Chrysler Repair: 02 Van: no starter motor action, chrysler voyager, gas gauge


Question
I drove my 2002 Chrysler Voyager EC the night before and experienced no
problems; however, the next morning it would not even turn over (crank). I
thought it was the battery but the lights, radio, etc. comes works fine.
Previously, while stopped at a traffic light the gas gauge would suddenly
drop from full to empty but the engine has never stopped running and when I
press on the accelerator to go, the guage shoots back up to "F".  Could this
be something in the fuel line? The Alternator? It does not make any sounds
when the ignition is turned.

Answer
Hi Elaine,
The starter may not respond either because the low current side of the circuit is bad, or the high current side is bad, or the battery is weak (even though lights work (low current) the battery may not be putting out sufficient current to activate the starter motor).
With a helper who will operate the key, go to the power distribution box in the engine compartment (near the battery) and open the lid. Then find the starter motor relay (front of the in-board row of relays). Then while the helper tries the starter, listen/feel for whether or not that relay clicks softly. If it does, then the low current side of the circuit is OK.
If not, then check to be sure that the gear shift is in neutral or park (move it slightly off the detent position in case it may be out of adjustment). If the relay still won't click, then check fuse 23 in the box. If it still won't click then the ignition switch may be faulty in the 'start' position, but a check with a voltmeter for that would be wise before trying to replace that.
If it does click, then listen for whether there is a louder click at the lower part of the engine proper, which is the sound of the starter motor solenoid that switches the high current battery source to the starter motor coils. If it clicks then either the battery is weak or the starter motor is in a "dead" spot as regards its brush/armature position. Try tapping on the side of the starter motor with a hammer while the helper tries the starter. If that doesn't do it, then I would suspect the battery is weak and needs to be charged/considered for replacement. You might try a jump start with cables from another vehicle.
If the relay clicks (softly) but you don't get the loud click from the starter motor solenoid, then the relay's internal points may not be conducting well or the wire from the relay to the solenoid may be compromised. You could try switching the starter relay with a different relay in the box which has the same part number to test whether the relay is the problem.
That is how I would go about solving this no starter problem.

Roland