TROUBLE SHOOTING
Note. See TROUBLE SHOOTING article in GENERAL INFORMATION.
ON-VEHICLE TESTING
| CAUTION | When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. |
CRANKING TEST
Note. Remove air cleaner assembly, if necessary, to access battery terminals.
Note. Ensure engine is at normal operating temperature. High viscosity oil, extreme cold temperatures, or an engine with tight piston ring-to-cylinder clearance, will increase amperage draw.
Note. If vehicle is equipped with dual batteries, ensure driver's side battery is used for this test.
- Using a battery load tester, connect positive and negative leads to battery. Connect inductive voltmeter pick-up to positive battery cable. Disable ignition and fuel systems. See «DISABLING/ENABLING IGNITION & FUEL SYSTEMS»(ref-91676-S36620344342001032700000) .
- Ensure all lights and accessories are off. Place Automatic Transmission (A/T) in "P" position or Manual Transmission (M/T) in Neutral. Apply parking brake. Crank engine and observe voltmeter. If voltage is more than 9.6 volts and cranking amperage draw is more than specified amps, perform «CIRCUIT RESISTANCE TESTS»(ref-91676-S08586680002001032700000) . For applicable amperage draw specifications, see appropriate table under «STARTER SPECIFICATIONS»(ref-91676-S10707232032001032700000) . If voltage is 12.5 volts or more and cranking amperage draw is less than specified, check starter circuit components in following order: starter solenoid, starter relay, starter relay circuit, park/neutral position switch or transmission range sensor (A/T), clutch pedal position switch (M/T), ignition switch, wiring harness and connections.
Battery Connection Resistance Test
- Disable vehicle ignition and fuel systems. See «DISABLING/ENABLING IGNITION & FUEL SYSTEMS»(ref-91676-S36620344342001032700000) . A voltmeter accurate to one tenth of a volt will be needed for following tests.
- Connect voltmeter positive lead to negative battery cable clamp. Connect voltmeter negative lead to negative battery terminal. Crank engine and observe voltmeter. Connect voltmeter positive lead to positive battery terminal. Connect voltmeter negative lead to positive battery cable clamp. Crank engine and observe voltmeter. If voltage is detected, during either procedure, repair poor contact between appropriate cable clamp and terminal.
Ground Connection Resistance Test
Connect voltmeter negative lead to negative battery terminal. Connect voltmeter positive lead to engine block, near negative battery cable grounding point. Crank engine and observe voltmeter. If voltmeter indicates more than 0.2 volt, repair poor ground connection or replace ground cable.
Starter Ground Connection Resistance Test
Connect voltmeter negative lead to negative battery terminal. Connect voltmeter positive lead to starter housing. Crank engine and observe voltmeter. If voltmeter indicates more than 0.2 volt, repair poor starter-to-ground connection.
Positive Battery Cable Resistance Test
- Remove starter heat shield (if equipped) to gain access to starter solenoid connections. Connect voltmeter negative lead to starter solenoid battery terminal and voltmeter positive lead to positive battery terminal.
- Crank engine and observe voltmeter. If voltmeter indicates more than 0.2 volt, repair poor connection between battery cable and starter solenoid or replace positive battery cable.
SOLENOID CIRCUIT TEST
- Disable vehicle ignition and fuel systems. See «DISABLING/ENABLING IGNITION & FUEL SYSTEMS»(ref-91676-S36620344342001032700000).
- Ensure battery is fully charged. Ensure solenoid connections are not loose or corroded. Remove starter relay from power distribution center. Refer to power distribution center cover for proper relay location. Power distribution center is located in engine compartment.
- Connect a remote starter switch or jumper wire between starter relay cavity terminal No. 87 and positive battery terminal. For identification, see appropriate RELAY TERMINAL IDENTIFICATION table under «STARTER RELAY TEST»(ref-91676-S04775966532001032700000). (Scheme 10), (Scheme 11) or (Scheme 12). If engine cranks, perform «STARTER RELAY TEST»(ref-91676-S04775966532001032700000).
- If engine fails to crank, or if solenoid chatters, check wiring and connectors from starter relay cavity to starter solenoid terminal. Repair any loose or corroded connections. On Neon models, if engine still fails to crank, replace starter. On all other models, if engine still fails to crank, remove starter. Perform «SOLENOID TEST»(ref-91676-S24238318812001032700000) under BENCH TESTING.
STARTER RELAY TEST
Note. Perform SOLENOID CIRCUIT TEST before testing starter relay.
Note. Relay terminals are identified using Bosch numbers. (Scheme 10), (Scheme 11) or (Scheme 12). See WIRING DIAGRAMS. For identification, see appropriate RELAY TERMINAL IDENTIFICATION table.
| Relay Terminal No. | (1) Wire Color |
|---|---|
| 30 | Red |
| 85 | Tan |
| 86 | Yellow |
| 87 | Brown |
| 87A | (2) |
| (1) In power distribution center. (2) Not used. | |
| (1) | In power distribution center. |
| (2) | Not used. |
RELAY TERMINAL IDENTIFICATION (CARS)
| Relay Terminal No. | (1) Wire Color |
|---|---|
| 30 | Red |
| 85 | Dark Green/Orange |
| 86 | Yellow |
| 87 | Yellow/Gray |
| 87A | (2) |
| (1) In power distribution center. (2) Not used. | |
| (1) | In power distribution center. |
| (2) | Not used. |
RELAY TERMINAL IDENTIFICATION (CARAVAN, TOWN & COUNTRY, & VOYAGER)
| Relay Terminal No. | (1) Wire Color |
|---|---|
| 30 | Red/Tan |
| 85 | Black/White |
| 86 | Red/Yellow |
| 87 | Brown |
| 87A | (2) |
| (1) In power distribution center. (2) Not used. | |
| (1) | In power distribution center. |
| (2) | Not used. |
RELAY TERMINAL IDENTIFICATION (DAKOTA & DURANGO)
| Relay Terminal | (1) Wire Color |
|---|---|
| 30 | Black/Pink |
| 85 | Brown/Yellow |
| 86 | Yellow |
| 87 | Brown |
| 87A | (2) |
| (1) In power distribution center. (2) Not used. | |
| (1) | In power distribution center. |
| (2) | Not used. |
RELAY TERMINAL IDENTIFICATION (RAM VAN & RAM WAGON)
| Relay Terminal | (1) Wire Color |
|---|---|
| 30 | Yellow |
| 85 | Black/White |
| 86 | Yellow/Red |
| 87 | Brown |
| 87A | (2) |
| (1) In power distribution center. (2) Not used. | |
| (1) | In power distribution center. |
| (2) | Not used. |
RELAY TERMINAL IDENTIFICATION (RAM PICKUP)
- Remove starter relay from power distribution center. Check continuity between starter relay terminals No. 87A and 30. Continuity should exist. No continuity should exist between starter relay terminals No. 87 and 30. (Scheme 10), (Scheme 11) or (Scheme 12). If continuity is not as specified, replace starter relay. If continuity is as specified, go to next step.
- Check resistance between starter relay terminals No. 85 and 86. If resistance is 65-85 ohms, go to next step. If resistance is not 65-85 ohms, replace starter relay.
- Connect 12-volt power supply to starter relay terminal No. 86 and ground terminal No. 85. Continuity should exist between terminals No. 30 and 87. No continuity should exist between terminals No. 87A and 30. If continuity is not as specified, replace starter relay. If continuity is as specified, perform «STARTER RELAY CIRCUIT TEST»(ref-91676-S34694669632001032700000).
Scheme 10
Scheme 11
Scheme 12
STARTER RELAY CIRCUIT TEST
Note. Perform STARTER RELAY TEST before performing STARTER RELAY CIRCUIT TEST.
- Ensure battery is fully charged. Remove starter relay from power distribution center. Refer to power distribution center cover for proper relay location. Power distribution center is located in engine compartment.
- Turn ignition switch to ON position. Check voltage between ground and starter relay cavity terminal No. 30. (Scheme 10), (Scheme 11) or (Scheme 12). If battery voltage is not present, repair open in circuit between starter relay cavity and battery. If battery voltage is present, go to next step.
- If equipped with Automatic Transmission (A/T) go to step 6. Check voltage between ground and starter relay cavity terminal No. 86. Turn ignition switch to START position and depress clutch pedal. If battery voltage is present, go to step 5. If battery voltage is not present, go to next step.
- Disconnect harness connector from clutch pedal position switch mounted on clutch pedal bracket. Connect a jumper wire between clutch pedal position switch harness connector terminals. Check voltage at starter relay cavity terminal No. 86 with ignition switch in START position. If battery voltage is present, perform «CLUTCH PEDAL POSITION SWITCH TEST»(ref-91676-S36025132492001032700000). If battery voltage is not present, repair open or short in wiring between ignition switch and starter relay cavity as necessary. See «WIRING DIAGRAMS»(ref-91676-S42550373152001032700000).
- Connect voltmeter negative lead to starter relay cavity terminal No. 85 and positive lead to terminal No. 86. Turn ignition switch to START position and depress clutch pedal. If battery voltage is present, replace faulty starter relay. If battery voltage is not present, repair ground wire circuit.
- Connect voltmeter negative lead to starter relay cavity terminal No. 85 and positive lead to terminal No. 86. Ensure transmission gear selector is in "P" or Neutral. Turn ignition switch to START position. If battery voltage is present, replace faulty starter relay. If battery voltage is not present, check PNP switch or TR sensor for loose or damaged connections. Check ground to PNP switch or TR sensor. Repair as necessary. If connections and ground are okay, check PNP switch or TR sensor. See «PARK/NEUTRAL POSITION SWITCH & TRANSMISSION RANGE SENSOR TEST»(ref-91676-S26261233062001032700000).
PARK/NEUTRAL POSITION SWITCH & TRANSMISSION RANGE SENSOR TEST
Note. Following test is for Ram pickup with 4-speed transmission. All other models are equipped with a Transmission Range (TR) sensor. If TR sensor or sensor circuit is defective, see appropriate ELECTRONIC CONTROLS article in AUTOMATIC TRANSMISSIONS.
- Place gear selector in Park. Disconnect negative battery cable. Raise and support vehicle. Disconnect Park Neutral Position (PNP) switch harness connector. Using an ohmmeter, check continuity between ground and PNP switch center terminal. (Scheme 13) If continuity exists, go to next step. If continuity does not exist, replace PNP switch.
- Place gear selector in Reverse. Check continuity between ground and PNP switch center terminal. If continuity does not exist, PNP switch is okay. If continuity exists, replace PNP switch.
Scheme 13
CLUTCH PEDAL POSITION SWITCH TEST
Note. Clutch pedal position switch is referred to as clutch interlock switch on Caravan, Concorde, Dakota, Intrepid, LHS, Neon, PT Cruiser, Town & Country, Voyager, and 300M.
Disconnect negative battery cable. Disconnect clutch pedal position switch connector. Using an ohmmeter, check continuity between clutch pedal position switch terminals (component side). With clutch pedal released, continuity should not exist. With clutch pedal depressed, continuity should exist. Replace clutch pedal position switch if continuity is not as specified.
IGNITION SWITCH TEST
Note. For ignition switch testing procedures, see appropriate STEERING COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT.
SOLENOID TEST
- Remove starter from vehicle. Remove starter motor field coil wire from solenoid field coil terminal. Using an ohmmeter, check continuity between solenoid terminal and field coil terminal of starter solenoid. Continuity should exist.
- Check continuity between solenoid terminal and solenoid housing. Continuity should exist. If continuity is not present in either test, replace starter and solenoid as an assembly.