON
RING GEAR.
6. ROTATE FLYWHEEL 360°, AND INSPECT TEETH AND RING
GEAR REPLACED IF DAMAGED.
STARTER
ENGAGES,
SPINS OUT
BEFORE
ENGINE
STARTS.
1. BROKEN TEETH ON
STARTER RING GEAR.
1. REMOVE STARTER. INSPECT RING GEAR AND REPLACE
IF NECESSARY.
2. STARTER ASSEMBLY
FAULTY.
2. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
STARTER DOES
NOT
DISENGAGE.
1. STARTER
IMPROPERLY
INSTALLED.
1. INSTALL STARTER. TIGHTEN STARTER MOUNTING
HARDWARE TO CORRECT TORQUE SPECIFICATIONS.
2. STARTER RELAY
FAULTY.
2. REFER TO RELAY TEST, IN THIS SECTION. REPLACE
RELAY, IF NECESSARY.
3. IGNITION SWITCH
FAULTY.
3. REFER TO IGNITION SWITCH TEST, IN THE STEERING
SECTION. REPLACE SWITCH, IF NECESSARY.
4. STARTER ASSEMBLY
FAULTY.
4. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
5. FAULTY TEETH ON
RING GEAR.
5. ROTATE FLYWHEEL 360°, AND INSPECT TEETH AND RING
GEAR REPLACED IF DAMAGED.
8F - 24
STARTING
LH
STARTING (Continued)
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