Dodge Durango (HB). Manual — part 261
•
Starter Solenoid - Visually inspect starter solenoid for indications of physical damage and loose or cor-
roded 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
Battery.
1. Connect volt-ampere tester to battery terminals (1),
(2) and (3). See instructions provided by manufac-
turer of volt-ampere tester being used. Note: Cer-
tain 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 gear-
shift selector lever in Neutral position and block
clutch pedal in fully depressed position. If equipped
with automatic transmission, place gearshift selec-
tor lever in Park position.
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 TO START ENGINE A FEW TIMES BEFORE PRO-
CEEDING 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.
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.
c. If voltage reads 12.5 volts or greater and starter motor does not turn, refer to Control Circuit Testing in
this section.
d. If voltage reads 12.5 volts or greater and starter motor turns very slowly, refer to Feed Circuit Test in
this section.
Note: A cold engine will increase starter current (amperage) draw reading, and reduce battery voltage
reading.
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STARTING
8F - 41
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, 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 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:
•
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, 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.
1. Connect positive lead of voltmeter (1) to negative
battery cable terminal post. Connect negative lead
of voltmeter to negative battery cable clamp. Rotate
and hold ignition switch in Start position. Observe
voltmeter (1). 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,
procedure must be performed twice, once for
each battery.
2. Connect positive lead of voltmeter (1) to positive
battery terminal post. Connect negative lead of volt-
meter to battery positive cable clamp. Rotate and
hold ignition switch in Start position. Observe volt-
meter (1). If voltage is detected, correct poor con-
tact between cable clamp and terminal post. Note:
Certain diesel equipped models use dual batter-
ies. If equipped with dual battery system, this
procedure must be performed twice, once for
each battery.
8F - 42
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3. Connect voltmeter (2) to measure between battery
positive terminal post and starter solenoid battery
terminal stud (3). Rotate and hold ignition switch in
Start position. Observe voltmeter. If reading is
above 0.2 volt, clean and tighten battery cable con-
nection 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 (1) to measure between nega-
tive battery terminal post and a good clean ground
on engine block (3). 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 nega-
tive battery cable. Note: Certain diesel equipped
models use dual batteries. If equipped with dual
battery system, this procedure must be per-
formed twice, once for each battery.
5. Connect positive lead of voltmeter (3) to starter
housing (1). Connect negative lead of voltmeter to
negative battery terminal post. 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 voltme-
ter 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, refer to Starter Motor in the Diagnosis and Testing.
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8F - 43
CONTROL CIRCUIT TESTING
The starter control circuit components should be tested in the order in which they are listed, as follows:
•
Starter Relay - Refer to Starter Relay Diagnosis 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
STARTING SYSTEM
Starter Motor and Solenoid
Manufacturer
Denso
Part Number
56028715AD
Engine Application
3.7L / 4.7L / 5.7L
Power Rating
1.4 Kilowatt / 1.9
Horsepower
Voltage
12 Volts
Number of Brushes
4
Drive Type
Gear Reduction
Free Running Test Voltage
11 Volts
Free Running Test Amperage
Draw
73 Amperes
Free Running Test Minimum
Speed
3601 rpm
Solenoid Closing Maximum
Voltage Required
7.5 Volts
* Cranking Amperage Draw
Test
125 - 250 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 (large nut)
25
19
221
Starter Solenoid Nut
(small nut)
6
-
55
Starter Mounting Bolts
68
50
-
Starter Mounting Nut
68
50
-
8F - 44
STARTING
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