Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 190
• If voltage reads above 9.6 volts, and amperage draw
reads above 250 amps, go to the starter feed circuit
resistance test.
• If voltage reads 12.4 volts or greater and amperage
reads 0 to 10 amps, go to starter control circuit test.
CAUTION: Do not overheat the starter motor or draw
the battery voltage below 9.6 volts during cranking
operations.
(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 ignition coil cable or ignition coil connec-
tor. Start the vehicle several times to assure the
problem has been corrected.
STARTER FEED CIRCUIT RESISTANCE TEST
Before proceeding with this operation, review Diag-
nostic Preparation and Starter Feed Circuit Tests in
this Group. The following operation will require a
voltmeter, accurate to 1/10 of a volt.
CAUTION: Ignition system also must be disabled to
prevent engine start while performing the following
tests.
(1) Disable ignition system as follows:
• VEHICLES WITH CONVENTIONAL DISTRIBU-
TORS
Disconnect the ignition coil cable from the distributor
cap. Connect a suitable jumper wire between the coil
cable end-terminal and a good body ground (Fig. 6).
• VEHICLES WITH DIRECT IGNITION SYSTEM:
Disconnect the ignition coils electrical connector (Fig.
7).
(2) With all wiring harnesses and components prop-
erly connected, perform the following:
(a) Connect the negative lead of the voltmeter to
the negative battery post, and positive lead to the
negative battery cable clamp (Fig. 9). Rotate and
hold the ignition switch key in the START position.
Observe the voltmeter. If voltage is detected, correct
poor contact between cable clamp and post.
Fig. 5 Volt-Ampere Tester Connections
Fig. 6 Ground Ignition Coil Cable
Fig. 7 Ignition Coils Electrical Connection
Fig. 8 Starter Draw Tests
.
BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
8A - 11
(b) Connect positive lead of the voltmeter to the
positive battery post, and negative lead to the posi-
tive battery cable clamp. Rotate and hold the ignition
switch key in the START position. Observe the volt-
meter. If voltage is detected, correct poor contact
between the cable clamp and post.
(c) Connect negative lead of voltmeter to negative
battery terminal, and positive lead to engine block
near the battery cable attaching point (Fig. 10).
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 correcting poor
contacts, replace ground cable.
(3) Remove starter heat shield. Refer to Group 8B,
Starter Replacement to gain access to the starter motor
and solenoid connections. Perform the following steps:
(a) Connect positive voltmeter lead to the starter
motor housing and the negative lead to the negative
battery terminal (Fig. 11). Hold the ignition switch
key in the START position. If voltage reads above 0.2
volt, correct poor starter to engine ground.
(b) Connect the positive voltmeter lead to the
positive battery terminal, and negative lead to bat-
tery cable terminal on starter solenoid (Fig. 12).
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 positive battery cable.
If resistance tests do not detect feed circuit failures,
remove the starter motor and go to Bench Testing
Starter Solenoid in this Group.
STARTER CONTROL CIRCUIT TESTS
The starter control circuit has:
• Starter solenoid
• Starter relay (Fig. 2)
• Neutral starting and back-up switch with automatic
transmissions only
• Ignition switch
• Battery
• All related wiring and connections
Fig. 9 Test Battery Connection Resistance (Negative
or Positive Posts)
Fig. 10 Test Ground Circuit Resistance
Fig. 11 Test Starter Motor Ground—Typical
Fig. 12 Test Positive Battery Cable Resistance
8A - 12
BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
.
CAUTION: Before performing any starter tests, the
ignition system must be disabled.
VEHICLES EQUIPPED WITH A CONVENTIONAL
DISTRIBUTOR: Disconnect coil wire from distributor
cap center tower. Secure wire to a good ground to
prevent engine from starting (Fig. 6).
• VEHICLES EQUIPPED WITH DIRECT IGNITION
SYSTEM: Unplug the coils electrical connector (Fig. 7).
STARTER SOLENOID TEST
WARNING: CHECK TO ENSURE THAT THE
TRANSMISSION 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 this 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 wir-
ing.
(5) Lower the vehicle.
(6) Locate the starter relay (Fig. 13).
(7) Remove the starter relay from the connector.
(8) Connect a remote starter switch or a jumper wire
between the battery positive post and terminal 87 on
the starter relay connector. To determine the starter
relay terminal numbers, refer to Fig. 14.
If engine cranks, starter/starter solenoid is good. Go
to the Starter Relay Test.
If engine does not or solenoid chatters, check wiring
and connectors from starter relay to starter solenoid
for loose or corroded connections. Particularly at
starter terminals.
Repeat test. If engine still fails to crank properly,
trouble is within starter or starter mounted solenoid,
and it must be removed for repairs. Refer to Group 8B,
Battery/Starter/Alternator Service, Starter Replace-
ment.
STARTER RELAY TEST
WARNING: CHECK TO ENSURE THAT THE
TRANSMISSION 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 the preceding starter solenoid tests BE-
FORE performing starter relay tests. Refer to Starter
Solenoid Test.
(3) Locate and remove the starter relay (Fig. 13).
(4) After the starter relay has been located and
removed, refer to Starter Relay Tests (Fig. 14).
NEUTRAL STARTING AND BACK-UP SWITCH
AUTOMATIC TRANSMISSION ONLY
For electrical diagnostics, when checking starter
circuits, refer to Starter Relay Tests (Fig. 14).
For removal and installation of neutral switch, refer
to Neutral Starting and Back-up Switch in Group 21,
Transaxle.
IGNITION SWITCH TEST
After testing starter solenoid and relay, test ignition
switch and wiring. Refer to Group 8D, Ignition Sys-
tems or Group 8W, Wiring Diagrams. Check all wiring
for opens or shorts, and all connectors for being loose or
corroded.
BENCH TESTING STARTER SOLENOID
(1) Disconnect field coil wire from field coil terminal
(Fig. 15 or 16).
(2) Check for continuity between solenoid terminal
and field coil terminal with a continuity tester. Conti-
nuity should be detected (Fig. 17 or 18).
(3) Check for continuity between solenoid terminal
and solenoid housing (Fig. 19 or 20). Continuity should
be detected. If continuity is detected, solenoid is good.
(4) If continuity is not detected in either test, sole-
noid has an open circuit and is defective.
Fig. 13 Starter Relay Location
.
BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
8A - 13
Fig. 14 STARTER RELAY TESTS
8A - 14
BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
.
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