Starting System Dodge Ram Wagon B1500

DESCRIPTION

Nippondenso starter is a 4-field, 4-brush, 12-volt motor with a solenoid mounted within the housing. The unit has a 2-to-1 reduction gear set in a die cast aluminum housing. Starter has serviceable gear and clutch assembly only. If starter solenoid fails, entire starter motor must be replaced.

Ram Van/Wagon uses a starter relay in starter circuit between the battery and starter solenoid terminal. Automatic Transmission (A/T) equipped vehicles use a neutral safety switch to provide ground path for the starter relay. Manual Transmission (M/T) equipped vehicles use a clutch pedal interlock switch to provide battery voltage from ignition switch to the starter relay. (Scheme 1)

STARTER APPLICATIONS

Scheme 1

TROUBLE SHOOTING

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

ON-VEHICLE TESTING

DISABLING/ENABLING IGNITION & FUEL SYSTEMS

Disabling Ignition & Fuel Systems

Remove Automatic Shutdown Relay (ASD) located in Power Distribution Center (PDC). Refer to PDC cover for proper relay location. PDC is located in engine compartment.

Enabling Ignition & Fuel Systems

When testing and/or repairs have been completed, verify battery condition. Recharge battery as required, after starter tests have been completed. Disconnect all test equipment. Install ASD relay. Start engine several times to verify malfunction has been corrected.

CRANKING TEST

Note. Ensure engine is at normal operating temperature. High viscosity oil, extreme cold temperatures, or tight engine will increase amperage draw.

1. Using a battery load tester, connect positive and negative leads to battery. Connect inductive ammeter pick-up to positive battery cable. Disable ignition and fuel systems. See DISABLING/ENABLING IGNITION & FUEL SYSTEMS.
2. Ensure all lights and accessories are off. Place A/T in Park position or M/T in Neutral position. Apply parking brake. Crank engine and observe voltmeter reading. If voltage reads more than 9.6 volts and cranking amperage draw is more than specified amps, proceed to CIRCUIT RESISTANCE TESTS. See STARTER SPECIFICATIONS. If voltage reads 12.4 volts or more and amperage reads 0-10 amps, proceed to SOLENOID CIRCUIT TEST. CAUTION: During cranking, DO NOT draw battery voltage down to less than 9.6 volts. Use care not to overheat starter.
3. If starter cranks engine freely, but problem with starter is still suspected, engage starter several times while observing volt/ammeter readings. A starter that has a problem should fail when performing this procedure.

CIRCUIT RESISTANCE TESTS

Note. If excessive resistance is not found in circuits being tested, remove starter and proceed to BENCH TESTING.

Battery Connection Resistance Test

1. Disable vehicle ignition and fuel systems. See DISABLING/ENABLING IGNITION & FUEL SYSTEMS. A voltmeter accurate to one tenth of a volt will be needed for the following tests.
2. Connect voltmeter positive lead to negative battery cable clamp. Connect voltmeter negative lead to negative battery post. Crank engine and observe voltmeter reading. If voltage is detected, repair poor contact between cable clamp and post. Perform same procedure to positive battery post and cable clamp.

Ground Connection Resistance Test

Connect voltmeter negative lead to negative battery post. Connect voltmeter positive lead to engine block, near negative battery cable grounding point. Crank engine and observe voltmeter reading. If voltmeter reading 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 post. Connect voltmeter positive lead to starter housing. Crank engine and observe voltmeter reading. If voltmeter reading indicates more than 0.2 volt, repair poor starter-to-ground connection.

Positive Battery Cable Resistance Test

1. 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 post.
2. Crank engine and observe voltmeter reading. If voltage reads more than 0.2 volt, correct poor connection between battery cable and starter solenoid or replace positive battery cable.

SOLENOID CIRCUIT TEST

Note. Perform SOLENOID CIRCUIT TEST before testing starter relay circuit and starter relay. Ensure A/T is in Park position or M/T is in Neutral position and parking brake is applied.

1. Disable vehicle ignition and fuel systems. See DISABLING/ENABLING IGNITION & FUEL SYSTEMS.
2. Ensure battery is fully charged. Ensure solenoid connections are not loose or corroded. Remove starter relay from Power Distribution Center (PDC). Refer to PDC cover for proper relay location. PDC is located in engine compartment.
3. Connect a remote starter switch or jumper wire between starter relay connector terminal No. 87 and positive battery post. (Scheme 2) If engine cranks, solenoid and starter are good. Go to STARTER RELAY CIRCUIT TEST.
4. If engine fails to crank, or if solenoid chatters, check wiring and connectors from starter relay connector to starter solenoid terminal for loose or corroded connections. Clean and retest. If engine still fails to crank, remove starter and proceed to SOLENOID TEST under BENCH TESTING.

STARTER RELAY CIRCUIT TEST

Note. Perform SOLENOID CIRCUIT TEST under ON-VEHICLE TESTING before testing starter relay circuit.

1. Ensure battery is fully charged. Remove starter relay from Power Distribution Center (PDC). Refer to PDC cover for proper relay location. PDC is located in engine compartment.
2. Connect a jumper wire between starter relay connector terminal No. 30 and terminal No. 87. (Scheme 2) If engine does not crank, go to SOLENOID TEST under BENCH TESTING. If engine cranks, go to next step.
3. Turn ignition on. Check for battery voltage at starter relay connector terminal No. 30. If voltage is not present, repair open in wiring from starter relay connector to battery.
4. If voltage is present at starter relay connector terminal No. 30, ensure battery voltage is also present at starter relay connector terminal No. 86. Check for voltage with ignition switch in START position and clutch pedal depressed (if equipped with M/T). If voltage is present, circuit is okay. Go to step 7) if equipped with M/T or step 8) if equipped with A/T.
5. If voltage is not present at starter relay connector terminal No. 86 and vehicle is equipped with A/T, repair open in wiring from ignition switch to starter relay connector. If vehicle is equipped with M/T, go to next step.
6. Unplug wiring connector from clutch interlock switch mounted on clutch pedal bracket. Connect jumper wire between interlock switch connector terminals. Recheck for voltage at starter relay connector terminal No. 86 with ignition switch in START position. If voltage is present at terminal No. 86 of starter relay, check clutch interlock switch adjustment. Adjust or replace clutch interlock switch on clutch pedal bracket as needed. If voltage is not present at terminal No. 86 of starter relay, repair wiring between ignition switch and starter relay connector.
7. If vehicle is equipped with M/T, connect voltmeter negative lead to starter relay connector terminal No. 85 and positive lead to terminal No. 86. Turn ignition switch to START position and depress clutch pedal. If voltmeter reads battery voltage, starter relay connector ground circuit is good. Replace faulty starter relay. If voltmeter reading is not battery voltage, repair ground wire circuit.
8. If vehicle is equipped with A/T, connect voltmeter negative lead to starter relay connector terminal No. 85 and positive lead to terminal No. 86. Ensure transmission gear selector is in Park or Neutral position. Ground circuit runs through neutral safety switch on transmission. Turn ignition switch to START position. If voltmeter reads battery voltage, starter relay connector ground circuit is good. Replace faulty starter relay.
9. If voltmeter reading is not battery voltage, check transmission neutral safety switch for loose or damaged connections. Repair or replace neutral safety switch as required. If neutral safety switch is okay, repair ground wire circuit.

STARTER RELAY TEST

Note. Perform SOLENOID CIRCUIT TEST under ON-VEHICLE TESTING before testing starter relay.

Remove starter relay from Power Distribution Center (PDC). Refer to PDC cover for proper relay location. PDC is located in engine compartment. Connect 12-volt power source to starter relay terminal No. 86 and ground terminal No. 85. (Scheme 2) Using ohmmeter, check continuity across starter relay terminals No. 30 and 87. If continuity is not present, replace starter relay.

Scheme 2

CLUTCH INTERLOCK SWITCH TEST

Note. Refer to TEST NS-1A in appropriate article; For Ram Van 3.9L see TESTS W/CODES - 3.9L article, For Ram Van 5.2L see TESTS W/CODES - 5.2L article, For Ram Van 5.2L see TESTS W/CODES - 5.9L article.

IGNITION SWITCH TEST

Note. Refer to TEST NS-1A in appropriate article; For Ram Van 3.9L see TESTS W/CODES - 3.9L article, For Ram Van 5.2L see TESTS W/CODES - 5.2L article, For Ram Van 5.2L see TESTS W/CODES - 5.9L article.

NEUTRAL SAFETY SWITCH

Note. Refer to TEST NS-1A in appropriate article; For Ram Van 3.9L see TESTS W/CODES - 3.9L article, For Ram Van 5.2L see TESTS W/CODES - 5.2L article, For Ram Van 5.2L see TESTS W/CODES - 5.9L article.

SOLENOID TEST

1. With starter removed from vehicle, remove starter motor field coil wire from solenoid field coil terminal. Using an ohmmeter, check for continuity between solenoid terminal and field coil terminal of starter solenoid. Continuity should be present.
2. Check for continuity between solenoid terminal and solenoid housing. Continuity should be present. If continuity is not present in either test, replace solenoid. On Nippondenso starter equipped vehicles, replace starter and solenoid as an assembly.

OVERHAUL

Note. Manufacturer does not recommend disassembling and servicing starters. If starter is found defective, a new unit must be installed.

STARTER SPECIFICATIONS

STARTER SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TROUBLE SHOOTING - BASIC PROCEDURES
• COMPUTER RELEARN PROCEDURES
• TESTS W/CODES - 3.9L
• TESTS W/CODES - 5.2L
• TESTS W/CODES - 5.9L