Dodge Neon / Neon SRT-4. Manual — part 84
(3) Connect positive voltmeter lead to the starter
motor housing and the negative lead to the battery
negative terminal (Fig. 3). Hold the ignition switch
key in the START position. If voltage reads above 0.2
volt, correct poor starter to engine ground.
(a) Connect the positive voltmeter lead to the
battery positive terminal, and negative lead to bat-
tery cable terminal on starter solenoid (Fig. 4).
Rotate and hold the ignition switch in the START
position. If voltage reads above 0.2 volt, correct
poor contact at battery cable to solenoid connec-
tion. If reading is still above 0.2 volt after correct-
ing poor contacts, replace battery positive cable.
(b) If resistance tests do not detect feed circuit
failures, replace the starter motor.
DIAGNOSIS AND TESTING - FEED CIRCUIT
The following procedure will require a suitable
volt-ampere tester (Fig. 5).
CAUTION:
Before performing any starter tests, the ignition and
fuel systems must be disabled.
(1) Check battery before performing this test. Bat-
tery must be fully charged.
Fig. 1 Battery Connection Resistance
1 - VOLTMETER
Fig. 2 Ground Circuit Resistance
1 - NEGATIVE BATTERY CABLE
Fig. 3 Starter Motor Ground Resistance
1 - VOLTMETER
Fig. 4 Battery Positive Cable Resistance
1 - VOLTMETER
8F - 32
STARTING
PL/SRT-4
STARTING (Continued)
(2) Connect a volt-ampere tester to the battery ter-
minals (Fig. 6). Refer to the operating instructions
provided with the tester being used.
(3) To disable the ignition and fuel systems, dis-
connect the Automatic Shutdown (ASD) Relay. The
ASD relay is located in the Power Distribution Cen-
ter (PDC). Refer to the PDC cover for proper relay
location.
(4) Verify that all lights and accessories are OFF,
and the transmission shift selector is in the PARK
position or with the clutch pedal depressed and SET
parking brake.
CAUTION:
Do not overheat the starter motor or draw the bat-
tery voltage below 9.6 volts during cranking opera-
tions.
(5) Rotate and hold the ignition switch in the
START position. Observe the volt-ampere tester (Fig.
5).
• If voltage reads above 9.6 volts, and amperage
draw reads above 280 amps, check for engine seizing
or faulty starter.
• If voltage reads 12.4 volts or greater and amper-
age reads 0 to 10 amps, check for corroded cables
and/or bad connections.
• If voltage is below 9.6 volts and amperage draw
is above 300 amps, the problem is the starter.
Replace the starter. Refer to Starter Removal and
Installation in this section.
(6) After the starting system problems have been
corrected, verify the battery state-of-charge and
charge battery if necessary. Disconnect all testing
equipment and connect the ASD relay. Start the vehi-
cle several times to assure the problem has been cor-
rected.
SPECIFICATIONS
TORQUE
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Starter Mounting Bolts
54
40
Starter Solenoid Battery
Nut
10
90
Fig. 5 Volt Ampere Tester - Typical
Fig. 6 Volt-Ampere Tester Connections - Typical
1 - POSITIVE CLAMP
2 - NEGATIVE CLAMP
3 - INDUCTION AMMETER CLAMP
PL/SRT-4
STARTING
8F - 33
STARTING (Continued)
STARTER MOTOR
Engine Application
2.0L OHC - DOHC
Power rating
1.1 Kw
Voltage
12 VOLTS
No. of Fields
6
No. of Poles
6
Brushes
4
Drive
Planetary Gear Train
Cranking Amperage Draw
test
150 - 280 Amps.
NOTE: Engine should be up to operating tempera-
ture. Extremely heavy oil or tight engine will
increase starter amperage draw.
STARTER MOTOR
DESCRIPTION
The starter is a permanent magnet starter motor.
The fields have six permanent magnets. A planetary
gear train transmits power between starter motor
and pinion shaft. The starter provides mechanical
torque to rotate the crankshaft at an RPM (crank
speed) necessary for self-sustained spark/ignition.
REMOVAL - 2.0L
(1) Disconnect and isolate the battery negative
cable (Fig. 7).
(2) Raise vehicle on hoist.
(3) Remove starter bolts (Fig. 8).
(4) Remove starter assembly.
(5) Disengage latch and remove solenoid connector
from starter assembly.
(6) Remove battery positive connector from starter
assembly. It is not necessary to remove the alternator
output lead from the connector.
INSTALLATION - 2.0L
(1) Clean corrosion/dirt from the cable and wire
terminals before installing wiring to the solenoid.
(2) Attach battery positive connector to starter.
Ensure alternator output connector is snapped into
the battery positive connector. Tighten the captive
nut to 10 N·m (90 in. lbs.).
CAUTION: It is critical that the alternator output ter-
minal be connected to the battery positive terminal
of the starter solenoid, for proper operation of the
charging and cranking systems.
(3) Install solenoid connector to starter. Ensure
that latch is fully engaged.
(4) Position the starter face into transmission
housing. Start bottom mounting bolt and thread in
until bolt is snug.
(5) Attach ground cable to upper starter mounting
bolt.
Fig. 7 Battery Negative Cable Remove/Install
1 - NEGATIVE CABLE
2 - NEGATIVE BATTERY POST
Fig. 8 Starter Mounting/Location
1 - NEGATIVE BATTERY CABLE
8F - 34
STARTING
PL/SRT-4
STARTING (Continued)
(6) Ensure the proper starter alignment before
tightening the starter mounting bolts to 54 N·m (40
ft. lbs.) torque.
(7) Lower vehicle.
(8) Connect negative battery cable.
STARTER MOTOR - 2.0L HIGH
OUTPUT
REMOVAL - 2.0L HIGH OUTPUT
(1) Disconnect and isolate the battery negative
cable (Fig. 9).
(2) Disconnect the inlet hose from intake manifold
and reposition the air cleaner box (Fig. 10).
(3) Starter location (Fig. 11).
(4) Remove starter bolts (Fig. 12).
(5) Remove starter assembly (Fig. 13).
(6) Disengage latch and remove solenoid connector
from starter assembly.
(7) Remove battery positive connector from starter
assembly. It is not necessary to remove the alternator
output lead from the connector (Fig. 14).
(8) Remove starter from vehicle.
INSTALLATION - 2.0L HIGH OUTPUT
(1) Clean corrosion/dirt from the cable and wire
terminals before installing wiring to the solenoid.
(2) Attach battery positive connector to starter.
Ensure alternator output connector is snapped into
the battery positive connector. Tighten the captive
nut to 10 N·m (90 in. lbs.).
CAUTION: It is critical that the alternator output ter-
minal be connected to the battery positive terminal
of the starter solenoid, for proper operation of the
charging and cranking systems.
(3) Install solenoid connector to starter. Ensure
that latch is fully engaged (Fig. 13).
(4) Position the starter face into transmission
housing. Start bottom mounting bolt and thread in
until bolt is snug (Fig. 8).
(5) Attach ground cable to upper starter mounting
bolt.
Fig. 9 Battery Negative Cable Remove/Install
1 - NEGATIVE CABLE
2 - NEGATIVE BATTERY POST
Fig. 10 AIR CLEANER BOX
Fig. 11 STARTER LOCATION
PL/SRT-4
STARTING
8F - 35
STARTER MOTOR (Continued)
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