Starting System Dodge Pickup R1500

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 MOTOR RELAY

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

The starter relay in 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 resister 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.

BASIC INSPECTION

For complete starter wiring circuit diagrams, 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. 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. See appropriate IGNITION SYSTEMS article.
3. Clutch Pedal Position Switch - If equipped with manual transmission, visually inspect clutch pedal position switch for indications of physical damaged and loose or corroded wire harness connections. See appropriate TRANSMISSIONS article under CLUTCHES.
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. See appropriate TRANSMISSIONS 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. See «WIRING DIAGRAMS»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system) .

COLD CRANKING TEST

For complete starter wiring circuit diagrams, see WIRING DIAGRAMS . The battery must be fully-charged and load-tested before proceeding.

Scheme 1

1. Connect volt-ampere tester to battery terminals. (Scheme 1) 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 Shut Down (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, see «STARTER MOTOR»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system__starter-motor) under COMPONENT TESTING. If starter motor is not OK, replace faulty starter motor. If voltage reads above 9.6 volts and current (amperage) draw reads below specifications, see «FEED CIRCUIT TEST»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system__feed-circuit-test). If voltage reads 12.5 volts or greater and starter motor does not turn, see «CONTROL CIRCUIT TESTING»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system__control-circuit-testing). If voltage reads 12.5 volts or greater and starter motor turns very slowly, see «FEED CIRCUIT TEST»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system__feed-circuit-test).

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, see 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.
2. Fully engage parking brake.
3. If equipped with manual transmission, place gearshift selector lever in Neutral position and block clutch pedal is 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 Shut Down (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 to negative battery cable terminal post. Connect negative lead of voltmeter to negative battery cable clamp. (Scheme 2) Rotate and hold ignition switch in Start position. Observe voltmeter. Of 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 to positive battery terminal post. Connect negative lead of voltmeter to battery positive cable clamp. (Scheme 3) Rotate and hold ignition switch in Start position. Observe voltmeter. 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 to measure between battery positive terminal post and starter solenoid battery terminal stud. (Scheme 4) 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 to measure between negative battery terminal post and a good clean ground on engine block. (Scheme 5) 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 to starter housing. Connect negative lead of voltmeter to negative battery terminal post. (Scheme 6) 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, see STARTER MOTOR under COMPONENT TESTING.

CONTROL CIRCUIT TESTING

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

1. Starter Relay - See «STARTER RELAY»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system__starter-relay) under COMPONENT TESTING.
2. Starter Solenoid - See «STARTER MOTOR»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system__starter-motor) under COMPONENT TESTING.
3. Ignition Switch - See appropriate STEERING COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT.
4. Clutch Pedal Position Switch - See appropriate article in CLUTCHES.
5. Park/Neutral Position Switch - See appropriate TRANSMISSIONS article.
6. Wire harnesses and connections - See «WIRING DIAGRAMS»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system) .

STARTER FAILS TO OPERATE

1. Battery Discharged or Faulty: Charge or replae if required
2. Starting Circuit Wiring Faulty: Test and replace if required
3. Starter Relay Faulty: Test and replace if required
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
8. Starter Motor Faulty: Check components, if ok, then replace starter motor

STARTER ENGAGES, FAILS TO TURN ENGINE

1. Battery Discharged Or Faulty: Charge or replace if required
2. Starting Circuit Wiring Faulty: Test and repair if required
3. Starter Motor Faulty: Check components, if ok the replace starter motor assembly
4. Engine Seized: See appropriate ENGINE article

STARTER ENGAGES, SPINS OUT BEFORE ENGINE STARTS

1. Starter Ring Gear Faulty: Remove and inspect ring gear, if damaged, replace if required
2. Starter Motor Faulty: Check components, if ok, then replace starer motor assembly

STARTER DOES NOT DISENGAGE

1. Starter Motor Improperly Installed: See «STARTER MOTOR»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system) under REMOVAL & INSTALLATION and «TORQUE SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system) use proper torque specifications
2. Starter Relay Faulty: See «STARTER RELAY»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system__starter-relay) replace if required
3. Ignition Switch Faulty: Replace if required
4. Starter Motor Faulty: Check components, if ok, then replace starter motor

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 - 8.3L - SRT-10 .

1. Remove starter motor from vehicle. See. «STARTER MOTOR»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system) under REMOVAL & 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. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system) 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 - 8.3L - SRT-10»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system__starter-83l-srt-10) 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 7

1. Remove starter motor from vehicle. See «STARTER MOTOR»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system) under REMOVAL & INSTALLATION.
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 7) 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. (Scheme 8) There should be continuity. If not OK, replace faulty starter motor assembly.

Scheme 8

STARTER RELAY

The starter relay is located in Power Distribution Center (PDC). (Scheme 9) Refer to PDC cover for relay identification and location. For complete starter relay wiring circuit diagrams, see WIRING DIAGRAMS.

1. Remove starter relay from PDC.
2. A relay in de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to next step. If not OK, replace faulty relay.
3. Resistance between terminals 85 and 86 (electromagnet) should be 75 +/- 5 ohms. If OK, go to next step. If not OK, replace faulty relay.
4. Connect 12V battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform Relay Circuit Test that follows. If not OK, replace faulty relay.

Scheme 9

TERMINAL LEGEND

RELAY CIRCUIT TEST

1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to next step. If not OK, repair open circuit to fuse in PDC as required.
2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to next step.
3. The relay normally open terminal (87) is connected to common feed terminal (30) in the energized position. This terminal supplies battery voltage to starter solenoid field coils. There should be continuity between cavity for relay terminal 87 and starter solenoid terminal at all times. If OK, go to next step. If not OK, repair open circuit to starter solenoid as required.
4. The coil battery terminal (86) is connected to electromagnet in relay. It is energized when ignition switch is held in Start position. On vehicles with manual transmission, clutch pedal must be fully depressed for this test. Check for battery voltage at cavity for relay terminal 86 with ignition switch in Start position, and no voltage when ignition switch is released to On position. If OK, go to next step. If not OK with automatic transmission, check for open or short circuit to ignition switch and repair, if required. If circuit to ignition switch is OK, see appropriate article on IGNITIONS. If not OK with a manual transmission, check circuit between relay and clutch pedal position switch for open or a short. If circuit is OK, see appropriate article on CLUTCHES.
5. The coil ground terminal (85) is connected to the electromagnet in the relay. On vehicles with manual transmission, it is grounded at all times. On vehicles with automatic transmission, it is grounded through park/neutral position switch only when gearshift selector lever is in Park or Neutral positions. Check for continuity to ground at cavity for relay terminal 85. If not OK with manual transmission, repair circuit to ground as required. If not OK with automatic transmission, check for pen or short circuit to park/neutral position switch and repair, if required.

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 1 bolt and 1 nut if equipped with a manual transmission. (Scheme 10)
5. Remove 2 bolts if equipped with an automatic transmission. (Scheme 11)
6. Move starter motor 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.
7. Tilt nose downwards and lower starter motor far enough to access and remove nut that secures battery positive cable wire harness connector eyelet to solenoid battery terminal stud. Do not let starter motor hang from wire harness.
8. Remove battery positive cable wire harness connector eyelet from solenoid battery terminal stud.
9. Disconnect battery positive cable wire harness connector from solenoid terminal connector receptacle.
10. Remove starter motor.

Scheme 11

INSTALLATION 3.7L / 4.7L

1. Connect solenoid wire to starter motor (snaps on).
2. Position battery cable to solenoid stud. Install and tighten battery cable eyelet nut. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system) . Do not allow starter motor to hang from wire harness.
3. Position starter motor to transmission.
4. If equipped with automatic transmission, slide cooler tube bracket into position.
5. Install and tighten both bolts (auto. trans.), or 1 nut and 1 bolt (man. trans.). See «TORQUE SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system) .
6. Lower vehicle.
7. Connect negative battery cable.

REMOVAL 5.7L GAS

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 2 mounting bolts. (Scheme 12)
5. Move starter motor 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 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 from solenoid battery terminal stud.
8. Disconnect battery positive cable wire harness connector from solenoid terminal connector receptacle.
9. Remove starter motor.

Scheme 12

INSTALLATION 5.7L GAS

1. Connect solenoid wire to starter motor (snaps on).
2. Position battery cable to solenoid stud. Install and tighten battery cable eyelet nut. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system) . Do not allow starter motor to hang from wire harness.
3. Position starter motor to engine.
4. If equipped with automatic transmission, slide cooler tube bracket into position.
5. Install and tighten both mounting bolts. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system) .
6. Lower vehicle.
7. Connect negative battery cable.

Scheme 13

1. Disconnect and isolate both negative battery cables at both batteries.
2. Raise and support vehicle.
3. Remove 3 starter mounting bolts. (Scheme 13)
4. Move starter motor 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.
5. Tilt nose downwards and lower starter motor far enough to access and remove nuts securing starter wiring harness to starter. (Scheme 14) Do not let starter motor hang from wire harness.
6. Remove starter motor from engine. Note: Certain diesel engines use an aluminum spacer. (Scheme 13) Note position and orientation of spacer before removal.

Scheme 14

INSTALLATION 5.9L DIESEL

1. If Equipped: Position and hold aluminum spacer to rear of starter while positioning starter to engine.
2. Connect solenoid wire to starter motor. Tighten nut.
3. Position battery cable to starter stud. Install and tighten battery cable nut. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system) . Do not allow starter motor to hang from wire harness.
4. Position starter motor to transmission.
5. If equipped with automatic transmission, slide cooler tube bracket into position.
6. Install and tighten 3 starter mounting bolts. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system) .
7. Lower vehicle.
8. Connect both negative battery cables to both batteries.

Scheme 15

Scheme 16

Scheme 17

1. Disconnect the negative battery cable.
2. Raise vehicle and support. (Scheme 15)
3. Disconnect the solenoid connector.
4. Remove the positive battery cable. (Scheme 16)
5. Remove the upper bolt. (Scheme 17)
6. Remove the lower bolt.
7. Remove the starter.

INSTALLATION 8.3L - SRT-10

1. Install the starter.
2. Install the lower bolt.
3. Install the upper bolt. (Scheme 17)
4. Install the positive battery cable. (Scheme 16)
5. Connect the solenoid connector.
6. Lower vehicle.
7. Connect the negative battery cable.

REMOVAL

The starter relay is located in the Power Distribution Center (PDC). (Scheme 18) Refer to label on PDC cover for relay location.

1. Disconnect and isolate negative battery cable.
2. Remove cover from Power Distribution Center (PDC) for relay identification and location.
3. Remove starter relay from PDC.
4. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay.
5. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay.

INSTALLATION

1. Push down firmly on starter relay until terminals are fully seated in PDC receptacle.
2. Install PDC cover.
3. Connect battery cable.

Scheme 18

STARTING SYSTEM SPECIFICATIONS

STARTER - 8.3L - SRT-10

STARTER - 8.3L - SRT-10 SPECIFICATIONS

Engine should be up to operating temperature. Extremely heavy oil or tight engine will increase starter amperage draw.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

2003

For starter wiring see SYSTEM WIRING DIAGRAM article

1. For 1500 see appropriate diagram under «STARTING/CHARGING»(ref-163744-S24421867632004071200000)
2. For 2500 see appropriate diagram under «STARTING/CHARGING»(ref-154277-S32778929602003051200000)
3. For 3500 see appropriate diagram under «STARTING/CHARGING»(ref-154278-S34550431162003051200000)

2004

For starter wiring see SYSTEM WIRING DIAGRAM article

1. For 1500 see appropriate diagram under «STARTING/CHARGING»(ref-163744-S24421867632004071200000)
2. For 2500 see appropriate diagram under «STARTING/CHARGING»(ref-163745-S11117231632004071200000)
3. For 3500 see appropriate diagram under «STARTING/CHARGING»(ref-163746-S40664380802004071200000)

See also:
• WIRING DIAGRAMS
• STARTER MOTOR
• FEED CIRCUIT TEST
• CONTROL CIRCUIT TESTING
• STARTER RELAY
• STARTER - 8.3L - SRT-10