Dodge Dakota (R1). Manual - part 308

(5) Connect positive lead of voltmeter to starter

housing. Connect negative lead of voltmeter to bat-
tery negative terminal post (Fig. 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: If equipped
with a dual battery system (diesel), this proce-
dure must be performed on driver side battery
only.

(6) If equipped with dual battery system (diesel),

connect positive lead of voltmeter to driver side bat-
tery positive cable clamp. Connect negative lead of
voltmeter to passenger side battery positive terminal
post. Rotate and hold ignition switch in Start posi-
tion. Observe voltmeter. If reading is above 0.2 volt,
clean and tighten passenger side battery positive
cable eyelet connection at driver side battery positive
cable clamp bolt. Repeat test. If reading is still above
0.2 volt, replace faulty passenger side battery posi-
tive cable.

If resistance tests detect no feed circuit problems,

refer to Starter Motor in the Diagnosis and Testing.

CONTROL CIRCUIT TESTING

The starter control circuit components should be

tested in the order in which they are listed, as fol-
lows:

• Starter Relay - Refer to Starter Relay Diag-

nosis and Testing.

• Starter Solenoid - Refer to Starter Motor

Diagnosis and Testing.

• Ignition Switch - Refer to Ignition Switch

and Key Lock Cylinder

• Clutch Pedal Position Switch - If equipped

with manual transmission, refer to Clutch Pedal
Position Switch in 6, Clutch.

• Park/Neutral Position Switch - If equipped

with automatic transmission, refer to Park/Neutral
Position Switch in 21, Transmission.

• Wire harnesses and connections - Refer to 8,

Wiring Diagrams.

SPECIFICATIONS

SPECIFICATIONS - STARTING SYSTEM

Starter Motor and Solenoid

Manufacturer

Mitsubishi

Denso

Part Number

56041013AC

56027702AC

56028715

Engine Application

2.5L

3.9L, 4.7L (Manual), 5.9L

4.7L (Auto)

Power Rating

1.2 Kilowatt - (1.6

Horsepower)

1.4 Kilowatt - (1.9

Horsepower

1.4 Kilowatt - (1.9

Horsepower

Voltage

12 Volts

Pinion Teeth

Number of Fields

Number of Poles

Number of Brushes

Drive Type

Planetary Gear

Reduction

Reduction Gear Train

Free Running Test Voltage

11.2 Volts

11 Volts

Fig. 6 Test Starter Ground - Typical

1 - STARTER MOTOR
2 - BATTERY
3 - VOLTMETER

8Fa - 14

STARTING

STARTING (Continued)

Starter Motor and Solenoid

Free Running Test Maximum
Amperage Draw

90 Amperes

73 Amperes

Free Running Test Minimum
Speed

2600 rpm

3601 rpm

Solenoid Closing Maximum
Voltage Required

7.8 Volts

7.5 Volts

* Cranking Amperage Draw
Test

130 Amperes

125 - 250 Amperes

* Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw.

SPECIFICATIONS - STARTING SYSTEM - DIESEL

Diesel Starter and Solenoid

Engine Application

2.5L Diesel

Power Rating

2.2 Kilowatt

Voltage

12 Volts

Number of Fields

Number of Poles

Number of Brushes

Drive Type

Planetary Gear Reduction

Free Running Test Voltage

11.5 Volts

Free Running Test Maximum
Amperage Draw

160 Amperes

Free Running Test Minimum
Speed

5500 rpm

Solenoid Closing Maximum
Voltage

7.8 Volts

* Cranking Amperage Draw
test

350 Amperes

* Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw.

SPECIFICATIONS - TORQUE - STARTING SYSTEM

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Battery Cable Eyelet Nut

at Solenoid Stud

120

Starter Mounting Bolts –

2.5L Engine

Starter Mounting

Nuts/Bolts – V-6/V-8

Engines

STARTING

8Fa - 15

STARTING (Continued)

SPECIFICATIONS - TORQUE – STARTING SYSTEM (DIESEL)

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Engine Mount to Engine

Mounting Bolts

Engine Mount Insulator

Retaining Nuts

Lower Engine Mount Bolts

Stater Motor (B+) Terminal

Starter Motor Retaining

Bolts

213

Starter Motor Support

Bracket Bolt

Starter Motor Support

Bracket Nuts

STARTER MOTOR

DESCRIPTION

The 2.5L starter is mounted with two bolts to the

clutch housing on the right side of the engine. The
4.7L

automatic

transmission

starter

motor

mounted with two bolts to the torque converter hous-
ing on the left side of the engine. The starter motors
for all of the remaining engine and transmission
combinations are mounted with one bolt, a stud and
a nut to the clutch or convertor housing, and are
located on the left side of the engine.

The electric motors of both starters have four

brushes contacting the motor commutator. The 2.5L
starter motor uses four permanent magnets for the
field poles, while the other starter motors feature
four electromagnetic field coils wound around four
pole shoes.

The starter motors are serviced only as a unit with

starter solenoids, and cannot be repaired. If either
component is faulty or damaged, the entire starter
motor and starter solenoid unit must be replaced.

OPERATION

The starter motor is equipped with a gear reduc-

tion (intermediate transmission) system. The gear
reduction system consists of a gear that is integral to
the output end of the electric motor armature shaft
that is in continual engagement with a larger gear
that is splined to the input end of the starter pinion
gear shaft. This feature makes it possible to reduce
the dimensions of the starter. At the same time, it
allows higher armature rotational speed, and delivers
increased torque through the starter pinion gear to
the starter ring gear.

The starter motor is activated by an integral heavy

duty starter solenoid switch mounted to the overrun-
ning clutch housing. This electromechanical switch
connects and disconnects the feed of battery voltage
to the starter motor, and actuates a shift fork that
engages and disengages the starter pinion gear with
the starter ring gear.

The starter motor uses an overrunning clutch and

starter pinion gear unit to engage and drive the
gears on the flywheel (or flywheel ring gear).

DIAGNOSIS AND TESTING - STARTER MOTOR

Correct starter motor operation can be confirmed

by performing following free running bench test. This
test can only be performed with starter motor
removed from vehicle. Refer to Starting Specifica-
tions for starter motor specifications.

(1) Remove starter motor from vehicle. Refer to

Starter MotorRemoval and Installation.

(2) Mount starter motor securely in a soft-jawed

bench vise. The vise jaws should be clamped on
mounting flange of starter motor. Never clamp on
starter motor by field frame.

(3) Connect suitable volt-ampere tester and 12-volt

battery to starter motor in series, and set ammeter to
100 ampere scale. See instructions provided by man-
ufacturer 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 Specifications
for starter motor free running test voltage specifica-
tions.

8Fa - 16

STARTING

STARTING (Continued)

(6) Note reading on ammeter and compare reading

to free running test maximum amperage draw. Refer
to Starting Specifications section for starter motor
free running test maximum amperage draw specifica-
tions.

(7) If ammeter reading exceeds maximum amper-

age draw specification, replace faulty starter motor
assembly.

STARTER MOTOR SOLENOID

This test can only be performed with starter motor

removed from vehicle.

(1) Remove starter motor from vehicle. Refer to

Starter Motor Removal and Installation.

(2) Disconnect wire from solenoid field coil termi-

nal.

(3) Check for continuity between solenoid terminal

and solenoid field coil terminal with continuity tester
(Fig. 7) or (Fig. 8). There should be continuity. If OK,
go to Step 4. If not OK, replace faulty starter motor
assembly.

(4) Check for continuity between solenoid terminal

and solenoid case (Fig. 9) or (Fig. 10). There should
be continuity. If not OK, replace faulty starter motor
assembly.

REMOVAL

2.5L Engine

(1) Disconnect and isolate negative battery cable.
(2) Raise and support vehicle.
(3) Remove bolt and washer (forward facing) secur-

ing starter to clutch housing (Fig. 11).

(4) While supporting starter motor, remove bolt

and washer (rearward facing) securing starter motor
to transmission housing.

(5) Lower starter motor far enough to access and

remove battery cable eyelet terminal nut at starter
solenoid. Always support starter motor during this
process. Do not let starter motor hang from wire har-
ness.

(6) Remove battery cable from stud.
(7) Disconnect solenoid terminal wire harness con-

nector from starter solenoid.

(8) Remove starter motor from transmission hous-

ing.

All 3.9L/5.9L, or 4.7L With Manual Transmission

(1) Disconnect and isolate negative battery cable.
(2) Raise and support vehicle.
(3) Remove nut securing starter motor to stud on

transmission housing (Fig. 12).

Fig. 7 Continuity Test - 2.5L Engine - Typical

1 - SOLENOID
2 - SOLENOID TERMINAL
3 - OHMMETER
4 - FIELD COIL TERMINAL

Fig. 8 Continuity Test - 3.9L/4.7L/5.9L Engine -

Typical

1 - OHMMETER
2 - SOLENOID TERMINAL
3 - FIELD COIL TERMINAL

Fig. 9 Continuity Test - 2.5L Engine - Typical

1 - SOLENOID
2 - SOLENOID TERMINAL
3 - OHMMETER

Fig. 10 Continuity Test - 3.9L/4.7L/5.9L Engine -

Typical

1 - SOLENOID TERMINAL
2 - OHMMETER
3 - SOLENOID

STARTING

8Fa - 17

STARTER MOTOR (Continued)

Content .. 306 307 308 309 ..