Starters: Other Dodge Durango II

STARTING SYSTEM

The starting system consists of

1. Starter relay
2. Starter motor (including an integral starter solenoid)

Other components to be considered as part of starting system are

1. Battery
2. Battery cables
3. Ignition switch and key lock cylinder
4. Clutch pedal position switch (manual transmission)
5. Park/neutral position switch (automatic transmission)
6. Wire harnesses and connections.

The Battery, Starting, and Charging systems operate in conjunction with one another, and must be tested as a complete system. For correct operation of starting/charging systems, all components used in these 3 systems must perform within specifications. When attempting to diagnose any of these systems, it is important that you keep their interdependency in mind.

The diagnostic procedures used in each of these groups include the most basic conventional diagnostic methods, to the more sophisticated On-Board Diagnostics (OBD) built into the Powertrain Control Module (PCM). Use of an induction-type milliampere ammeter, volt/ohmmeter, battery charger, carbon pile rheostat (load tester), and 12-volt test lamp may be required.

Certain starting system components are monitored by the PCM and may produce a Diagnostic Trouble Code (DTC).

STARTER RELAY

The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when the ignition switch is turned to the Start position. The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. See the PDC cover for relay identification and location.

The starter relay is a International Standards Organization (ISO) relay. Relays conforming to ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions.

The starter relay cannot be repaired or adjusted. If faulty or damaged, it must be replaced.

The starting system components form two separate circuits. A high-amperage feed circuit that feeds the starter motor between 150 and 350 amperes (700 amperes - diesel engine), and a low-amperage control circuit that operates on less than 20 amperes. The high-amperage feed circuit components include the battery, the battery cables, the contact disc portion of the starter solenoid, and the starter motor. The low-amperage control circuit components include the ignition switch, the clutch pedal position switch (manual transmission), the park/neutral position switch (automatic transmission), the starter relay, the electromagnetic windings of the starter solenoid, and the connecting wire harness components.

If the vehicle is equipped with a manual transmission, it has a clutch pedal position switch installed in series between the ignition switch and the coil battery terminal of the starter relay. This normally open switch prevents the starter relay from being energized when the ignition switch is turned to the Start position, unless the clutch pedal is depressed. This feature prevents starter motor operation while the clutch disc and the flywheel are engaged. The starter relay coil ground terminal is always grounded on vehicles with a manual transmission.

If the vehicle is equipped with an automatic transmission, battery voltage is supplied through the low-amperage control circuit to the coil battery terminal of the starter relay when the ignition switch is turned to the Start position. The park/neutral position switch is installed in series between the starter relay coil ground terminal and ground. This normally open switch prevents the starter relay from being energized and the starter motor from operating unless the automatic transmission gear selector is in the Neutral or Park positions.

When the starter relay coil is energized, the normally open relay contacts close. The relay contacts connect the relay common feed terminal to the relay normally open terminal. The closed relay contacts energize the starter solenoid coil windings.

The energized solenoid pull-in coil pulls in the solenoid plunger. The solenoid plunger pulls the shift lever in the starter motor. This engages the starter overrunning clutch and pinion gear with the starter ring gear.

As the solenoid plunger reaches the end of its travel, the solenoid contact disc completes the high-amperage starter feed circuit and energizes the solenoid plunger hold-in coil. Current now flows between the solenoid battery terminal and the starter motor, energizing the starter.

Once the engine starts, the overrunning clutch protects the starter motor from damage by allowing the starter pinion gear to spin faster than the pinion shaft. When the ignition switch is released to the On position, the starter relay coil is de-energized. This causes the relay contacts to open. When the relay contacts open, the starter solenoid plunger hold-in coil is de-energized.

When the solenoid plunger hold-in coil is de-energized, the solenoid plunger return spring returns the plunger to its relaxed position. This causes the contact disc to open the starter feed circuit, and the shift lever to disengage the overrunning clutch and pinion gear from the starter ring gear.

The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When electromagnetic coil is energized, it draws the movable contact away from normally closed fixed contact, and holds it against the other (normally open) fixed contact.

When electromagnetic coil is de-energized, spring pressure returns movable contact to normally closed position. The resistor or diode is connected in parallel with electromagnetic coil within relay, and helps to dissipate voltage spikes produced when coil is de-energized.

STARTER FAILS TO OPERATE

1. Battery Discharged Or Faulty: Charge or replace if required.
2. Starting Circuit Wiring Faulty: Test and repair if required. See «WIRING DIAGRAMS»(ref-164418-S35933793572004080400000) .
3. Starter Relay Faulty: Test and replace if required. See «STARTER RELAY»(ref-164418-S19330634652004082300000) under COMPONENT TESTING
4. Ignition Switch Faulty: replace if required.
5. Clutch Pedal Position Switch Faulty: Replace if required.
6. Park/Neutral Position Switch Faulty Or Misadjusted: Replace if required.
7. Starter Solenoid Faulty: Replace if required. See «STARTER SOLENOID»(ref-164418-S29861093012004082300000) under COMPONENT TESTING.
8. Starter Motor Faulty: Check components, if ok, then replace starter motor. See «STARTER MOTOR»(ref-164418-S11968605782004082300000) under COMPONENT TESTING.

STARTER ENGAGES, FAILS TO TURN ENGINE

1. Battery Discharged Or Faulty: Charge or replace if necessary.
2. Starting Circuit Wiring Faulty: Test and repair if required. See «WIRING DIAGRAMS»(ref-164418-S35933793572004080400000) .
3. Starter Motor Faulty: Check components, if ok then replace starter motor assembly. See «STARTER MOTOR»(ref-164418-S11968605782004082300000) under COMPONENT TESTING.
4. Engine Seized: See appropriate article in ENGINES.

STARTER ENGAGES, SPINS OUT BEFORE ENGINE STARTS

1. Starter Ring Gear Faulty: Inspect and replace if required.
2. Starter Motor Faulty: Check components, if ok, then replace starter motor assembly. See «STARTER MOTOR»(ref-164418-S11968605782004082300000) under COMPONENT TESTING.

STARTER DOES NOT DISENGAGE

1. Starter Motor Improperly Installed: Check, and use proper torque specifications. See «TORQUE SPECIFICATIONS»(ref-164418-S39781588512004080600000) and «STARTER MOTOR»(ref-164418-S11968605782004082300000) under COMPONENT TESTING.
2. Starter Relay Faulty: Replace if required. See «STARTER RELAY»(ref-164418-S19330634652004082300000) under COMPONENT TESTING.
3. Ignition Switch Faulty: Replace if required.
4. Starter Motor Faulty: Check components, if ok, then replace starter motor. See «STARTER MOTOR»(ref-164418-S11968605782004082300000) under COMPONENT 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. See STARTER SPECIFICATIONS .

1. Remove starter motor from vehicle.
2. Mount starter motor securely in a soft-jaw 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. See «STARTER SPECIFICATIONS»(ref-164418-S19963533102004080600000) for starter motor free running test voltage specifications.
6. Note reading on ammeter and compare reading to free running test maximum amperage draw. See «STARTER SPECIFICATIONS»(ref-164418-S19963533102004080600000) for starter motor free running test maximum amperage draw specifications.
7. If ammeter reading exceeds maximum amperage draw specification, replace faulty starter motor assembly.

STARTER SOLENOID

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

Scheme 11

1. Remove starter motor from vehicle.
2. Disconnect wire from solenoid field coil terminal.
3. Check for continuity between solenoid terminal and solenoid field coil terminal with a continuity tester. (Scheme 11), (Scheme 12) and see scheme 3. There should be continuity. If OK, go to next step. If not OK, replace faulty starter motor assembly.
4. Check for continuity between solenoid terminal and solenoid case. There should be continuity. If not OK, replace faulty starter motor assembly.

Scheme 12

Note. Manufacturer does not supply testing information.

2003

See STARTING/CHARGING in SYSTEM WIRING DIAGRAMS article.

2004

See STARTING/CHARGING in SYSTEM WIRING DIAGRAMS article.