2002 CHRYSLER CARAVAN jump start

CONDITION POSSIBLE CAUSE CORRECTION
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 360É, AND INSPECT TEETH AND RING
GEAR REPLACED IF DAMAGED.
DIAGNOSIS AND TESTING - CONTROL
CIRCUIT TEST
The starter control circuit has:
²Starter motor with integral solenoid
²Starter relay
²Transmission range sensor, or Park/Neutral
Position switch with automatic transmissions
²Ignition switch
²Battery
²All related wiring and connections
²Powertrain Control Module (PCM)
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
²To disable ignition and fuel systems, disconnect
the Automatic Shutdown Relay (ASD). The ASD relay
is located 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) Perform a visual inspection of the starter/
starter solenoid for corrosion, loose connections or
faulty wiring.
(4) Locate and remove the starter relay from the
Power Distribution Center (PDC). Refer to the PDC
label for relay identification and location.
(5) 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 crank or solenoid chatters,
check wiring and connectors from starter relay to
starter solenoid for loose or corroded connections.
Particularly 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. Inspect the ring gear
teeth.
STARTER RELAY
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN THE PARK/NEUTRAL POSITION
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.
8Fa - 34 STARTINGRG
STARTING (Continued)
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8W-21 STARTING SYSTEM
Component Page
Battery.......................... 8W-21-2, 3
Clutch Pedal Interlock Switch......... 8W-21-2, 3
Clutch Pedal Interlock Switch Jumper.... 8W-21-2
Engine Control Module................ 8W-21-3
Front Control Module................. 8W-21-2
Fuse 9........................... 8W-21-2, 3
Fuselink......................... 8W-21-2, 3Component Page
G101............................ 8W-21-2, 3
Generator........................ 8W-21-2, 3
Ignition Switch.................... 8W-21-2, 3
Integrated Power Module............ 8W-21-2, 3
Powertrain Control Module............. 8W-21-2
Starter Motor..................... 8W-21-2, 3
Starter Motor Relay................ 8W-21-2, 3
RS8W-21 STARTING SYSTEM8W-21-1
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CLOCKSPRING C5 - YELLOW 4 WAY
CAV CIRCUIT FUNCTION
1 R45 18OR/LB DRIVER SQUIB 1 LINE 2
2 R43 18BK/LB DRIVER SQUIB 1 LINE 1
3 R63 18TN/LB DRIVER SQUIB 2 LINE 2
4 R61 18OR/LB DRIVER SQUIB 2 LINE 1
CLUTCH PEDAL INTERLOCK SWITCH (MTX) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 T141 20YL/OR IGNITION SWITCH OUTPUT (START)
2 T751 20YL IGNITION SWITCH OUTPUT (START)
CLUTCH PEDAL INTERLOCK SWITCH JUMPER (ATX) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 T141 20YL/OR IGNITION SWITCH OUTPUT (START)
2 T751 20YL IGNITION SWITCH OUTPUT (START)
CLUTCH PEDAL UPSTOP SWITCH (DIESEL) - RED 2 WAY
CAV CIRCUIT FUNCTION
1 K119 20DB/LG CLUTCH PEDAL UPSTOP SWITCH SENSE
2 Z150 20BK/LG GROUND
RS8W-80 CONNECTOR PIN-OUTS8W-80-45
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