Starting System - 2.0L Engine: Diagnosis Dodge Avenger I

TROUBLE SHOOTING

Note. See TROUBLE SHOOTING - BASIC PROCEDURES article in GENERAL INFORMATION section.

ON-VEHICLE TESTING

CIRCUIT TEST

Note. Although other scan tools are available, manufacturer recommends using Diagnostic Readout Box (DRB) to perform the following circuit tests. Because DRB is grounded through Data Link Connector (DLC), only one volt/ohmmeter test lead is required when using volt/ohmmeter option.

Scheme 6

1. Ensure transmission gear selector is in Park or Neutral. Using DRB scan tool, read park/neutral position switch sense. If park/neutral position switch senses park position, go to next step. If park/neutral position switch does not sense park position, repair open park/neutral switch ground circuit.
2. Disconnect starter relay and ensure connector is clean and not damaged. (Scheme 6) Using scan tool in voltmeter mode, check voltage at starter relay connector terminal No. 5 (Red/Black wire). (Scheme 7) If voltage is more than 11.6 volts, go to next step. If volt age is 11.6 volts or less, repair open Red/Black wire.
3. Using scan tool in voltmeter mode, check voltage at starter relay connector terminal No. 1 (Black/Red wire). (Scheme 7) Check voltage with ignition switch in START position. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open Black/Red wire. WARNING: Before performing next step, ensure transaxle selector is in Park and parking brake is set. Engine may crank in next step. Keep clear of engine components that move.
4. Briefly connect a jumper wire between starter relay connector terminals No. 4 (Black/Yellow wire) and No. 5 (Red/Black wire). (Scheme 7) If starter cranks, go to step 7). If starter does not crank and starter solenoid clicks, reinstall starter relay and go to step 6). If starter does not crank and starter solenoid does not click, disconnect jumper wire and go to next step.
5. Disconnect starter relay output wire connector from starter solenoid and ensure connector is clean and not damaged. Using an external ohmmeter, check resistance of Black/Yellow wire between solenoid and starter relay connector terminal No. 4. If resistance is less than 5 ohms, reinstall starter relay and go to next step. If resistance is more than 5 ohms, repair open Black/Yellow wire.
6. Check battery cables for a voltage drop. If either cable has a voltage drop of more than 0.2 volt, replace or repair battery cable(s). If voltage drop of both cables is less than 0.2 volt, rotate crankshaft 360 degrees. If crankshaft cannot be rotated 360 degrees, repair engine mechanical problem. If crankshaft can be rotated 360 degrees, replace starter.
7. Using scan tool in ohmmeter mode, check resistance on starter relay connector terminal No. 3 (Black/Yellow wire). (Scheme 7) If resistance is less than 5 ohms, replace starter relay. If resistance is more than 5 ohms, repair open Black/Yellow wire.

Scheme 7

1. Disconnect starter relay and ensure connector is clean and not damaged. (Scheme 6) Using DRB scan tool in ohmmeter mode, check resistance on starter relay connector terminal No. 1 (Green/Black wire). (Scheme 8) If resistance is less than 5 ohms, go to next step. If resistance is more than 5 ohms, repair open Green/Black wire.
2. Using scan tool in voltmeter mode, check voltage on starter relay connector terminal No. 4 (Black/Red wire). (Scheme 8) If voltage is more than 11.6 volts, go to next step. If voltage is 11.6 volts or less, repair open Black/Red wire.
3. Using an external voltmeter, check voltage between ground and starter relay connector terminal No. 2 (Black/Red wire). (Scheme 8) Check voltage with ignition switch in START position and clutch pedal depressed. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open Black/Red wire and/or ensure clutch switch is adjusted correctly and/or is operating properly. WARNING: Before performing next step, ensure transaxle selector is in Park and parking brake is set. Engine may crank in next step. Keep clear of engine components that move.
4. Briefly connect a jumper wire between starter relay connector terminals No. 3 (Black/Yellow wire) and No. 4 (Black/Red wire). (Scheme 8) If starter cranks, replace starter relay. If starter does not crank and starter solenoid does not click, disconnect jumper wire and go to next step. If starter does not crank and starter solenoid clicks, reinstall starter relay and go to step 6).
5. Disconnect starter relay output wire connector from starter solenoid and ensure connector is clean and not damaged. Using an external ohmmeter, check resistance of Black/Yellow wire between solenoid and starter relay connector terminal No. 3. If resistance is 5 ohms or less, reinstall starter relay and go to next step. If resistance is more than 5 ohms, repair open Black/Yellow wire.
6. Check battery cables for a voltage drop. If either cable has a voltage drop of more than 0.2 volt, replace or repair battery cable(s). If voltage drop of both cables is less than 0.2 volt, rotate crankshaft 360 degrees. If crankshaft cannot be rotated 360 degrees, repair engine mechanical problem. If crankshaft can be rotated 360 degrees, replace starter.

Scheme 8

IGNITION SWITCH TEST

1. Disable air bag. See AIR BAG RESTRAINT SYSTEM article in ACCESSORIES/SAFETY EQUIPMENT section. Remove instrument cluster undercover. Remove steering column covers to locate ignition switch 6-pin connector. Disconnect ignition switch 6-pin connector.
2. Put ignition switch in ON position. Using an ohmmeter, check continuity between switch terminals No. 1 (White wire), No. 2 (Black/White wire), No. 4 (Blue/Black) and No. 6 (Blue wire). If continuity is not present, replace ignition switch.

BENCH TESTING

Return Test (Reduction Gear Drive Starter)

1. Disconnect field coil wire from terminal "M" at starter solenoid. see scheme 6 Connect jumper wire between positive battery terminal and terminal "B" of starter solenoid.
2. Connect a second jumper wire from negative battery terminal and touch starter housing for no longer than 10 seconds. Manually, pull pinion outward and release. Pinion should retract. Replace solenoid if pinion remains extended.

Solenoid Continuity Test (Direct Drive Starter)

Disconnect field coil wire from terminal "M" at starter solenoid. Check for continuity between solenoid terminals "S" and "M". Check for continuity between solenoid terminal "S" and solenoid housing. see scheme 6 If continuity is not present, solenoid has an open and is defective. If solenoid is defective, replace starter.

STARTER MOTOR INSPECTION

1. After starter disassembly, inspect field housing and permanent magnets for damage. Magnets are permanently attached to field housing. If field housing or magnets are damaged, replace them as an assembly.
2. Inspect condition of armature end bushings and bearings. Replace planetary gear assembly and pinion shaft if worn or damaged. Replace any other worn parts.
3. If bushings or bearings have worn to point where armature-to-frame contact has occurred, replace complete starter.
4. Inspect brushes and brush holder. Ensure there is no continuity between brush holder plate and brush holder. Replace brushes if damaged or worn below minimum length. See «STARTER SPECIFICATIONS - REDUCTION GEAR»(ref-58731-S09250900172001011700000) table under STARTER SPECIFICATIONS. Replace brush holder assembly if cracked, bent or distorted.
5. Hold clutch housing and rotate drive pinion in both directions. Drive pinion should only rotate in one direction. Replace drive pinion if operation is not as specified.

Ground Test

Connect one ohmmeter lead to armature core and other lead to each commutator bar, one at a time. If continuity exists on any test, armature is grounded. Replace armature.

Short Test

Place armature in growler and turn on growler. Hold thin steel blade parallel and just above armature while armature is rotated in growler. If blade vibrates, a short is indicated. Replace armature.

Commutator Continuity Test

Using ohmmeter, touch leads to adjacent commutator bar segments. Continuity should exist. Check all commutator bar segments in same manner. If continuity does not exist on any 2 adjacent segments, replace armature.

Runout Test

Place armature in a pair of "V" blocks. Using dial indicator, check commutator and armature shaft runout. If runout exceeds specification, replace armature. See STARTER SPECIFICATIONS - REDUCTION GEAR table under STARTER SPECIFICATIONS.