Starting System: Diagnosis Dodge Dakota III

INSPECTION

For complete starter wiring circuit diagrams, refer to SYSTEM WIRING DIAGRAMS . Before removing any unit from starting system for repair or diagnosis, perform the following inspections

1. Battery - Visually inspect battery for indications of physical damage and loose or corroded cable connections. Determine state-of-charge and cranking capacity of battery. Charge or replace battery if required. Refer to «BATTERY SYSTEM»(ref-247603) . Note: If equipped with diesel engine, a dual battery system may be used, and both batteries must be inspected.
2. Ignition Switch - Visually inspect ignition switch for indications of physical damage and loose or corroded wire harness connections. Refer to «IGNITION SWITCH AND KEY LOCK CYLINDER»(ref-247622-S17744325722007020100000)
3. Clutch Pedal Position Switch - If equipped with manual transmission, visually inspect clutch pedal position switch for indications of physical damage and loose or corroded wire harness connections. Refer to «CLUTCH PEDAL POSITION SWITCH»(ref-247656-S19007640062007020100000) .
4. Park/Neutral Position Switch - If equipped with automatic transmission, visually inspect park/neutral position switch for indications of physical damage and loose or corroded wire harness connections. Refer to Transmission Range Sensor in appropriate Transmission SERVICE INFORMATION article.
5. Starter Relay - Visually inspect starter relay for indications of physical damage and loose or corroded wire harness connections.
6. Starter Motor - Visually inspect starter motor for indications of physical damage and loose or corroded wire harness connections.
7. Starter Solenoid - Visually inspect starter solenoid for indications of physical damage and loose or corroded wire harness connections.
8. Wiring - Visually inspect wire harnesses for damage. Repair or replace any faulty wiring, as required. Refer to «SYSTEM WIRING DIAGRAMS»(ref-172288) or «WIRING DIAGRAM INFORMATION»(ref-247683) .

Scheme 1

For complete starter wiring circuit diagrams, refer to SYSTEM WIRING DIAGRAMS . The battery must be fully-charged and load-tested before proceeding. Refer to BATTERY SYSTEM .

1. Connect volt-ampere tester to battery terminals (1), (2) and (3). See instructions provided by manufacturer of volt-ampere tester being used. Note: Certain diesel equipped models use dual batteries. If equipped with dual battery system, tester should be connected to battery on left side of vehicle only. Also, tester current reading must be taken from positive battery cable lead that connects to starter motor.
2. Fully engage parking brake.
3. If equipped with manual transmission, place gearshift selector lever in Neutral position and block clutch pedal in fully depressed position. If equipped with automatic transmission, place gearshift selector lever in Park position.
4. Verify that all lamps and accessories are turned off.
5. To prevent a gasoline engine from starting, remove Automatic ShutDown (ASD) relay. To prevent a diesel engine from starting, remove Fuel Pump Relay. These relays are located in Power Distribution Center (PDC). Refer to label on PDC cover for relay location. WARNING: IF EQUIPPED WITH DIESEL ENGINE, ATTEMPT TO START ENGINE A FEW TIMES BEFORE PROCEEDING WITH FOLLOWING STEP.
6. Rotate and hold ignition switch in Start position. Note cranking voltage and current (amperage) draw readings shown on volt-ampere tester. If voltage reads below 9.6 volts, refer to «STARTER»(ref-247621-S09201060152007020100000) . If starter motor is OK, refer to appropriate Engine SERVICE INFORMATION article for further testing of engine. If starter motor is not OK, replace faulty starter motor. If voltage reads above 9.6 volts and current (amperage) draw reads below specifications, refer to «FEED CIRCUIT TEST»(ref-247621-S01525527042007020100000) . If voltage reads 12.5 volts or greater and starter motor does not turn, refer to «CONTROL CIRCUIT TESTING»(ref-247621-S28481276312007020100000) . If voltage reads 12.5 volts or greater and starter motor turns very slowly, refer to «FEED CIRCUIT TEST»(ref-247621-S01525527042007020100000) .

Note. A cold engine will increase starter current (amperage) draw reading, and reduce battery voltage reading.

FEED CIRCUIT TEST

The starter feed circuit test (voltage drop method) will determine if there is excessive resistance in high-amperage feed circuit. For complete starter wiring circuit diagrams, refer SYSTEM WIRING DIAGRAMS .

When performing these tests, it is important to remember that voltage drop is giving an indication of resistance between two points at which voltmeter probes are attached.

Example: When testing resistance of positive battery cable, touch voltmeter leads to positive battery cable clamp and cable connector at starter solenoid. If you probe positive battery terminal post and cable connector at starter solenoid, you are reading combined voltage drop in positive battery cable clamp-to-terminal post connection and positive battery cable.

The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing tests, be certain that following procedures are accomplished

1. Battery is fully-charged and load-tested. Refer to «BATTERY SYSTEM»(ref-247603) .
2. Fully engage parking brake.
3. If equipped with manual transmission, place gearshift selector lever in Neutral position and block clutch pedal in fully depressed position. If equipped with automatic transmission, place gearshift selector lever in Park position.
4. Verify that all lamps and accessories are turned off.
5. To prevent a gasoline engine from starting, remove Automatic ShutDown (ASD) relay. To prevent a diesel engine from starting, remove Fuel Pump Relay. These relays are located in Power Distribution Center (PDC). Refer to label on PDC cover for relay location.

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

1. Connect positive lead of voltmeter (1) to negative battery cable terminal post. Connect negative lead of voltmeter to negative battery cable clamp. Rotate and hold ignition switch in Start position. Observe voltmeter (1). If voltage is detected, correct poor contact between cable clamp and terminal post. Note: Certain diesel equipped models use dual batteries. If equipped with dual battery system, procedure must be performed twice, once for each battery.
2. Connect positive lead of voltmeter (1) to positive battery terminal post. Connect negative lead of voltmeter to battery positive cable clamp. Rotate and hold ignition switch in Start position. Observe voltmeter (1). If voltage is detected, correct poor contact between cable clamp and terminal post. Note: Certain diesel equipped models use dual batteries. If equipped with dual battery system, this procedure must be performed twice, once for each battery.
3. Connect voltmeter (2) to measure between battery positive terminal post and starter solenoid battery terminal stud (3). Rotate and hold ignition switch in Start position. Observe voltmeter. If reading is above 0.2 volt, clean and tighten battery cable connection at solenoid. Repeat test. If reading is still above 0.2 volt, replace faulty positive battery cable. Note: Certain diesel equipped models use dual batteries. If equipped with dual battery system, this procedure must be performed on driver side battery only.
4. Connect voltmeter (1) to measure between negative battery terminal post and a good clean ground on engine block (3). Rotate and hold ignition switch in Start position. Observe voltmeter. If reading is above 0.2 volt, clean and tighten negative battery cable attachment on engine block. Repeat test. If reading is still above 0.2 volt, replace faulty negative battery cable. Note: Certain diesel equipped models use dual batteries. If equipped with dual battery system, this procedure must be performed twice, once for each battery.
5. Connect positive lead of voltmeter (3) to starter housing (1). Connect negative lead of voltmeter to negative battery terminal post. Rotate and hold ignition switch in Start position. Observe voltmeter. If reading is above 0.2 volt, correct poor starter to engine block ground contact. Note: Certain diesel equipped models use dual batteries. If equipped with dual battery system, this procedure must be performed on driver side battery only.
6. If equipped with dual battery system (certain diesel equipped models), connect positive lead of voltmeter to positive battery cable clamp on battery located on left side of vehicle. Connect negative lead of voltmeter to positive battery terminal post on battery located on right side of vehicle. Rotate and hold ignition switch in Start position. Observe voltmeter. If reading is above 0.2 volt, clean and tighten battery cables at both batteries. Repeat test. If reading is still above 0.2 volt, replace faulty positive battery cable.

If resistance tests detect no feed circuit problems, refer to STARTER .

CONTROL CIRCUIT TESTING

The starter control circuit components should be tested in the order in which they are listed, as follows

1. Starter Relay - Refer to «RELAY-STARTER MOTOR»(ref-247621-S37185567942007020100000) .
2. Starter Solenoid - Refer to «STARTER SOLENOID»(ref-247621-S20441686342007020100000) .
3. Ignition Switch - Refer to «IGNITION SWITCH AND KEY LOCK CYLINDER»(ref-247622-S17744325722007020100000)
4. Clutch Pedal Position Switch - If equipped with manual transmission, refer to «CLUTCH PEDAL POSITION SWITCH»(ref-247656-S19007640062007020100000) .
5. Park/Neutral Position Switch - If equipped with automatic transmission, refer to Transmission Range Sensor in appropriate Transmission SERVICE INFORMATION article.
6. Wire harnesses and connections - Refer to «SYSTEM WIRING DIAGRAMS»(ref-172288) .

DIAGNOSIS AND TESTING - STARTER MOTOR

Correct starter motor operation can be confirmed by performing the following free running bench test. This test can only be performed with starter motor removed from vehicle. Refer to STARTING SYSTEM for starter motor specifications.

1. Remove starter motor from vehicle. Refer to «STARTER»(ref-247621-S09201060152007020100000) Removal and Installation.
2. Mount starter motor securely in a soft-jawed bench vise. The vise jaws should be clamped on the mounting flange of starter motor. Never clamp on starter motor by field frame.
3. Connect a suitable volt-ampere tester and a 12-volt battery to starter motor in series, and set ammeter to 100 ampere scale. See instructions provided by manufacturer of volt-ampere tester being used.
4. Install jumper wire from solenoid terminal to solenoid battery terminal. The starter motor should operate. If starter motor fails to operate, replace faulty starter motor assembly.
5. Adjust carbon pile load of tester to obtain free running test voltage. Refer to «STARTING SYSTEM»(ref-247621-S03182193202007020100000) for starter motor free running test voltage specifications.
6. Note reading on ammeter and compare reading to free running test maximum amperage draw. Refer to «STARTING SYSTEM»(ref-247621-S03182193202007020100000) for starter motor free running test maximum amperage draw specifications.
7. If ammeter reading exceeds maximum amperage draw specification, replace faulty starter motor assembly. Refer to «STARTER»(ref-247621-S09201060152007020100000) .

Scheme 7

This test can only be performed with starter motor removed from vehicle.

Scheme 8

1. Remove starter motor from vehicle. Refer to «STARTER»(ref-247621-S09201060152007020100000) Removal and Installation.
2. Disconnect wire from solenoid field coil terminal.
3. Check for continuity between solenoid terminal (3) and solenoid field coil terminal (2) with a continuity tester (1). There should be continuity. If OK, go to step 4 . If not OK, replace faulty starter motor assembly. Refer to «STARTER»(ref-247621-S09201060152007020100000) .
4. Check for continuity between solenoid terminal (1) and solenoid case. There should be continuity. If not OK, replace faulty starter motor assembly. Refer to «STARTER»(ref-247621-S09201060152007020100000) .

Scheme 9

1. Disconnect and isolate negative battery cable.
2. Raise and support vehicle.
3. Note: If equipped with 4WD and certain transmissions, a support bracket is used between front axle and side of transmission. Remove 2 support bracket bolts at transmission. Pry support bracket slightly to gain access to lower starter mounting bolt.
4. Remove one bolt (9) and one nut (8) if equipped with a manual transmission.
5. Move starter motor (5) towards front of vehicle far enough for nose of starter pinion housing to clear housing. Always support starter motor during this process, do not let starter motor hang from wire harness.
6. Tilt nose downwards and lower starter motor far enough to access and remove nut (2) that secures battery positive cable wire harness connector eyelet to solenoid battery terminal stud. Do not let starter motor hang from wire harness.
7. Remove battery positive cable wire harness connector eyelet (1) from solenoid battery terminal stud.
8. Disconnect battery positive cable wire harness connector (7) from solenoid terminal connector receptacle.
9. Remove starter motor.

Scheme 10

1. Disconnect and isolate negative battery cable.
2. Raise and support vehicle.
3. Note: If equipped with 4WD and certain transmissions, a support bracket is used between front axle and side of transmission. Remove 2 support bracket bolts at transmission. Pry support bracket slightly to gain access to lower starter mounting bolt.
4. Remove two bolts (3) if equipped with an automatic transmission.
5. Move starter motor (4) towards front of vehicle far enough for nose of starter pinion housing to clear housing. Always support starter motor during this process, do not let starter motor hang from wire harness.
6. Tilt nose downwards and lower starter motor far enough to access and remove nut (2) that secures battery positive cable wire harness connector eyelet (1) to solenoid battery terminal stud. Do not let starter motor hang from wire harness.
7. Remove battery positive cable wire harness connector eyelet (5) from solenoid battery terminal stud.
8. Disconnect battery positive cable wire harness connector from solenoid terminal connector receptacle.
9. Remove starter motor.