2004 CHRYSLER VOYAGER Service Manual

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Page 481 of 2585

CHRYSLER VOYAGER 2004 Service Manual (9) Remove accessory drive belt, refer to the Cool-
ing System section for proper procedures. (10) Remove the generator.
REMOVAL - 2.5L
(1) Disconnect the negative battery cable (Fig. 1).
(2) Remove t

Page 482 of 2585

CHRYSLER VOYAGER 2004 Service Manual REMOVAL - 3.3/3.8L
(1) Release hood latch and open hood.
(2) Disconnect battery negative cable.
(3) Disconnect the push-in field wire connector
from back of generator. (4) Remove nut holding B+ wire t

Page 483 of 2585

CHRYSLER VOYAGER 2004 Service Manual (11) Remove the 3 mounting bolts.
(12) Lower vehicle.
(13) Remove oil dip stick tube from vehicle.
(14) Roll and remove the generator from vehicle
(Fig. 10).
INSTALLATION
INSTALLATION - 2.4L
(1) Insta

Page 484 of 2585

CHRYSLER VOYAGER 2004 Service Manual (11) Install accessory drive belt, refer to the Cool-
ing System section for proper procedures. (12) Install the right front lower splash shield.
(13) Lower vehicle.
(14) Install wiring harness to the

Page 485 of 2585

CHRYSLER VOYAGER 2004 Service Manual REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect battery negative cable.
(3) Raise vehicle and support.
(4) Remove the right front lower splash shield.
(5) Remove accessory drive belt, ref

Page 486 of 2585

CHRYSLER VOYAGER 2004 Service Manual 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

Page 487 of 2585

CHRYSLER VOYAGER 2004 Service Manual STARTING
TABLE OF CONTENTS
page page
STARTING DESCRIPTION .........................30
OPERATION ...........................30
DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - STARTINGSYSTEM TEST ........

STARTING
TABLE OF CONTENTS
page page
STARTING DESCRIPTION .........................30
OPERATION ...........................30
DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - STARTINGSYSTEM TEST .......................30
DIAGNOSIS AND TESTING - CONTROL CIRCUIT TEST ........................32
DIAGNOSIS AND TESTING - FEED CIRCUIT RESISTANCE TEST ....................34
DIAGNOSIS AND TESTING - FEED CIRCUIT TEST ...............................35 SPECIFICATIONS
Torques .............................35
STARTER ...........................36
STARTER MOTOR REMOVAL REMOVAL - 2.4L ......................36
REMOVAL - 3.3/3.8L ...................36
REMOVAL - 2.5L ......................36
INSTALLATION INSTALLATION - 2.4L ..................37
INSTALLATION - 3.3/3.8L ................37
INSTALLATION - 2.5L ..................38
STARTING
DESCRIPTION
The starting system consists of:
²Starter relay
² Starter motor (including an integral starter sole-
noid) Other components to be considered as part of start-
ing system are: ² Battery
² Battery cables
² Ignition switch and key lock cylinder
² Clutch pedal position switch (manual transmis-
sion) ² Park/neutral position switch (automatic trans-
mission) ² 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.
INSPECTION
Before removing any unit from the starting system
for repair or diagnosis, perform the following inspec-
tions: ² 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
8Fs - 30 STARTINGRS

Page 488 of 2585

CHRYSLER VOYAGER 2004 Service Manual the battery, if required. Refer to the Battery section
for more information.² Ignition Switch - Visually inspect the ignition
switch for indications of physical damage and loose
or corroded wire harn

the battery, if required. Refer to the Battery section
for more information.² Ignition Switch - Visually inspect the ignition
switch for indications of physical damage and loose
or corroded wire harness connections. ² 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. ² Starter Relay - Visually inspect the starter
relay for indications of physical damage and loose or
corroded wire harness connections. ² Starter Motor - Visually inspect the starter
motor for indications of physical damage and loose or
corroded wire harness connections. ²
Starter Solenoid - Visually inspect the starter
solenoid for indications of physical damage and loose
or corroded wire harness connections. ² 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. ² 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 360É, 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.
RS
STARTING8Fs-31
STARTING (Continued)

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