Dodge Durango (DN). Manual — part 268

INSPECTION

For complete circuit diagrams, refer to Starting

System in the Contents of Group 8W - Wiring Dia-
grams. Before removing any unit from the starting
system for repair or diagnosis, perform the following
inspections:

WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS,

REFER

TO

GROUP

8M

-

PASSIVE

RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING

WHEEL,

STEERING

COLUMN,

OR

INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

• Battery - Visually inspect the battery for indi-

cations of physical damage and loose or corroded
cable connections. Determine the state-of-charge and
cranking capacity of the battery. Charge or replace
the battery, if required. Refer to Battery in the
proper section of Group 8A - Battery for complete ser-
vice information for the battery.

• Ignition Switch - Visually inspect the ignition

switch for indications of physical damage and loose
or corroded wire harness connections. Refer to Igni-
tion Switch and Key Lock Cylinder in the proper
section of Group 8D - Ignition System for complete
service information for the ignition switch.

•

Park/Neutral Position Switch - Visually

inspect the park/neutral position switch for indica-
tions of physical damage and loose or corroded wire
harness connections. Refer to Park/Neutral Posi-
tion Switch in the proper section of Group 21 -
Transmission for complete service information for the
park/neutral position switch.

• Starter Relay - Visually inspect the starter

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

• Starter Motor - Visually inspect the starter

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

• Starter Solenoid - Visually inspect the starter

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

• Wiring - Visually inspect the wire harnesses for

damage. Repair or replace any faulty wiring, as
required. Refer to the proper section of Group 8W -
Wiring Diagrams for complete service information
and circuit diagrams for the starting system wiring
components.

TESTING

COLD CRANKING TEST

For complete circuit diagrams, refer to Starting

System in the Contents of Group 8W - Wiring Dia-
grams. The battery must be fully-charged and load-
tested before proceeding. Refer to Battery in the
Diagnosis and Testing section of Group 8A - Battery
for the procedures.

(1) Connect a suitable volt-ampere tester to the

battery terminals (Fig. 1). See the instructions pro-
vided by the manufacturer of the volt-ampere tester
being used.

(2) Fully engage the parking brake.
(3) Place the automatic transmission gearshift

selector lever in the Park position.

(4) Verify that all lamps and accessories are

turned off.

(5) To prevent the engine from starting, remove

the Automatic ShutDown (ASD) relay. The ASD relay
is located in the Power Distribution Center (PDC), in
the engine compartment. Refer to the fuse and relay
layout label affixed to the underside of the PDC cover
for ASD relay identification and location.

(6) Rotate and hold the ignition switch in the Start

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

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

Starter Motor in the Diagnosis and Testing sec-
tion of this group. If the starter motor is OK, refer
to Engine Diagnosis in the Diagnosis and Testing
section of Group 9 - Engine for further testing of
the engine. If the starter motor is not OK, replace
the faulty starter motor.

Fig. 1 Volts-Amps Tester Connections - Typical

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

DN

STARTING SYSTEMS

8B - 5

DIAGNOSIS AND TESTING (Continued)

(b) If the voltage reads above 9.6 volts and the

current (amperage) draw reads below specifica-
tions, refer to Feed Circuit Test in this section.

(c) If the voltage reads 12.5 volts or greater and

the starter motor does not turn, refer to Control
Circuit Testing in this section.

(d) If the voltage reads 12.5 volts or greater and

the starter motor turns very slowly, refer to Feed
Circuit Test in this section.

NOTE: A cold engine will increase the starter cur-
rent (amperage) draw reading, and reduce the bat-
tery voltage reading.

FEED CIRCUIT TEST

The starter feed circuit test (voltage drop method)

will determine if there is excessive resistance in the
high-amperage feed circuit. For complete circuit dia-
grams, refer to Starting System in the Contents of
Group 8W - Wiring Diagrams.

When performing these tests, it is important to

remember that the voltage drop is giving an indica-
tion of the resistance between the two points at
which the voltmeter probes are attached.

Example: When testing the resistance of the bat-

tery positive cable, touch the voltmeter leads to the
battery positive cable clamp and the cable connector
at the starter solenoid. If you probe the battery pos-
itive terminal post and the cable connector at the
starter solenoid, you are reading the combined volt-
age drop in the battery positive cable clamp-to-termi-
nal post connection and the battery positive cable.

The following operation will require a voltmeter

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

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

Battery in the Diagnosis and Testing section of
Group 8A - Battery for the procedures.

• Fully engage the parking brake.

• Place the automatic transmission gearshift selec-

tor lever in the Park position.

• Verify that all lamps and accessories are turned

off.

• To prevent the engine from starting, remove the

Automatic ShutDown (ASD) relay. The ASD relay is
located in the Power Distribution Center (PDC), in
the engine compartment. Refer to the fuse and relay
layout label affixed to the underside of the PDC cover
for ASD relay identification and location.

(1) Connect the positive lead of the voltmeter to

the battery negative terminal post. Connect the neg-
ative lead of the voltmeter to the battery negative
cable clamp (Fig. 2). Rotate and hold the ignition
switch in the Start position. Observe the voltmeter. If

voltage is detected, correct the poor contact between
the cable clamp and the terminal post.

(2) Connect the positive lead of the voltmeter to

the battery positive terminal post. Connect the nega-
tive lead of the voltmeter to the battery positive cable
clamp (Fig. 3). Rotate and hold the ignition switch in
the Start position. Observe the voltmeter. If voltage
is detected, correct the poor contact between the
cable clamp and the terminal post.

(3) Connect the voltmeter to measure between the

battery positive terminal post and the starter sole-
noid battery terminal stud (Fig. 4). Rotate and hold
the ignition switch in the Start position. Observe the
voltmeter. If the reading is above 0.2 volt, clean and

Fig. 2 Test Battery Negative Connection Resistance

- Typical

1 – VOLTMETER
2 – BATTERY

Fig. 3 Test Battery Positive Connection Resistance -

Typical

1 – VOLTMETER
2 – BATTERY

8B - 6

STARTING SYSTEMS

DN

DIAGNOSIS AND TESTING (Continued)

tighten the battery cable connection at the solenoid.
Repeat the test. If the reading is still above 0.2 volt,
replace the faulty battery positive cable.

(4) Connect the voltmeter to measure between the

battery negative terminal post and a good clean
ground on the engine block (Fig. 5). Rotate and hold
the ignition switch in the Start position. Observe the
voltmeter. If the reading is above 0.2 volt, clean and
tighten the battery negative cable attachment on the
engine block. Repeat the test. If the reading is still
above 0.2 volt, replace the faulty battery negative
cable.

(5) Connect the positive lead of the voltmeter to

the starter housing. Connect the negative lead of the

voltmeter to the battery negative terminal post (Fig.
6). Rotate and hold the ignition switch in the Start
position. Observe the voltmeter. If the reading is
above 0.2 volt, correct the poor starter to engine
block ground contact.

If the resistance tests detect no feed circuit prob-

lems, refer to Starter Motor in the Diagnosis and
Testing section of this group.

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 in the

Diagnosis and Testing section of this group for the
procedures.

• Starter Solenoid - Refer to Starter Motor in

the Diagnosis and Testing section of this group for
the procedures.

• Ignition Switch - Refer to Ignition Switch

and Key Lock Cylinder in the Diagnosis and Test-
ing section of Group 8D - Ignition System for the pro-
cedures.

•

Park/Neutral Position Switch - Refer to

Park/Neutral Position Switch in the Diagnosis
and Testing section of Group 21 - Transmission for
the procedures.

• Wire harnesses and connections - Refer to

Starting System in the Contents of Group 8W -
Wiring Diagrams for complete circuit diagrams.

STARTER MOTOR

Correct starter motor operation can be confirmed

by performing the following free running bench test.
This test can only be performed with the starter
motor removed from the vehicle. Refer to Starting

Fig. 4 Test Battery Positive Cable Resistance -

Typical

1 – BATTERY
2 – VOLTMETER
3 – STARTER MOTOR

Fig. 5 Test Ground Circuit Resistance - Typical

1 – VOLTMETER
2 – BATTERY
3 – ENGINE GROUND

Fig. 6 Test Starter Ground - Typical

1 – STARTER MOTOR
2 – BATTERY
3 – VOLTMETER

DN

STARTING SYSTEMS

8B - 7

DIAGNOSIS AND TESTING (Continued)

System in the Specifications section of this group for
the starter motor specifications.

(1) Remove the starter motor from the vehicle.

Refer to Starter Motor in the Removal and Instal-
lation section of this group for the procedures.

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

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

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

12-volt battery to the starter motor in series, and set
the ammeter to the 100 ampere scale. See the
instructions provided by the manufacturer of the
volt-ampere tester being used.

(4) Install a jumper wire from the solenoid termi-

nal to the solenoid battery terminal. The starter
motor should operate. If the starter motor fails to
operate, replace the faulty starter motor assembly.

(5) Adjust the carbon pile load of the tester to

obtain the free running test voltage. Refer to Start-
ing System in the Specifications section of this
group for the starter motor free running test voltage
specifications.

(6) Note the reading on the ammeter and compare

this reading to the free running test maximum
amperage draw. Refer to Starting System in the
Specifications section of this group for the starter
motor free running test maximum amperage draw
specifications.

(7) If the ammeter reading exceeds the maximum

amperage draw specification, replace the faulty
starter motor assembly.

STARTER SOLENOID

This test can only be performed with the starter

motor removed from the vehicle.

(1) Remove the starter motor from the vehicle.

Refer to Starter Motor in the Removal and Instal-
lation section of this group for the procedures.

(2) Disconnect the wire from the solenoid field coil

terminal.

(3) Check for continuity between the solenoid ter-

minal and the solenoid field coil terminal with a con-
tinuity tester (Fig. 7). There should be continuity. If
OK, go to Step 4. If not OK, replace the faulty starter
motor assembly.

(4) Check for continuity between the solenoid ter-

minal and the solenoid case (Fig. 8). There should be
continuity. If not OK, replace the faulty starter motor
assembly.

STARTER RELAY

The starter relay (Fig. 9) is located in the Power

Distribution Center (PDC), in the engine compart-
ment. Refer to the fuse and relay layout label affixed
to the underside of the PDC cover for starter relay
identification and location. For complete circuit dia-
grams, refer to Starting System in the Contents of
Group 8W - Wiring Diagrams.

(1) Remove the starter relay from the PDC. Refer

to Starter Relay in the Removal and Installation
section of this group for the procedures.

(2) A relay in the de-energized position should

have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 3. If not OK, replace the faulty relay.

(3) Resistance between terminals 85 and 86 (elec-

tromagnet) should be 75

6 5 ohms. If OK, go to Step

4. If not OK, replace the faulty relay.

(4) Connect a 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 the Relay Circuit Test that
follows. If not OK, replace the faulty relay.

Fig. 7 Continuity Test Between Solenoid Terminal

and Field Coil Terminal - Typical

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

Fig. 8 Continuity Test Between Solenoid Terminal

and Solenoid Case - Typical

1 – SOLENOID TERMINAL
2 – OHMMETER
3 – SOLENOID

8B - 8

STARTING SYSTEMS

DN

DIAGNOSIS AND TESTING (Continued)