Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 194
STARTER
INDEX
page
page
General Information
. . . . . . . . . . . . . . . . . . . . . . . . 3
Neutral Starting and Back-up Switch
. . . . . . . . . . . . 7
Starter Component Replacement
. . . . . . . . . . . . . . 5
Starter Motor Replacement . . . . . . . . . . . . . . . . . . . 3
Starting System
. . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Supply Circuit and Control Circuit
. . . . . . . . . . . . . . 3
GENERAL INFORMATION
This section will cover STARTER replacement and
service procedures only. For starter diagnostic proce-
dures, refer to Group 8A, Battery/Starting/Charging
Systems Diagnostics.
STARTING SYSTEM
The starting system has:
• Ignition switch
• Starter relay
• Neutral starting and back-up switch
• Wiring harness
• Battery
• Starter motor with an integral solenoid
BOSCH STARTERS
• A Bosch permanent magnet starter motor is avail-
able on
• 2.5L and 3.0L engines on all vehicles. A planetary
gear train transmits power between starter motor and
pinion shaft. The fields have six permanent magnets.
NIPPONDENSO STARTERS
• A Nippondenso reduction gear-field coil starter mo-
tor is available on 3.0L, and 3.3L engines.
SUPPLY CIRCUIT AND CONTROL CIRCUIT
Both starter systems consists of two separate cir-
cuits:
• A high amperage supply to feed the starter motor.
• A low amperage circuit to control the starter sole-
noid.
For additional information on starter motor supply
and
control
circuits,
refer
to
Group
8A,
Battery/Starting/Charging Systems Diagnostics.
STARTER MOTOR REPLACEMENT
BOSCH STARTER 2.5L ENGINE
(1) Disconnect battery NEGATIVE cable (Fig. 1).
(2) Raise vehicle.
(3) Remove heat shield clip from the starter and
heat shield (Fig. 2).
(4) Remove two bolts and one nut attaching starter
to engine (Fig. 3).
(5) Remove starter/starter solenoid assembly from
engine. Position the starter to gain access to the wiring
connectors.
(6) Disconnect the positive battery cable and wiring
at the starter.
(7) Remove the starter from vehicle.
Fig. 7 Battery Cables Disconnected
Fig. 1 Remove or Install Battery Cable
.
BATTERY/STARTER/ALTERNATOR SERVICE
8B - 3
(8) For installation, reverse above procedures. Clean
corrosion/dirt from the cable and wire terminals before
installing wiring to the solenoid.
BOSCH OR NIPPONDENSO STARTER—3.0L OR
3.3L ENGINE
(1) Disconnect NEGATIVE battery cable (Fig. 1).
(2) Raise vehicle.
(3) Remove three starter attaching bolts from
engine/transaxle (Fig. 4).
(3) Remove two wire connector terminal nuts and
remove connector (Bosch, Fig. 5) (Nippondenso, Fig. 6
or 7).
(4) Remove starter from vehicle (Bosch, Fig. 8) (Nip-
pondenso, Fig. 9).
(5) For installation, reverse above procedures. Clean
corrosion/dirt from the cable and wire terminals before
installing wiring to the solenoid.
Fig. 2 Starter Heat Shield—4 Cylinder Engines
For easier servicing, do not remove the wiring
from starter at this time.
Fig. 3 Bosch Starter—2.5L Engine
Fig. 4 Remove or Install Attaching Bolts
Fig. 5 Wire Terminal Connections—Bosch Starter
Fig. 6 Wire Terminal Connections—3.0L
Engine—Nippondenso Starter
8B - 4
BATTERY/STARTER/ALTERNATOR SERVICE
.
STARTER COMPONENT REPLACEMENT
Caution: When servicing the starter assembly off the
vehicle, do not clamp the starter to a vice. Internal
damage may result.
NIPPONDENSO STARTER GEAR AND CLUTCH
(1) Remove the two gear housing attaching screws
and separate the gear housing from the solenoid hous-
ing (Fig. 10). The pinion gear, pinion gear bearing, and
drive gear will be loose between the solenoid housing
and gear housing (Fig. 11). When reinstalling pinion
gear and bearing, wipe with a clean rag and coat with
lightweight high temperature wheel bearing grease.
Place the lubricated bearing and gear over bearing
shaft in the gear housing (Fig. 12).
(2) Remove the starter gear and clutch assembly
from the solenoid housing (Fig. 13).
(3) For
installation,
reverse
above
procedures.
Fig. 9 Remove/Install
Starter—Nippondenso—Typical
Fig. 7 Wire Terminal Connections—3.3L
Engine—Nippondenso Starter
Fig. 8 Remove/Install Starter—Bosch—Typical
Fig. 10 Remove or Install Gear Housing
Fig. 11 Remove or Install Drive and Pinion Gears
.
BATTERY/STARTER/ALTERNATOR SERVICE
8B - 5
BOSCH STARTER SOLENOID REPLACEMENT
(1) Remove field terminal nut (Fig. 14).
(2) Remove field terminal (Fig. 15).
(3) Remove field washer (Fig. 16).
(4) Remove three solenoid mounting screws (Fig.
17).
(5) Remove the solenoid from the starter assembly.
(6) For installation, reverse above procedures.
Fig. 12 Lubricate and Install Pinion Gear Bearing
Fig. 13 Gear and Clutch Assembly
Fig. 14 Field Terminal Nut
Fig. 15 Field Coil Terminal
Fig. 16 Field Terminal Washer
Fig. 17 Solenoid Mounting Screws
8B - 6
BATTERY/STARTER/ALTERNATOR SERVICE
.
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