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HOMESERVICE MANUALSCHRYSLER2004PT CRUISER TOURING, 2.4 B, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 35 (STARTING SYSTEM)SYSTEM TESTINGFEED CIRCUIT RESISTANCE TEST
2004 Chrysler PT Cruiser Touring, 2.4 B, Automatic

Feed Circuit Resistance Test

2004 Chrysler PT Cruiser Touring, 2.4 B, AutomaticSECTION Feed Circuit Resistance Test
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2004 Dodge Intrepid, 2004 Chrysler Intrepid, 2004 Chrysler Concorde, 2004 Chrysler 300M, and 2003 Dodge Intrepid. However, it is still accessible from the selected car via links, so may be relevant.

Before proceeding with this operation, review Diagnostic Preparation and Starter Feed Circuit Tests. The following operation will require a voltmeter, accurate to 1/10 of a volt.

CAUTION: Ignition and Fuel systems must be disabled to prevent engine start while performing the following tests.
  1. To disable the 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 proper relay location.
  2. Gain access to battery terminals.
  3. With all wiring harnesses and components properly connected, perform the following:
    1. Connect the negative lead of the voltmeter to the battery negative post, and positive lead to the battery negative cable clamp. Rotate and hold the ignition switch in the START position. Observe the voltmeter. If voltage is detected, correct poor contact between cable clamp and post.
    2. Connect positive lead of the voltmeter to the battery positive post, and negative lead to the battery positive cable clamp. Rotate and hold the ignition switch key in the START position. Observe the voltmeter. If voltage is detected, correct poor contact between the cable clamp and post.
    3. Connect negative lead of voltmeter to battery negative terminal, and positive lead to engine block near the battery cable attaching point. Rotate and hold the ignition switch in the START position. If voltage reads above 0.2 volt, correct poor contact at ground cable attaching point. If voltage reading is still above 0.2 volt after correcting poor contacts, replace ground cable.
  4. Connect positive voltmeter lead to the starter motor housing and the negative lead to the battery negative terminal. Hold the ignition switch key in the START position. If voltage reads above 0.2 volt, correct poor starter to engine ground.
    1. Connect the positive voltmeter lead to the battery positive terminal, and negative lead to battery cable terminal on starter solenoid. Rotate and hold the ignition switch in the START position. If voltage reads above 0.2 volt, correct poor contact at battery cable to solenoid connection. If reading is still above 0.2 volt after correcting poor contacts, replace battery positive cable.
    2. If resistance tests do not detect feed circuit failures, replace the starter motor.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.