2005 CHRYSLER CARAVAN starter motor installation

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

(5) Remove the starter mounting bolts (Fig. 9).
(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. 4).
(4) Place solenoid and B+ wires in position on
starter terminals (Fig. 3).
(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. 4) 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 - 2.5L
(1) Raise vehicle and support.
(2) Install the starter.
(3) Install the starter mounting bolts (Fig. 9).
(4) Install the electrical connectors to the starter
(Fig. 8).
(5) Install the lower engine splash shield.
(6) Connect the negative battery cable.
(7) Lower vehicle.
Fig. 9 STARTER MOUNTING BOLTS
1 - Starter
2 - Mounting Bolts
RSSTARTING8F-39
STARTER MOTOR (Continued)

(69) Install and tighten solenoid/pressure switch
assembly-to-transaxle case bolts to 12 N´m (110 in.
lbs.) (Fig. 158).
(70) Install and torque input and output speed
sensors to case to 27 N´m (20 ft. lbs.).
INSTALLATION
NOTE: If transaxle assembly has been replaced or
overhauled (clutch and/or seal replacement), it is
necessary to perfrom the ªQuick-Learnº procedure.
(Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES/TRANSMISSION CONTROL MODULE -
STANDARD PROCEDURE)
(1) Using a transmission jack and a helper, posi-
tion transaxle assembly to engine. Install and torque
bellhousing bolts to 95 N´m (70 ft. lbs.).
(2) Install upper mount assembly to transaxle and
torque bolts to 54 N´m (40 ft. lbs.) (Fig. 159).
(3) Raise engine/transaxle assembly into position.
Install and torque upper mount-to-bracket thru-bolt
to 75 N´m (55 ft. lbs.) (Fig. 159).
(4) Remove transmission jack and screw jack.
(5) Secure left wheelhouse splash shield.
(6) Install torque converter-to-drive plate bolts and
torque to 88 N´m (65 ft. lbs.)
(7) Install inspection cover.
(8) Install lateral bending brace.
(9) Install starter motor.(10) Install front mount/bracket assembly.
(11) Align and install rear mount bracket-to-case
bolts by hand (Fig. 160). Torque horizontal bolt to
102 N´m (75 ft. lbs.).
(12) AWD models: Install power transfer unit.
(Refer to 21 - TRANSMISSION/TRANSAXLE/
POWER TRANSFER UNIT - INSTALLATION)
(13) Install left and right halfshaft assemblies.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - INSTALLATION)
(14) Install front wheel/tire assemblies.
(15) Lower vehicle.
(16) Torque remaining rear mount bracket-to-tran-
saxle vertical bolts (Fig. 160) to 102 N´m (75 ft. lbs.).
(17) Install transaxle upper bellhousing-to-block
bolts and torque to 95 N´m (70 ft. lbs.).
(18) Install and connect crank position sensor (if
equipped).
(19) Connect gearshift cable to upper mount
bracket and transaxle manual valve lever (Fig. 161).
(20) Connect solenoid/pressure switch assembly
(Fig. 162).
(21) Connect transmission range sensor connector
(Fig. 162).
(22) Connect input and output speed sensor con-
nectors (Fig. 162).
Fig. 158 Attaching Bolts
1 - BOLTS
2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
Fig. 159 Left Mount to Bracket and Transaxle
1 - BOLT - BRACKET TO FRAME RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO RAIL THRU 75 N´m (55 ft. lbs.)
3 - BOLT - LEFT MOUNT TO TRANSAXLE 54 N´m (40 ft. lbs.)
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
RS40TE AUTOMATIC TRANSAXLE21-51
40TE AUTOMATIC TRANSAXLE (Continued)

(69) Install and tighten solenoid/pressure switch
assembly-to-transaxle case bolts to 12 N´m (110 in.
lbs.) (Fig. 158).
(70) Install and torque input and output speed
sensors to case to 27 N´m (20 ft. lbs.).
INSTALLATION
NOTE: If transaxle assembly has been replaced or
overhauled (clutch and/or seal replacement), it is
necessary to perfrom the ªQuick-Learnº procedure.
(Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES/TRANSMISSION CONTROL MODULE -
STANDARD PROCEDURE)
(1) Using a transmission jack and a helper, posi-
tion transaxle assembly to engine. Install and torque
bellhousing bolts to 95 N´m (70 ft. lbs.).
(2) Install upper mount assembly to transaxle and
torque bolts to 54 N´m (40 ft. lbs.) (Fig. 159).
(3) Raise engine/transaxle assembly into position.
Install and torque upper mount-to-bracket thru-bolt
to 75 N´m (55 ft. lbs.) (Fig. 159).
(4) Remove transmission jack and screw jack.
(5) Secure left wheelhouse splash shield.
(6) Install torque converter-to-drive plate bolts and
torque to 88 N´m (65 ft. lbs.)
(7) Install inspection cover.
(8) Install lateral bending brace.
(9) Install starter motor.
(10) Install front mount/bracket assembly.
(11) Align and install rear mount bracket-to-case
bolts by hand (Fig. 160). Torque horizontal bolt to
102 N´m (75 ft. lbs.).(12) AWD models: Install power transfer unit.
(Refer to 21 - TRANSMISSION/TRANSAXLE/
POWER TRANSFER UNIT - INSTALLATION)
(13) Install left and right halfshaft assemblies.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - INSTALLATION)
(14) Install front wheel/tire assemblies.
(15) Lower vehicle.
(16) Torque remaining rear mount bracket-to-tran-
saxle vertical bolts (Fig. 160) to 102 N´m (75 ft. lbs.).
(17) Install transaxle upper bellhousing-to-block
bolts and torque to 95 N´m (70 ft. lbs.).
(18) Install and connect crank position sensor (if
equipped).
(19) Connect gearshift cable to upper mount
bracket and transaxle manual valve lever (Fig. 161).
(20) Connect solenoid/pressure switch assembly
(Fig. 162).
(21) Connect transmission range sensor connector
(Fig. 162).
(22) Connect input and output speed sensor con-
nectors (Fig. 162).
(23) Remove plugs and connect transaxle oil cooler
lines. (Refer to 7 - COOLING/TRANSMISSION -
STANDARD PROCEDURE)
(24) Remove plug and Install fluid level indicator/
tube assembly.
Fig. 158 Solenoid Pack-to-Transaxle Bolts
1 - BOLTS
2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
Fig. 159 Left Mount to Bracket and Transaxle
1 - BOLT - BRACKET TO FRAME RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO RAIL THRU 75 N´m (55 ft. lbs.)
3 - BOLT - LEFT MOUNT TO TRANSAXLE 54 N´m (40 ft. lbs.)
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
21 - 196 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

SLEEVE - THIRD ROW - FOLD-IN-FLOOR- INSTALLATION, HEADREST ...........23-153
SLEEVE - THIRD ROW - FOLD-IN-FLOOR - REMOVAL, HEADREST ..............23-152
SLIDING DOOR - INSTALLATION .........23-29
SLIDING DOOR - REMOVAL ............23-29
SLIDING DOOR ADJUSTMENT, STANDARD PROCEDURE - POWER ......8N-49
SLIDING DOOR ADJUSTMENTS, ADJUSTMENTS ...................... 23-30
SLIDING DOOR CONTROL MODULE - DESCRIPTION ....................... 8E-18
SLIDING DOOR CONTROL MODULE - OPERATION ......................... 8E-18
SLIDING DOOR CONTROL MODULE, DIAGNOSIS AND TESTING .............8E-18
SLIDING DOOR GLASS - INSTALLATION . . 23-163
SLIDING DOOR GLASS - REMOVAL .....23-163
SLIDING DOOR LEARN CYCLE, STANDARD PROCEDURE - POWER ......8N-48
SLIDING DOOR LOCK MOTOR - INSTALLATION ...................... 8N-25
SLIDING DOOR LOCK MOTOR - REMOVAL .......................... 8N-25
SLIDING DOOR MOTOR - DESCRIPTION . . 8N-51
SLIDING DOOR MOTOR - INSTALLATION . . 8N-51
SLIDING DOOR MOTOR - OPERATION ....8N-51
SLIDING DOOR MOTOR - REMOVAL .....8N-51
SLIDING DOOR SILL PLATE - INSTALLATION ....................... 23-99
SLIDING DOOR SILL PLATE - REMOVAL ....23-98
SLIDING DOOR STOP BUMPER BEZEL - INSTALLATION ....................... 23-25
SLIDING DOOR STOP BUMPER BEZEL - REMOVAL .......................... 23-25
SLIDING DOOR SYSTEM - DESCRIPTION, POWER ............................ 8N-40
SLIDING DOOR SYSTEM - OPERATION, POWER ............................ 8N-41
SLIDING DOOR SYSTEM, DIAGNOSIS AND TESTING - POWER ...............8N-42
SLIDING DOOR WEATHERSTRIP - INSTALLATION ...................... 23-168
SLIDING DOOR WEATHERSTRIP - REMOVAL ......................... 23-168
SOCKET - INSTALLATION, STABILIZER ....23-33
SOCKET - REMOVAL, STABILIZER .......23-33
SOLENOID - DESCRIPTION, EVAP/PURGE . 25-13
SOLENOID - DESCRIPTION, SHIFT INTERLOCK .................. 21-113,21-264
SOLENOID - DIAGNOSIS AND TESTING, BRAKE/TRANSMISSION SHIFT
INTERLOCK .................. 21-115,21-266
SOLENOID - INSTALLATION, EVAP/ PURGE ............................. 25-13
SOLENOID - INSTALLATION, SHIFT INTERLOCK .................. 21-116,21-267
SOLENOID - OPERATION, EVAP/PURGE . . . 25-13
SOLENOID - OPERATION, SHIFT INTERLOCK .................. 21-114,21-265
SOLENOID - REMOVAL, EVAP/PURGE .....25-13
SOLENOID - REMOVAL, SHIFT INTERLOCK .................. 21-115,21-266
SOLENOID/PRESSURE SWITCH ASSY - DESCRIPTION ................ 21-117,21-268
SOLENOID/PRESSURE SWITCH ASSY - INSTALLATION ................ 21-119,21-270
SOLENOID/PRESSURE SWITCH ASSY - OPERATION .................. 21-118,21-268
SOLENOID/PRESSURE SWITCH ASSY - REMOVAL ................... 21-118,21-269
SPARE TIRE (TEMPORARY) - DESCRIPTION ....................... 22-14
SPARK PLUG CABLE - DESCRIPTION .....8I-10
SPARK PLUG CABLE RESISTANCE, SPECIFICATIONS ...................... 8I-2
SPARK PLUG, SPECIFICATIONS ...........8I-2
SPEAKER, DIAGNOSIS AND TESTING .....8A-18
SPEED CONTROL - DESCRIPTION ........8P-1
SPEED CONTROL (4 SPEED EATX ONLY) - OPERATION, INTERACTIVE .............8P-2
SPEED OPERATION - STANDARD PROCEDURE, TIRE PRESSURE FOR
HIGH .............................. 22-17
SPEED SENSOR - AWD - INSTALLATION, REAR WHEEL ........................ 5-92
SPEED SENSOR - AWD - REMOVAL, REAR WHEEL ........................ 5-92SPEED SENSOR - DESCRIPTION, ENGINE . 14-30
SPEED SENSOR - FWD - INSTALLATION,
REAR WHEEL ........................ 5-93
SPEED SENSOR - FWD - REMOVAL, REAR WHEEL ........................ 5-93
SPEED SENSOR - INPUT - DESCRIPTION ................ 21-120,21-271
SPEED SENSOR - INPUT - INSTALLATION ................ 21-121,21-272
SPEED SENSOR - INPUT - OPERATION . . 21-120, 21-271
SPEED SENSOR - INPUT - REMOVAL . . . 21-121, 21-272
SPEED SENSOR - INSTALLATION, FRONT WHEEL ............................. 5-92
SPEED SENSOR - OPERATION, ENGINE . . . 14-30
SPEED SENSOR - OUTPUT - DESCRIPTION ................ 21-122,21-273
SPEED SENSOR - OUTPUT - INSTALLATION ................ 21-123,21-274
SPEED SENSOR - OUTPUT - OPERATION .................. 21-122,21-273
SPEED SENSOR - OUTPUT - REMOVAL . . 21-123, 21-274
SPEED SENSOR - REMOVAL, FRONT WHEEL ............................. 5-91
SPEED SENSOR AIR GAP, SPECIFICATIONS - WHEEL ..............5-91
SPIRAL PLATE BATTERY CHARGING, STANDARD PROCEDURE ...............8F-10
SPLASH SHIELD - INSTALLATION, FRONT WHEELHOUSE .................23-57
SPLASH SHIELD - REMOVAL, FRONT WHEELHOUSE ....................... 23-57
SPLICE INFORMATION - DESCRIPTION, CONNECTOR, GROUND ..............8W-01-7
SPLICING - STANDARD PROCEDURE, WIRE ...........................8W -01-15
SPLIT - INSTALLATION, BENCH SEAT RISER - 50/50 ...................... 23-145
SPLIT - REMOVAL, BENCH SEAT RISER - 50/50 ............................. 23-145
SPLIT, BENCH - INSTALLATION, SEAT BACK HINGE COVERS - QUAD BUCKET,
50/50 ............................. 23-146
SPLIT, BENCH - INSTALLATION, SEAT CUSHION COVER - QUAD BUCKET,
50/50 ............................. 23-144
SPLIT, BENCH - REMOVAL, SEAT BACK HINGE COVERS - QUAD BUCKET, 50/50 . . 23-146
SPLIT, BENCH - REMOVAL, SEAT CUSHION COVER - QUAD BUCKET,
50/50 ............................. 23-144
SPRING - AWD - INSTALLATION ..........2-39
SPRING - AWD - REMOVAL .............2-38
SPRING - CARGO - INSTALLATION ........2-40
SPRING - CARGO - REMOVAL ...........2-40
SPRING - FWD - INSTALLATION ..........2-42
SPRING - FWD - REMOVAL .............2-40
SPRING ASSEMBLY - INSTALLATION, QUAD BUCKET SEAT SIDE SHIELD/CUP
HOLDER - FLAP ..................... 23-151
SPRING ASSEMBLY - REMOVAL, QUAD BUCKET SEAT SIDE SHIELD/CUP
HOLDER - FLAP ..................... 23-151
SPRING FRONT - INSTALLATION, BUSHING - LEAF ...................... 2-30
SPRING FRONT - REMOVAL, BUSHING - LEAF ............................... 2-29
SPRING MOUNTS - FRONT - INSTALLATION ........................ 2-43
SPRING MOUNTS - FRONT - REMOVAL ....2-42
SPRING MOUNTS - REAR - INSTALLATION ........................ 2-43
SPRING MOUNTS - REAR - REMOVAL .....2-43
SPRING SHACKLE - INSTALLATION .......2-44
SPRING SHACKLE - REMOVAL ...........2-44
SPRINGS - DESCRIPTION, VALVE ........9-109
SPRINGS - OPERATION, VALVE .........9-109
SPROCKET - INSTALLATION, CRANKSHAFT ................... 9-160,9-67
SPROCKET - INSTALLATION, TIMING CHAIN AND CAMSHAFT ...............9-160
SPROCKET - REMOVAL, CRANKSHAFT . . . 9-159,
9-66
SPROCKET - REMOVAL, TIMING CHAIN AND CAMSHAFT ..................... 9-159SPROCKETS - INSTALLATION,
CAMSHAFT .......................... 9-67
SPROCKETS - REMOVAL, CAMSHAFT ......9-66
STABILIZER - INSTALLATION ...........23-33
STABILIZER - REMOVAL ...............23-33
STABILIZER BAR - DESCRIPTION .....2-16,2-44
STABILIZER BAR - INSPECTION ..........2-17
STABILIZER BAR - INSTALLATION ........2-17
STABILIZER BAR - OPERATION .......2-16,2-44
STABILIZER BAR - REMOVAL ............2-17
STABILIZER BAR CUSHION - INSTALLATION .........................2-4
STABILIZER BAR CUSHION - REMOVAL .....2-4
STABILIZER SOCKET - INSTALLATION ....23-33
STABILIZER SOCKET - REMOVAL ........23-33
STAKING - STANDARD PROCEDURE, HEAT ............................... 23-9
STANDARD 4 CYLINDER - DESCRIPTION . . . 8I-9
STARTER, SPECIFICATIONS .............8F-37
STARTING - DESCRIPTION .............8F-31
STARTING - OPERATION ...............8F-31
STARTING - STANDARD PROCEDURE, JUMP ............................... 0-25
STARTING SYSTEM TEST - DIAGNOSIS AND TESTING ....................... 8F-31
STATE DISPLAY TEST MODE, OPERATION - DRB III T................ 25-10
STEERING - DIAGNOSIS AND TESTING, SUSPENSION .......................... 2-50
STEERING BELT TENSION - STANDARD PROCEDURE, CHECKING POWER ..........7-8
STEERING COLUMN - DESCRIPTION .....19-10
STEERING COLUMN - DIAGNOSIS AND TESTING ........................... 19-11
STEERING COLUMN COVER - INSTALLATION, LOWER ................23-74
STEERING COLUMN COVER - INSTALLATION, OVER .................23-76
STEERING COLUMN COVER - REMOVAL, LOWER ............................ 23-74
STEERING COLUMN COVER - REMOVAL, OVER .............................. 23-76
STEERING FASTENER TORQUE, SPECIFICATIONS - POWER ..............19-9
STEERING FLUID LEVEL CHECKING - STANDARD PROCEDURE, POWER .......19-44
STEERING GEAR, SPECIAL TOOLS - POWER ............................ 19-34
STEERING KNUCKLE - INSPECTION ........2-9
STEERING KNUCKLE - INSTALLATION ......2-9
STEERING KNUCKLE - REMOVAL ..........2-7
STEERING PUMP INITIAL OPERATION - STANDARD PROCEDURE, POWER .......19-37
STEERING PUMP, SPECIAL TOOLS - POWER ............................ 19-44
STEERING, SPECIAL TOOLS - POWER .....19-9
STEERING SYSTEM - DESCRIPTION, POWER ............................. 19-1
STEERING SYSTEM - OPERATION, POWER ............................. 19-1
STEERING SYSTEM DIAGNOSIS CHARTS - DIAGNOSIS AND TESTING .............19-3
STEERING SYSTEM FLOW AND PRESSURE TEST - DIAGNOSIS AND
TESTING, POWER ..................... 19-1
STEERING WHEEL - INSTALLATION ......19-24
STEERING WHEEL - REMOVAL ..........19-23
STEM SEALS - DESCRIPTION, VALVE .....9-114
STEM SEALS - INSTALLATION, VALVE ....9-115
STEM SEALS - REMOVAL, VALVE ........9-115
STOP BUMPER - INSTALLATION .........23-25
STOP BUMPER - REMOVAL ............23-25
STOP BUMPER BEZEL - INSTALLATION, SLIDING DOOR ...................... 23-25
STOP BUMPER BEZEL - REMOVAL, SLIDING DOOR ...................... 23-25
STOP LAMP - INSTALLATION, CENTER HIGH MOUNTED ...................... 8L-6
STOP LAMP - REMOVAL, CENTER HIGH MOUNTED ........................... 8L-6
STOP LAMP UNIT - INSTALLATION, CENTER HIGH MOUNTED ...............8L-6
STOP LAMP UNIT - REMOVAL, CENTER HIGH MOUNTED ...................... 8L-6
STORAGE BIN - INSTALLATION, UNDER SEAT ............................. 23-149
STORAGE BIN - REMOVAL, UNDER SEAT . 23-149
30 INDEXRS
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