Dodge Dakota (R1). Manual - part 302

operating unless the automatic transmission gear
selector is in the Neutral or Park positions.

When the starter relay coil is energized, the nor-

mally 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 sole-

noid 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 on the manual transmission flywheel or on
the

automatic

transmission

torque

converter

torque converter drive plate.

As the solenoid plunger reaches the end of its

travel, the solenoid contact disc completes the high-
amperage starter feed circuit and energizes the sole-
noid 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 pro-

tects the starter motor from damage by allowing the

starter pinion gear to spin faster than the pinion
shaft. When the driver releases the ignition switch 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-ener-

gized, the solenoid plunger return spring returns the
plunger to its relaxed position. This causes the con-
tact disc to open the starter feed circuit, and the shift
lever to disengage the overrunning clutch and pinion
gear from the starter ring gear.

DIAGNOSIS AND TESTING - STARTING
SYSTEM

The battery, starting, and charging systems oper-

ate in conjunction with one another, and must be
tested as a complete system. For correct starting/
charging system operation, all of the components
involved in these 3 systems must perform within
specifications.

Starting System Diagnosis

CONDITION

POSSIBLE CAUSE

CORRECTION

STARTER FAILS TO
OPERATE.

1. Battery discharged or
faulty.

1. Refer to Battery. Charge or replace battery, if required.

2. Starting circuit wiring
faulty.

2. Refer to 8, Wiring Diagrams. Test and repair starter
feed and/or control circuits, if required.

3. Starter relay faulty.

3. Refer to Starter Relay in the Diagnosis and Testing
section of this group. Replace starter relay, if required.

4. Ignition switch faulty.

4. Refer to Ignition Switch and Key Lock Cylinder.
Replace ignition switch, if required.

5. Clutch pedal position
switch faulty.

5. Refer to Clutch Pedal Position Switch.

6. Park/Neutral position
switch faulty or
misadjusted.

6. Refer to Park/Neutral Position Switch. Replace
park/neutral position switch, if required.

7. Starter solenoid faulty.

7. Refer to Starter Motor. Replace starter motor assembly,
if required.

8. Starter motor faulty.

8. If all other starting system components and circuits test
OK, replace starter motor.

STARTER ENGAGES,
FAILS TO TURN
ENGINE.

1. Battery discharged or
faulty.

1. Refer to Battery. Charge or replace battery, if required.

2. Starting circuit wiring
faulty.

2. Refer to 8, Wiring Diagrams. Test and repair starter
feed and/or control circuits, if required.

3. Starter motor faulty.

3. If all other starting system components and circuits test
OK, replace starter motor assembly.

4. Engine seized.

4. Refer to Engine Diagnosis in the Diagnosis and Testing
section of 9, Engine.

8F - 30

STARTING

STARTING (Continued)

Starting System Diagnosis

CONDITION

POSSIBLE CAUSE

CORRECTION

STARTER ENGAGES,
SPINS OUT BEFORE
ENGINE STARTS.

1. Starter ring gear faulty.

1. Refer to Starter Motor in Removal and Installation.
Remove starter motor to inspect starter ring gear.
Replace starter ring gear, if required.

2. Starter motor faulty.

2. If all other starting system components and circuits test
OK, replace the starter motor assembly.

STARTER DOES NOT
DISENGAGE.

1. Starter motor
improperly installed.

1. Refer to Starter Motor in the Removal and Installation
section of this group. Tighten the starter mounting
hardware to the correct tightness specifications.

2. Starter relay faulty.

2. Refer to Starter Relay in the Diagnosis and Testing
section of this group. Replace starter relay, if required.

3. Ignition switch faulty.

3. Refer to Ignition Switch and Key Lock Cylinder.
Replace ignition switch, if required.

4. Starter motor faulty.

4. If all other starting system components and circuits test
OK, replace starter motor.

INSPECTION

For complete starter wiring circuit diagrams, refer

to 8, Wiring Diagrams. Before removing any unit
from starting system for repair or diagnosis, perform
the following inspections:

WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO 8, PASSIVE RESTRAINT SYS-
TEMS,

BEFORE

ATTEMPTING

ANY

STEERING

WHEEL, STEERING COLUMN, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT AND POSSIBLE PERSONAL INJURY.

• Battery - Visually inspect battery for indica-

tions of physical damage and loose or corroded cable
connections.

Determine

the

state-of-charge

and

cranking capacity of battery. Charge or replace bat-
tery, if required. Refer to Battery in 8, Battery.
Note: If equipped with diesel engine, a dual bat-
tery system is used, and both batteries must be
inspected.

• Ignition Switch - Visually inspect ignition

switch for indications of physical damage and loose
or corroded wire harness connections. Refer to Igni-
tion Switch and Key Lock Cylinder.

• Clutch Pedal Position Switch - If equipped

with manual transmission, visually inspect clutch
pedal position switch for indications of physical dam-
age and loose or corroded wire harness connections.
Refer to Clutch Pedal Position Switch in 6,
Clutch.

• 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 connec-

tions. Refer to Park/Neutral Position Switch in
21, Transmission.

• Starter Relay - Visually inspect starter relay

for indications of physical damage and loose or cor-
roded wire harness connections.

• Starter Motor - Visually inspect starter motor

for indications of physical damage and loose or cor-
roded wire harness connections.

• Starter Solenoid - Visually inspect starter sole-

noid for indications of physical damage and loose or
corroded wire harness connections.

• Wiring - Visually inspect wire harnesses for

damage. Repair or replace any faulty wiring, as
required. Refer to 8, Wiring Diagrams.

TESTING

COLD CRANKING TEST

For complete starter wiring circuit diagrams, refer

to 8, Wiring Diagrams. The battery must be fully-
charged and load-tested before proceeding. Refer to
Battery in 8, Battery.

(1) Connect volt-ampere tester to battery terminals

(Fig. 1). See instructions provided by manufacturer of
volt-ampere tester being used. Note: If equipped
with dual battery system (diesel), tester should
be connected to driver side battery only. Also,
tester current reading must be taken from bat-
tery positive 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.

STARTING

8F - 31

STARTING (Continued)

(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

START

ENGINE

FEW

TIMES

BEFORE PROCEEDING WITH FOLLOWING STEP.

(6) Rotate and hold ignition switch in Start posi-

tion. Note cranking voltage and current (amperage)
draw readings shown on volt-ampere tester.

(a) If voltage reads below 9.6 volts, refer to

Starter Motor in Diagnosis and Testing. If starter
motor is OK, refer to Engine Diagnosis in 9,
Engine for further testing of engine. If starter
motor is not OK, replace faulty starter motor.

(b) If voltage reads above 9.6 volts and current

(amperage) draw reads below specifications, refer
to Feed Circuit Test in this section.

starter motor does not turn, refer to Control Cir-
cuit Testing in this section.

(d) If voltage reads 12.5 volts or greater and

starter motor turns very slowly, refer to Feed Cir-
cuit Test in this section.

NOTE: A cold engine will increase starter current
(amperage) draw reading, and reduce battery volt-
age 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 wir-
ing circuit diagrams, refer 8, 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 battery posi-

tive cable, touch voltmeter leads to battery positive
cable clamp and cable connector at starter solenoid.
If you probe battery positive terminal post and cable
connector at starter solenoid, you are reading com-
bined voltage drop in battery positive cable clamp-to-
terminal post connection and battery positive cable.

The following operation will require a voltmeter

accurate to 1/10 (0.10) volt. Before performing tests,
be certain that following procedures are accom-
plished:

• Battery is fully-charged and load-tested. Refer to

Battery in 8, Battery.

• Fully engage parking brake.

• 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.

• Verify that all lamps and accessories are turned

off.

• To prevent a gasoline engine from starting,

(1) Connect positive lead of voltmeter to battery

negative terminal post. Connect negative lead of volt-
meter to battery negative cable clamp (Fig. 2). Rotate
and hold ignition switch in Start position. Observe
voltmeter. If voltage is detected, correct poor contact
between cable clamp and terminal post. Note: If
equipped with a dual battery system (diesel),
procedure must be performed twice, once for
each battery.

(2) Connect positive lead of voltmeter to battery

positive terminal post. Connect negative lead of volt-
meter to battery positive cable clamp (Fig. 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: If
equipped with a dual battery system (diesel),
this procedure must be performed twice, once
for each battery.

Fig. 1 Volts-Amps Tester Connections - Typical

1 - POSITIVE CLAMP
2 - NEGATIVE CLAMP
3 - INDUCTION AMMETER CLAMP

8F - 32

STARTING

STARTING (Continued)

(3) Connect voltmeter to measure between battery

positive terminal post and starter solenoid battery
terminal stud (Fig. 4). Rotate and hold ignition
switch in Start position. Observe voltmeter. If read-
ing 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 battery positive cable.
Note: If equipped with a dual battery system
(diesel), this procedure must be performed on
driver side battery only.

(4) Connect voltmeter to measure between battery

negative terminal post and a good clean ground on
engine block (Fig. 5). Rotate and hold ignition switch
in Start position. Observe voltmeter. If reading is
above 0.2 volt, clean and tighten battery negative
cable attachment on engine block. Repeat test. If
reading is still above 0.2 volt, replace faulty battery
negative cable. Note: If equipped with dual bat-
tery system (diesel), this procedure must be
performed twice, once for each battery.

Fig. 2 Test

1 - VOLTMETER
2 - BATTERY

Fig. 3 Test Battery Positive Connection Resistance -

Typical

1 - VOLTMETER
2 - BATTERY

Fig. 4 Test Battery Positive Cable

1 - BATTERY
2 - VOLTMETER
3 - STARTER MOTOR

Fig. 5 Test Ground Circuit Resistance - Typical

1 - VOLTMETER
2 - BATTERY
3 - ENGINE GROUND

STARTING

8F - 33

STARTING (Continued)

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