2005 CHRYSLER CARAVAN steering

REMOTE RADIO SWITCH TEST
Switch Switch Position Resistance
Right
(White)Volume Up 1.210 Kilohms
Right
(White)Volume Down 3.010 Kilohms
Right
(White)Mode Advance 0.0511 Kilohms
Left
(Black)Seek Up 0.261 Kilohms
Left
(Black)Seek Down 0.681 Kilohms
Left
(Black)Pre-Set Station
Advance0.162 Kilohms
NOTE: The right remote radio switch back is white
in color. The left switch back is black in color. The
right/left remote radio switch orientation is with the
steering wheel installed, and driver in drivers seat.
(4) If the switch resistance checks OK, go to Step
5. If not OK, replace the faulty switch.
(5) Check for continuity between the ground cir-
cuit cavity of the switch wire harness connector and
a good ground. There should be continuity. If OK, go
to Step 6. If not OK, repair the open circuit as
required.
(6) Unplug the 24-way white wire harness connec-
tor from the Body Control Module (BCM). Check for
continuity between the radio control circuit cavity of
the remote radio switch wire harness connector and a
good ground. There should be no continuity. If OK, go
to Step 7. If not OK, repair the short circuit as
required.
(7) Check for continuity between the radio control
circuit cavities of the remote radio switch wire har-
ness connector and the BCM wire harness connector.
There should be continuity. If OK, refer to the proper
Diagnostic Procedures manual to test the BCM and
the PCI data bus. If not OK, repair the open circuit
as required.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY 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.(1) Disconnect and isolate the battery negative
cable.
(2) Remove the driver side airbag (Refer to 8 -
ELECTRICAL/RESTRAINTS/DRIVER AIRBAG -
REMOVAL).
(3) Remove the steering wheel (Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
REMOVAL).
(4) Unplug the wire harness connector from the
remote radio switch (es).
(5) Remove three screws securing steering wheel
rear cover.
(6) Remove the remote radio switch from the steer-
ing wheel by depressing tabs on each side of each
switch.
NOTE: The right remote radio switch back is white
in color. The left switch back is black in color. The
right/left remote radio switch orientation is with the
steering wheel installed, and driver in drivers seat.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY 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.
(1) Install remote radio switch to the steering
wheel.
(2) Install three screws securing steering wheel
rear cover.
(3) Connect the wire harness to the remote radio
switch.
(4) Install the steering wheel (Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
INSTALLATION).
(5) Install the driver side airbag (Refer to 8 -
ELECTRICAL/RESTRAINTS/DRIVER AIRBAG -
INSTALLATION).
(6) Connect the battery negative cable.
RSAUDIO/VIDEO8A-17
REMOTE SWITCHES (Continued)

SPEAKER
DIAGNOSIS AND TESTING
SPEAKER
WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, SEAT BELT TENSIONER, SIDE
AIRBAG, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
Any diagnosis of the Audio system should
begin with the use of the DRB IIItdiagnostic
tool. For information on the use of the DRB
IIIt, refer to the appropriate Diagnostic Service
Manual.
(1) If all speakers are inoperative, check the radio
fuses in the Junction Block (JB). If OK, go to Step 2.
If not OK, repair the shorted circuit or component as
required and replace the faulty fuse.
(2) Check the amplifier fuse (if equipped) in the
junction block. If OK, go to Step 3. If not OK, repair
the shorted circuit or component as required and
replace the faulty fuse.
(3) Turn the ignition switch to the ON position.
Turn the radio receiver ON. Adjust the balance and
fader control controls to check the performance of
each individual speaker. Note the speaker locations
that are not performing correctly. Go to Step 4.
(4) Turn the radio receiver OFF. Turn the ignition
OFF. Disconnect and isolate the battery negative
cable. If vehicle isnotequipped with a amplifier,
remove the radio receiver. If vehicle is equipped with
an amplifier. disconnect wire harness connector at
output side of amplifier. Go to Step 4.
(5) Check both the speaker feed (+) circuit and
return (-) circuit cavities for the inoperative speaker
at the radio receiver wire harness connector for con-
tinuity to ground. There should be no continuity. If
OK, go to Step 5. If not OK, repair the shorted
speaker feed (+) and/or return (-) circuits(s) to the
speaker as required.(6) Disconnect wire harness connector at the inop-
erative speaker. Check for continuity between the
speaker feed (+) circuit cavities of the radio receiver
wire harness connector or if equipped, the amplifier
wire harness connector and the speaker wire harness
connector. Repeat the check between the speaker
return (-) circuit cavities of the radio receiver wire
harness connector and the speaker wire harness con-
nector. In each case, there should be continuity. If
OK, replace the faulty speaker. If not OK, repair the
open speaker feed (+) and/or return (-) circuits(s) as
required.
REMOVAL
D-PILLAR SPEAKER
(1) Disconnect and isolate the battery negative
cable.
(2) Remove rear header trim (right side speaker).
(3) Remove jack cover (left side speaker).
(4) Remove liftgate scuff plate.
(5) Remove upper seat belt bolt. (Refer to 8 -
ELECTRICAL/RESTRAINTS/SEAT BELT OUT-
BOARD FRONT - REMOVAL).
(6) Partially remove quarter trim panel to access
the D-pillar speaker.
(7) Slide the speaker from the retainer (Fig. 17).
(8) Disconnect the wire harness connector from the
speaker.
Fig. 17 D-PILLAR SPEAKER
1 - SPEAKER
2 - RETAINER
3 - TRIM PANEL
8A - 18 AUDIO/VIDEORS

PARK ASSIST SYSTEM
The Park Assist System display activates an audi-
ble tone that changes from intermittent to continu-
ous as the final two Light Emitting Diodes (LED's)
are illuminated on one side or both sides of the dis-
play.
The system detection length from the rear of the
vehicle is 0.3 meters to 1.5 meters. This area extends
around the rear side of the vehicle. The system detec-
tion height from the ground is 0.2 meters to about
1.5 meters. The radio mutes when the system acti-
vates its audible tone.
When the driver selects Reverse the system scans
for objects behind the vehicle using four sensors
located in the rear bumper. A warning display above
the rear window provides both visible and audible
warnings indicating the range of the object.
The system is active only when the transmission
gear selector is in reverse for vehicle speeds less than
16 Km/h (10 mph). If the vehicle's Parking/Emer-
gency Brake is applied, the system is deactivated.
The display contains two sets of yellow and red
Light Emitting Diode's (LED's) that the driver can
see as they look over their shoulder while backing
up. Each side of the vehicle has its own warning
LED's. The system provides a visual warning by illu-
minating one or more yellow LED's as the vehicle
gets closer to the object. As the vehicle continues to
approach the object, one red LED is illuminated and
the system emits a series of short beeps. The tone
will remain constant and both red LED's are illumi-
nated once the vehicle is within 12 inches (30.5 cm)
of the object.
The system can be turned ON or OFF through the
Electronic Vehicle Information Center (EVIC) when
the vehicle is in PARK. If the park assist system is
turned OFF, a single chime will sound and the EVIC
will display the following message ªREAR PARK
ASSIST OFFº, when the vehicle is in reverse.
²Ensure that the rear bumper is free of dirt and
debris to keep the system operating properly.
²Jackhammers, large trucks, and other vibrations
could affect the performance of the system.
²Ensure that the parking brake is not applied.
If ªService Park Assist Systemº appears in the
EVIC after making sure the rear bumper is clean,
proceed to diagnose the system using a scan tool and
the appropriate diagnostic information.
WARNING
On vehicles equipped with airbags, disable
the airbag system before attempting any steer-
ing wheel, steering column, or instrument
panel component diagnosis or service. Discon-
nect and isolate the battery negative (ground)
cable, then wait two minutes for the airbag sys-
tem capacitor to discharge before performing
further diagnosis or service. This is the only
sure way to disable the airbag system. Failure
to take the proper precautions could result in
accidental airbag deployment, personal injury,
or death.
DIAGNOSIS AND TESTING - CHIME SYSTEM
Refer to the proper Body Diagnostic Procedures
manual for complete Diagnosis and Testing of the
Chime System.
NO TONE WHEN IGNITION SWITCH IS TURNED ON
AND DRIVER'S SEAT BELT IS NOT BUCKLED.
(1) Using a DRB llltscan tool, actuate chime
(BCM actuates).
(2) Using a voltmeter, check for voltage:
(a) BCM has two battery feeds at pin 1 and pin
5 of the 6±way connector.
(b) Pin 5 of the (BX2) 32 way connector of the
BCM for ignition feed.
(c) Check voltage (PX2) connector, pin 34 for 12v.
(d) If voltage OK, go to step Step 3
(e) If NO voltage repair as necessary. Refer to
the appropriate wiring information. The wiring
information includes wiring diagrams, proper wire
and connector repair procedures, further details on
wire harness routing and retention, as well as pin-
out and location views for the various wire harness
connectors, splices and grounds.
(3) Check drivers seat belt buckle switch input
(from Occupant Restraint Controller (ORC) for a
closed circuit when not buckled. If input not seen,
look for open in wiring or switch. The switch is
grounded when belt is not buckled.
(4) Verify Programmable Communication Interface
(PCI) data bus communication between ORC and
BCM.
8B - 2 CHIME/BUZZERRS
CHIME/BUZZER (Continued)

INSTALLATION
(1) Install the Power Liftgate (PLG) control mod-
ule on the D-pillar and install retaining screw.
(2) Connect the wire harness connections to the
PLG control module. Be certain to slide connector
locks to the locked position.
(3) Install the D-pillar trim panel on the vehicle.
(Refer to 23 - BODY/INTERIOR/LEFT D-PILLAR
TRIM PANEL - INSTALLATION)
(4) Connect the battery negative cable.
(5) Using an appropriate scan tool, check and
erase any PLG control module diagnostic trouble
codes.
(6) Verify PLG system operation. Cycle the PLG
through one complete open and close cycle, this will
allow the PLG control module to relearn its cycle
with the new components.
POWERTRAIN CONTROL
MODULE
DESCRIPTION
DESCRIPTION
The Powertrain Control Module (PCM) is a digital
computer containing a microprocessor (Fig. 9). ThePCM receives input signals from various switches
and sensors referred to as Powertrain Control Mod-
ule Inputs. Based on these inputs, the PCM adjusts
various engine and vehicle operations through
devices referred to as Powertrain Control Module
Outputs.
NOTE: PCM Inputs:
²Air Conditioning Pressure Transducer
²Ambient temperature Sensor
²ASD Relay
²Battery Temperature Sensor (NGC)
²Battery Voltage
²Brake Switch
²Camshaft Position Sensor
²Crankshaft Position Sensor
²Distance Sensor (from transmission control mod-
ule)
²EGR Position Feedback
²Engine Coolant Temperature Sensor
²Heated Oxygen Sensors
²Ignition sense
²Intake Air Temperature Sensor
²Knock Sensor
²Leak Detection Pump Feedback
²Manifold Absolute Pressure (MAP) Sensor
²Park/Neutral
²PCI Bus
²Power Steering Pressure Switch
²Proportional Purge Sense
Fig. 8 POWER LIFTGATE CONTROL MODULE
1 - POWER LIFTGATE CONTROL MODULE
2 - RETAINING SCREWS
3 - D-PILLAR
4 - POWER LIFTGATE MOTOR
5 - ELECTRICAL CONNECTORS
Fig. 9 Powertrain Control Module (PCM)
1 - Battery
2 - Power Distribution Center
3 - Powertrain Control Module
RSELECTRONIC CONTROL MODULES8E-11
POWER LIFTGATE CONTROL MODULE (Continued)

The power grounds are used to control the ground
side relays, solenoids, ignition coil or injectors. The
signal ground is used for any input that uses sensor
return for ground, and the ground side of any inter-
nal processing component.
The PCM case is shielded to prevent RFI and EMI.
The PCM case is grounded and must be firmly
attached to a good, clean body ground.
Internally all grounds are connected together, how-
ever there is noise suppression on the sensor ground.
For EMI and RFI protection the housing and cover
are also grounded separately from the ground pins.
OPERATION - 5 VOLT SUPPLY - PCM OUTPUT
The PCM supplies 5 volts to the following sensors:
²A/C pressure transducer
²Ambient Temperature sensor
²Battery temperature
²Camshaft Position Sensor (NGC)
²Crankshaft Position Sensor (NGC)
²Engine coolant temperature sensor
²Inlet Air Temperature Sensor
²Knock sensor
²Linear EGR solenoid (if equipped)
²Manifold absolute pressure sensor
²Oil Pressure Switch
²Throttle position sensor
STANDARD PROCEDURE
STANDARD PROCEDURE - OBTAINING
DIAGNOSTIC TROUBLE CODES
BULB CHECK
Key on: Bulb illuminated until vehicle starts, as
long as all once per trip (readiness) monitors com-
pleted. If monitors havenotbeen completed, then:
Key on: bulb check for about 5 to 8 seconds, lamp
then flashes if once per trip (readiness) monitors
havenotbeen completed until vehicle is started,
then MIL is extinguished.
OBTAINING DTC'S USING DRB SCAN TOOL
(1) Connect the DRB scan tool to the data link
(diagnostic) connector. This connector is located in
the passenger compartment; at the lower edge of
instrument panel; near the steering column.
(2) Turn the ignition switch on and access the
ªRead Faultº screen.
(3) Record all the DTC's and ªfreeze frameº infor-
mation shown on the DRB scan tool.
(4) To erase DTC's, use the ªErase Trouble Codeº
data screen on the DRB scan tool.Do not erase any
DTC's until problems have been investigated
and repairs have been performed.
STANDARD PROCEDURE - PINION FACTOR
SETTING
NOTE: This procedure must be performed if the
PCM has been replaced with a NEW or replacement
unit. Failure to perform this procedure will result in
an inoperative or improperly calibrated speedome-
ter.
The vehicle speed readings for the speedometer are
taken from the output speed sensor. The PCM must
be calibrated to the different combinations of equip-
ment (final drive and tires) available. Pinion Factor
allows the technician to set the Powertrain Control
Module initial setting so that the speedometer read-
ings will be correct. To properly read and/or reset the
Pinion Factor, it is necessary to use a DRBIIItscan
tool.
(1) Plug the DRBIIItscan tool into the diagnostic
connector located under the instrument panel.
(2) Select the Transmission menu.
(3) Select the Miscellaneous menu.
(4) Select Pinion Factor. Then follow the instruc-
tions on the DRBIIItscan tool screen.
STANDARD PROCEDURE - QUICK LEARN
PROCEDURE
The quick learn procedure requires the use of the
DRBIIItscan tool. This program allows the PCM to
recalibrate itself. This will provide the best possible
transaxle operation.
NOTE: The quick learn procedure should be per-
formed if any of the following procedures are per-
formed:
²Transaxle Assembly Replacement
²Powertrain Control Module Replacement
²Solenoid/Pressure Switch Assembly Replacement
²Clutch Plate and/or Seal Replacement
²Valve Body Replacement or Recondition
To perform the Quick Learn Procedure, the follow-
ing conditions must be met:
²The brakes must be applied
²The engine speed must be above 500 rpm
²The throttle angle (TPS) must be less than 3
degrees
²The shift lever position must stay until
prompted to shift to overdrive
²The shift lever position must stay in overdrive
after the Shift to Overdrive prompt until the
DRBIIItindicates the procedure is complete
²The calculated oil temperature must be above
60É and below 200É
RSELECTRONIC CONTROL MODULES8E-15
POWERTRAIN CONTROL MODULE (Continued)

STARTING
TABLE OF CONTENTS
page page
STARTING
DESCRIPTION.........................31
OPERATION...........................31
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - STARTING
SYSTEM TEST.......................31
DIAGNOSIS AND TESTING - CONTROL
CIRCUIT TEST........................33
DIAGNOSIS AND TESTING - FEED CIRCUIT
RESISTANCE TEST....................35
DIAGNOSIS AND TESTING - FEED CIRCUIT
TEST...............................36SPECIFICATIONS
Torques.............................36
STARTER ...........................37
STARTER MOTOR
REMOVAL
REMOVAL - 2.4L......................37
REMOVAL - 3.3/3.8L...................38
REMOVAL - 2.5L......................38
INSTALLATION
INSTALLATION - 2.4L..................39
INSTALLATION - 3.3/3.8L................39
INSTALLATION - 2.5L..................39
STARTING
DESCRIPTION
The starting system consists of:
²Starter relay
²Starter motor (including an integral starter sole-
noid)
Other components to be considered as part of start-
ing system are:
²Battery
²Battery cables
²Ignition switch and key lock cylinder
²Clutch pedal position switch (manual transmis-
sion)
²Park/neutral position switch (automatic trans-
mission)
²Wire 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:
²Battery- 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
RSSTARTING8F-31

the battery, if required. Refer to the Battery section
for more information.
²Ignition Switch- Visually inspect the ignition
switch for indications of physical damage and loose
or corroded wire harness connections.
²Transmission 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.
²Starter Relay- Visually inspect the starter
relay for indications of physical damage and loose or
corroded wire harness connections.
²Starter Motor- Visually inspect the starter
motor for indications of physical damage and loose or
corroded wire harness connections.²Starter Solenoid- Visually inspect the starter
solenoid for indications of physical damage and loose
or corroded wire harness connections.
²Wiring- 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.
²Power 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.
8F - 32 STARTINGRS
STARTING (Continued)

CONDITION POSSIBLE CAUSE CORRECTION
2. STARTING CIRCUIT
WIRING FAULTY.2. REFER TO THE FEED CIRCUIT RESISTANCE TEST AND
THE FEED CIRCUIT TEST IN THIS SECTION. REPAIR AS
NECESSARY.
3. STARTER ASSEMBLY
FAULTY.3. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
4. ENGINE SEIZED. 4. REFER TO THE ENGINE SECTION, FOR DIAGNOSTIC AND
SERVICE PROCEDURES.
5. LOOSE
CONNECTION AT
BATTERY, PDC,
STARTER, OR ENGINE
GROUND.5. INSPECT FOR LOOSE CONNECTIONS.
6. FAULTY TEETH ON
RING GEAR.6. ROTATE FLYWHEEL 360É, AND INSPECT TEETH AND RING
GEAR REPLACED IF DAMAGED.
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. THIS MAY RESULT IN
PERSONAL INJURY OR DEATH.
(1) Verify battery condition. Battery must be in
good condition with a full charge before performing
any starter tests. Refer to Battery Tests.
RSSTARTING8F-33
STARTING (Continued)