2002 CHRYSLER VOYAGER Starter motor

(3) To disable the ignition and fuel systems, dis-
connect the Automatic Shutdown Relay (ASD). The
ASD relay is located in the Power Distribution Cen-
ter (PDC). Refer to the PDC cover for proper relay
location.
(4) Verify that all lights and accessories are OFF,
and the transmission shift selector is in the PARK
and SET parking brake.
CAUTION: Do not overheat the starter motor or
draw the battery voltage below 9.6 volts during
cranking operations.
(5) Rotate and hold the ignition switch in the
START position. Observe the volt-ampere tester (Fig.
3).
²If voltage reads above 9.6 volts, and amperage
draw reads above 280 amps, check for engine seizing
or faulty starter.
²If voltage reads 12.4 volts or greater and amper-
age reads 0 to 10 amps, check for corroded cables
and/or bad connections.
²Voltage below 9.6 volts and amperage draw
above 300 amps, the problem is the starter. Replace
the starter refer to starter removal.
(6) 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 ASD relay. Start the vehicle
several times to assure the problem has been cor-
rected.SPECIFICATIONS
STARTER
MANUFACTURER NIPPONDENSO
Engine Application 2.4L /3.3/3.8L
Power rating 1.2 Kw
Voltage 12 VOLTS
No. of Fields 4
No. of Poles 4
Brushes 4
Drive Conventional Gear Train
Free running Test
Voltage 11
Amperage Draw 73 Amp
Minimum Speed 3401 RPM
SolenoidClosing Voltage 7.5 Volts
Cranking Amperage Draw
test150 - 200 Amps.
Engine should be up to operating temperature.
Extremely heavy oil or tight engine will increase
starter amperage draw.
Torques
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Starter Mounting Bolts 47.4 35
Starter Solenoid Battery Nut 11.3 8.3 100
RGSTARTING8Fa-37
STARTING (Continued)
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STARTER MOTOR
REMOVAL
REMOVAL - 2.4L
(1) Release hood latch and open hood (Fig. 4).
(2) Disconnect and isolate the battery negative
cable.
(3) Disconnect solenoid wire connector from termi-
nal (Fig. 5).
(4) Remove nut holding B+ wire to terminal.
(5) Disconnect solenoid and B+ wires from starter
terminals.
(6) Remove the lower bolt.
(7) Remove the upper bolt and ground wire (Fig.
6).
(8) Remove starter.
Fig. 4 STARTER 2.4L
Fig. 5 BATTERY CABLE AND FIELD WIRE 2.4L
Fig. 6 Upper Bolt and Ground Wire
8Fa - 38 STARTINGRG
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REMOVAL - 3.3/3.8L
(1) Release hood latch and open hood.
(2) Disconnect and isolate the battery negative
cable.
(3) Hoist and support vehicle on safety stands.
(4) Remove nut holding B+ terminal to starter
solenoid (Fig. 7).
(5) Disconnect solenoid connector from starter.
(6) Remove bolts holding starter to transaxle bell-
housing (Fig. 8).(7) Remove starter from bellhousing (Fig. 9).
(8) Separate starter spacer from transaxle bell-
housing.
REMOVAL - 3.5L
(1) Disconnect the negative battery cable.
(2) Raise vehicle and support
(3) Disconnect the battery positive cable at starter
(Fig. 10).
Fig. 7 Starter
1 - SOLENOID CONNECTOR
2 - B+ CONNECTOR
Fig. 8 Starter Bolts
1-STARTER
2 - STARTER BOLTS
3 - TRANSAXLE
4 - ENGINE MOUNT
Fig. 9 STARTER 3.3/3.8L
1 - BELL HOUSING PLATE
2 - FLYWHEEL
3 - ENGINE MOUNT
4-STARTER
5 - SPACER
Fig. 10 ELECTRICAL CONNECTIONS
RGSTARTING8Fa-39
STARTER MOTOR (Continued)
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(4) Disconnect the solenoid connector (Fig. 10).
(5) Turn front wheels to the left and use long
extension to reach the upper mounting bolt (Fig. 11).
(6) Remove the ground wires from the upper
mounting bolt.
(7) Remove the upper mounting bolt.
(8) Remove the middle mounting bolts (Fig. 12).(9) Remove the lower mounting bolt (Fig. 13).
(10) Remove starter.
REMOVAL - 2.5L
(1) Disconnect the negative battery cable.
(2) Raise vehicle and support.
(3) Remove the lower engine splash shield.
(4) Remove the electrical connectors from the
starter (Fig. 14).
Fig. 11 STARTER BOLTS AND STUD
Fig. 12 MIDDLE BOLT
Fig. 13 LOWER BOLT
Fig. 14 STARTER LOCATION
8Fa - 40 STARTINGRG
STARTER MOTOR (Continued)
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(5) Remove the starter mounting bolts (Fig. 15).
(6) Remove the starter.
INSTALLATION
INSTALLATION - 2.4L
(1) Place starter in position on vehicle.
(2) Install the lower bolts to hold starter to trans-
axle bellhousing.
(3) Install the upper bolt and ground wire (Fig. 6).
(4) Place solenoid and B+ wires in position on
starter terminals (Fig. 5).
(5) Install nut to hold B+ wire to terminal.
(6) Connect solenoid wire connector onto terminal.
(7) Connect battery negative cable.(8) Verify starter operation.
INSTALLATION - 3.3/3.8L
(1) Place starter spacer in position on transaxle
bellhousing, flange toward flywheel.
(2) Place starter in position on bellhousing.
(3) Install bolts and ground wire (Fig. 6) to hold
starter to transaxle bellhousing.
(4) Connect solenoid connector into starter.
(5) Install nut to hold B+ terminal to starter sole-
noid.
(6) Lower vehicle.
(7) Connect battery negative cable.
(8) Verify starter operation.
INSTALLATION - 3.5L
(1) Install starter.
(2) Install the middle (Fig. 12) and lower (Fig. 13)
mounting bolts.
Turn front wheels to the left and use long exten-
sion to reach the upper mounting bolt (Fig. 11).
(3) Install the upper mounting bolt.
(4) Install the ground wires to the upper mounting
bolt.
(5) Connect the solenoid connector (Fig. 10).
(6) Connect the battery positive cable at starter
(Fig. 10).
(7) Lower vehicle.
(8) Connect the negative battery cable.
INSTALLATION - 2.5L
(1) Raise vehicle and support.
(2) Install the starter.
(3) Install the starter mounting bolts (Fig. 15).
(4) Install the electrical connectors to the starter
(Fig. 14).
(5) Install the lower engine splash shield.
(6) Connect the negative battery cable.
(7) Lower vehicle.
Fig. 15 STARTER MOUNTING BOLTS
1 - Starter
2 - Mounting Bolts
RGSTARTING8Fa-41
STARTER MOTOR (Continued)
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Component Page
Mid Reading Lamps.................... 8W-44
Mode Door Actuator.................... 8W-42
Multi- Function Switch........... 8W-50, 52, 53
Output Speed Sensor................... 8W-31
Overhead Console..................... 8W-49
Oxygen Sensor 1/1 Upstream............. 8W-30
Oxygen Sensor 1/2 Downstream.......... 8W-30
Park Lamp Relay...................... 8W-10
Park Lamps.......................... 8W-50
Park/Turn Signal Lamps................ 8W-50
Parking Brake Switch.................. 8W-40
Passenger Airbag...................... 8W-43
Positive Temperature Coefficients......... 8W-10
Power Liftgate Module.................. 8W-61
Power Liftgate Motor................... 8W-61
Power Mirror Switch................... 8W-62
Power Mirrors........................ 8W-62
Power Outlet......................... 8W-41
Power Seat Circuit Breaker.............. 8W-10
Power Seat Front Riser Motors........... 8W-63
Power Seat Horizontal Motors............ 8W-63
Power Seat Horizontal Position Sensors.... 8W-63
Power Seat Rear Riser Motors............ 8W-63
Power Seat Rear Riser Position Sensors.... 8W-63
Power Seat Recliner Motors.............. 8W-63
Power Seat Switches................... 8W-63
Power Window Circuit Breaker........... 8W-10
Power Window Motors.................. 8W-60
Power Window Switches................ 8W-60
Powertrain Control Module.............. 8W-30
Radiator Fan Relays................... 8W-42
Radiator Fans........................ 8W-42
Radio Choke.......................... 8W-47
Radio............................... 8W-47
Reading Lamps....................... 8W-44
Rear A/C-Heater Unit.................. 8W-42
Rear Auto Temp Control Switch........... 8W-42
Rear Blower Front Control Switch......... 8W-42
Rear Blower Motor Power Module......... 8W-42
Rear Blower Motor Relay................ 8W-42
Rear Blower Motor..................... 8W-42
Rear Blower Rear Control Switch......... 8W-42
Rear Intrusion Sensor.................. 8W-39Component Page
Rear Lamp Assemblies.................. 8W-51
Rear Mode Motor...................... 8W-42
Rear Power Outlet..................... 8W-41
Rear Temperature Motor................ 8W-42
Rear Washer Pump Motor............... 8W-53
Rear Window Defogger Grid............. 8W-48
Recirculation Door Actuator.............. 8W-42
Remote Keyless Entry Antenna........... 8W-61
Remote Radio Switches................. 8W-47
Repeater Lamps....................... 8W-52
Seat Airbag.......................... 8W-43
Seat Belt Tensioners................... 8W-43
Sentry Key Immobilizer Module.......... 8W-39
Side Impact Airbag Control Modules....... 8W-43
Siren............................... 8W-39
Sliding Door Control Modules............ 8W-61
Sliding Door Latch Sensing Switches....... 8W-61
Sliding Door Lock Motor/Ajar Switches..... 8W-61
Sliding Door Lock Motors............... 8W-61
Sliding Door Motors.................... 8W-61
Solenoid/Pressure Switch Assy............ 8W-31
Speakers............................ 8W-47
Speed Control Servo................... 8W-33
Speed Control Switches................. 8W-33
Splice Information..................... 8W-70
Starter Motor Relay.................... 8W-21
Starter Motor......................... 8W-21
Stop/Turn Signal Relays................ 8W-54
Thatcham Alarm Module................ 8W-39
Throttle Position Sensor................ 8W-30
Torque Converter Clutch Solenoid......... 8W-31
Traction Control Switch................. 8W-35
Trailer Tow Connector.................. 8W-54
Transmission Control Module............ 8W-31
Transmission Range Sensor.............. 8W-31
Turn Signal Lamps.................... 8W-52
TXV Solenoid......................... 8W-42
Vehicle Speed Sensor................... 8W-30
Vent Motors.......................... 8W-60
Visor/Vanity Lamps.................... 8W-44
Washer Fluid Level Switch.............. 8W-53
Water In Fuel Sensor................... 8W-30
Wheel Speed Sensors................... 8W-35
8W - 02 - 2 8W-02 COMPONENT INDEXRS
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Component Page
Headlamp Washer Pump Motor....... 8W-10-26, 52
Headlamp Washer Relay......... 8W-10-26, 52, 63
High Note Horn..................... 8W-10-36
Horn Relay................... 8W-10-17, 36, 59
Ignition Coil........................ 8W-10-42
Ignition Switch . . 8W-10-18, 25, 37, 45, 46, 48, 53, 54,
60
Instrument Cluster................ 8W-10-25, 51
Integrated Power Module . . . 8W-10-3, 4, 5, 13, 15, 16,
17, 18, 19, 20, 21, 22, 23,
24, 25, 26, 27, 28, 29, 30,
31, 32, 33, 36, 37, 38, 39,
40, 41, 42, 43, 44, 45, 46,
47, 48, 49, 51, 52, 53, 54,
55, 56, 57, 58, 59, 60, 61,
62, 63, 64, 65, 66, 68
Leak Detection Pump................. 8W-10-46
Left B-Pillar Switch.................. 8W-10-33
Left Combination Relay............... 8W-10-67
Left Fog Lamp................... 8W-10-15, 27
Left Front Park/Turn Signal
Lamp................... 8W-10-15, 28, 56, 65
Left Headlamp...................... 8W-10-57
Left Headlamp Leveling Motor..... 8W-10-29, 62, 65
Left High Beam Lamp................ 8W-10-58
Left Low Beam Lamp................. 8W-10-58
Left Park Lamp................... 8W-10-29, 65
Left Power Mirror.................... 8W-10-39
Left Rear Lamp Assembly . . . 8W-10-28, 29, 65, 66, 67
Left Repeater Lamp.................. 8W-10-51
Left Side Impact Airbag Control Module . . . 8W-10-62
Left Sliding Door Control Module........ 8W-10-52
Left Stop/Turn Signal Relay............ 8W-10-67
Left Turn Signal Lamp................ 8W-10-56
License Lamp................. 8W-10-28, 29, 65
Lift Pump Motor.................. 8W-10-23, 43
Lift Pump Relay.................. 8W-10-23, 43
Low Note Horn...................... 8W-10-36
Mass Air Flow Sensor................. 8W-10-44
Memory Seat/Mirror Module............ 8W-10-49
Message Center..................... 8W-10-51
Name Brand Speaker Relay....... 8W-10-20, 39, 59
Overhead Console.................... 8W-10-40
Oxygen Sensor 1/1 Upstream........... 8W-10-42
Oxygen Sensor 1/2 Downstream......... 8W-10-42
Park Lamp Relay............ 8W-10-15, 28, 29, 59
Park/Neutral Position Switch........... 8W-10-65
Passenger Door Lock Switch......... 8W-10-31, 33
Passenger Folding Mirror Relay . 8W-10-22, 24, 45, 47
Passenger Heated Seat Module.......... 8W-10-50
Passenger Power Seat Switch........... 8W-10-50
Passenger Power Window Switch........ 8W-10-31
Power Liftgate Module............. 8W-10-26, 52
Power Mirror Switch......... 8W-10-22, 24, 46, 47
Power Outlet....................... 8W-10-36
Component Page
Power Seat Circuit Breaker.......... 8W-10-25, 49
Power Window Circuit Breaker....... 8W-10-16, 31
Power Window Switch................. 8W-10-34
Powertrain Control
Module.... 8W-10-18, 21, 22, 37, 41, 42, 45, 46, 55
PTC4 .......................... 8W-10-20, 39
PTC7 .................... 8W-10-16, 17, 18, 36
Radiator Fan Relay............. 8W-10-26, 51, 55
Radiator Fan Relay No. 1........... 8W-10-13, 44
Radiator Fan Relay No. 2......... 8W-10-26, 44, 51
Radiator Fan Relay No. 3.............. 8W-10-44
Radio.......................... 8W-10-32, 40
Radio Choke..................... 8W-10-20, 39
Rear A/C-Heater Unit.............. 8W-10-19, 38
Rear Blower Motor Power Module..... 8W-10-19, 38
Rear Blower Motor Relay...... 8W-10-19, 20, 38, 63
Rear Power Outlet.............. 8W-10-16, 31, 32
Rear Washer Pump Motor........ 8W-10-16, 31, 68
Rear Window Defogger Grid......... 8W-10-20, 39
Rear Wiper Motor.................... 8W-10-33
Remote Keyless Entry Module........... 8W-10-40
Right B-Pillar Switch................. 8W-10-33
Right Combination Relay.............. 8W-10-67
Right Fog Lamp.................. 8W-10-15, 27
Right Front Park/Turn Signal
Lamp................... 8W-10-15, 28, 56, 60
Right Headlamp..................... 8W-10-57
Right Headlamp Leveling Motor.... 8W-10-29, 60, 62
Right High Beam Lamp............... 8W-10-58
Right Low Beam Lamp................ 8W-10-58
Right Park Lamp................. 8W-10-29, 60
Right Power Mirror................... 8W-10-39
Right Rear Lamp Assembly.... 8W-10-15, 28, 29, 66
Right Repeater Lamp................. 8W-10-51
Right Side Impact Airbag Control Module . . 8W-10-62
Right Sliding Door Control Module....... 8W-10-52
Right Stop/Turn Signal Relay........... 8W-10-67
Right Turn Signal Lamp............... 8W-10-56
Sentry Key Immobilizer
Module............... 8W-10-40, 46, 48, 53, 54
Solenoid/Pressure Switch Assy.......... 8W-10-41
Starter Motor............... 8W-10-13, 14, 18, 37
Starter Motor Relay.......... 8W-10-18, 37, 53, 54
Thatcham Alarm Module...... 8W-10-46, 48, 54, 68
Torque Converter Clutch Solenoid........ 8W-10-46
Trailer Tow Connector.............. 8W-10-28, 65
Transmission Control
Module............ 8W-10-18, 21, 37, 41, 61, 62
Transmission Control Relay.......... 8W-10-21, 41
Transmission Range Sensor............. 8W-10-65
TXV Solenoid....................... 8W-10-38
Vehicle Speed Sensor................. 8W-10-43
Washer Fluid Level Switch............. 8W-10-60
Wiper Module................. 8W-10-16, 30, 59
8W - 10 - 2 8W-10 POWER DISTRIBUTIONRS
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8W-20 CHARGING SYSTEM
Component Page
Auto Shut Down Relay................ 8W-20-2
Battery.......................... 8W-20-2, 3
Battery Temperature Sensor............ 8W-20-3
ECM/PCM Relay..................... 8W-20-3
Engine Control Module................ 8W-20-3
Fuse 16.......................... 8W-20-2, 3
Fuse 17............................ 8W-20-2Component Page
Fuselink......................... 8W-20-2, 3
G100............................ 8W-20-2, 3
G101............................ 8W-20-2, 3
Generator........................ 8W-20-2, 3
Integrated Power Module............ 8W-20-2, 3
Powertrain Control Module............. 8W-20-2
Starter Motor..................... 8W-20-2, 3
RS8W-20 CHARGING SYSTEM8W-20-1
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