Dodge Neon / Neon SRT-4. Manual — part 83

INSPECTION

Before removing any unit from the starting system

for repair or diagnosis, perform the following inspec-
tions:

• 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 the Battery section
for more information.

• Ignition Switch - Visually inspect the ignition

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

• Transmission Range Sensor or Park/Neu-

tral Switch - Visually inspect the transmission
range sensor for indications of physical damage and
loose or corroded wire harness connections.

• 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 harness for

damage. Repair or replace any faulty wiring, as
required. Check for loose or corroded wire harness
connections at main engine ground and remote jump
post.

• Power Distribution Center (PDC) - Visually

inspect the B+ connections at the PDC for physical
damage and loose or corroded harness connections.

STARTING SYSTEM DIAGNOSIS

CONDITION

POSSIBLE CAUSE

CORRECTION

STARTER FAILS
TO ENGAGE.

1. BATTERY
DISCHARGED OR
FAULTY.

1. REFER TO THE BATTERY SECTION FOR MORE
INFORMATION. CHARGE OR REPLACE BATTERY, IF
REQUIRED.

2. STARTING CIRCUIT
WIRING FAULTY.

2. REFER TO FEED CIRCUIT RESISTANCE TEST AND FEED
CIRCUIT TEST IN THIS SECTION.

3. STARTER RELAY
FAULTY.

3. REFER TO RELAY TEST, IN THIS SECTION. REPLACE
RELAY, IF NECESSARY.

4. IGNITION SWITCH
FAULTY.

4. REFER TO IGNITION SWITCH TEST, IN THE STEERING
SECTION OR 8 WIRING DIAGRAMS. REPLACE SWITCH, IF
NECESSARY.

5. PARK/NEUTRAL
POSITION SWITCH
(AUTO TRANS) FAULTY
OR MIS-ADJUSTED.

5. REFER PARK/NEUTRAL POSITION SWITCH TEST, IN THE
TRANSAXLE. SECTION FOR MORE INFORMATION. REPLACE
SWITCH, IF NECESSARY.

6. CLUTCH INTERLOCK
SWITCH (MAN TRANS)
FAULTY.

6. REFER TO CLUTCH PEDAL POSITION SWITCH TEST, IN
THE CLUTCH. SECTION. REPLACE SWITCH, IF NECESSARY.

7. STARTER SOLENOID
FAULTY.

7. REFER TO SOLENOID TEST, IN THIS SECTION. REPLACE
STARTER ASSEMBLY, IF NECESSARY.

8. STARTER ASSEMBLY
FAULTY.

8. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.

9. FAULTY TEETH ON
RING GEAR.

9. ROTATE FLYWHEEL 360°, AND INSPECT TEETH AND RING
GEAR REPLACED IF DAMAGED.

10. PCM DOUBLE
START OVERRIDE
OUTPUT FAILURE.

10. REFER TO PCM DIAGNOSTIC. CHECK FOR CONTINUITY
BETWEEN PCM AND TERMINAL 85. REPAIR OPEN CIRCUIT
AS REQUIRED. IF OK, PCM MAY BE DEFECTIVE.

STARTER
ENGAGES,
FAILS TO TURN
ENGINE.

1. BATTERY
DISCHARGED OR
FAULTY.

1. REFER TO THE BATTERY SECTION FOR MORE
INFORMATION. CHARGE OR REPLACE BATTERY AS
NECESSARY.

8F - 28

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PL/SRT-4

STARTING (Continued)

CONDITION

POSSIBLE CAUSE

CORRECTION

2. STARTING CIRCUIT
WIRING FAULTY.

2. REFER TO THE FEED CIRCUIT RESISTANCE TEST AND
THE FEED CIRCUIT TEST IN THIS SECTION. REPAIR AS
NECESSARY.

3. STARTER ASSEMBLY
FAULTY.

3. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.

4. ENGINE SEIZED.

4. REFER TO THE ENGINE SECTION, FOR DIAGNOSTIC AND
SERVICE PROCEDURES.

5. LOOSE
CONNECTION AT
BATTERY, PDC,
STARTER, OR ENGINE
GROUND.

5. INSPECT FOR LOOSE CONNECTIONS.

6. FAULTY TEETH ON
RING GEAR.

6. ROTATE FLYWHEEL 360°, AND INSPECT TEETH AND RING
GEAR REPLACED IF DAMAGED.

STARTER
ENGAGES,
SPINS OUT
BEFORE
ENGINE
STARTS.

1. BROKEN TEETH ON
STARTER RING GEAR.

1. REMOVE STARTER. INSPECT RING GEAR AND REPLACE
IF NECESSARY.

2. STARTER ASSEMBLY
FAULTY.

2. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.

STARTER DOES
NOT
DISENGAGE.

1. STARTER
IMPROPERLY
INSTALLED.

1. INSTALL STARTER. TIGHTEN STARTER MOUNTING
HARDWARE TO CORRECT TORQUE SPECIFICATIONS.

2. STARTER RELAY
FAULTY.

2. REFER TO RELAY TEST, IN THIS SECTION. REPLACE
RELAY, IF NECESSARY.

3. IGNITION SWITCH
FAULTY.

3. REFER TO IGNITION SWITCH TEST, IN THE STEERING
SECTION. REPLACE SWITCH, IF NECESSARY.

4. STARTER ASSEMBLY
FAULTY.

4. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.

5. FAULTY TEETH ON
RING GEAR.

5. ROTATE FLYWHEEL 360°, AND INSPECT TEETH AND RING
GEAR REPLACED IF DAMAGED.

DIAGNOSIS AND TESTING - CONTROL
CIRCUIT TEST

The starter control circuit has:
• Starter motor with integral solenoid

• Starter relay

• Transmission range sensor, or Park/Neutral

Position switch with automatic transmissions

• Ignition switch

• Battery

• All related wiring and connections

• Powertrain Control Module (PCM)

CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.

• To disable ignition and fuel systems, disconnect

the Automatic Shutdown Relay (ASD). The ASD relay
is located in the Power Distribution Center (PDC).
Refer to the PDC cover for the proper relay location.

STARTER SOLENOID

WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN THE PARK POSITION WITH THE
PARKING BRAKE APPLIED. THIS MAY RESULT IN
PERSONAL INJURY OR DEATH.

(1) Verify battery condition. Battery must be in

good condition with a full charge before performing
any starter tests. Refer to Battery Tests.

PL/SRT-4

STARTING

8F - 29

STARTING (Continued)

(2) Perform Starter Solenoid test BEFORE per-

forming the starter relay test.

(3) Perform a visual inspection of the starter/

starter solenoid for corrosion, loose connections or
faulty wiring.

(4) Locate and remove the starter relay from the

Power Distribution Center (PDC). Refer to the PDC
label for relay identification and location.

(5) Connect a remote starter switch or a jumper

wire between the remote battery positive post and
terminal 87 of the starter relay connector.

(a) If engine cranks, starter/starter solenoid is

good. Go to the Starter Relay Test.

(b) If engine does not crank or solenoid chatters,

check wiring and connectors from starter relay to
starter solenoid and from the battery positive ter-
minal to starter post for loose or corroded connec-
tions. Particularly at starter terminals.

(c) Repeat test. If engine still fails to crank prop-

erly, trouble is within starter or starter mounted
solenoid, and replace starter. Inspect the ring gear
teeth.

STARTER RELAY

WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN THE PARK/NEUTRAL POSITION
WITH THE PARKING BRAKE APPLIED. THIS MAY
RESULT IN PERSONAL INJURY OR DEATH.

RELAY TEST

The starter relay is located in the Power Distribu-

tion Center (PDC) in the engine compartment. Refer
to the PDC label for relay identification and location.

Remove

the

starter

relay

from

the

PDC

as

described in this group to perform the following tests:

(1) 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 2. If not OK, replace the faulty relay.

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

tromagnet) should be 75 ±5 ohms. If OK, go to Step
3. If not OK, replace the faulty relay.

(3) Connect a battery B+ lead to terminals 85 and

a ground lead to terminal 86 to energize the relay.
The relay should click. Also test for continuity
between terminals 30 and 87, and no continuity
between terminals 87A and 30. If OK, refer to Relay
Circuit Test procedure. If not OK, replace the faulty
relay.

CAV

FUNCTION

30

B (+)

85

IGNITION SWITCH OUTPUT

86

PCM-CONTROLLED GROUND

87

STARTER RELAY OUTPUT

87A

NO CONNECT

Starter Relay Pinout

Starter Relay Pinout

Starter Relay Pinout

8F - 30

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PL/SRT-4

STARTING (Continued)

RELAY CIRCUIT TEST

(1) The relay common feed terminal cavity (30) is

connected to battery voltage and should be hot at all
times. If OK, go to Step 2. If not OK, repair the open
circuit to the PDC fuse as required.

(2) The relay normally closed terminal (87A) is

connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3.

(3) The relay normally open terminal (87) is con-

nected to the common feed terminal (30) in the ener-
gized position. This terminal supplies battery voltage
to the starter solenoid field coils. There should be
continuity between the cavity for relay terminal 87
and the starter solenoid terminal at all times. If OK,
go to Step 4. If not OK, repair the open circuit to the
starter solenoid as required.

(4) The coil battery terminal (85) is connected to

the electromagnet in the relay. It is energized when
the ignition switch is held in the Start position and
the clutch pedal is depressed (manual trans). Check
for battery voltage at the cavity for relay terminal 86
with the ignition switch in the Start position and the
clutch pedal is depressed (manual trans), and no
voltage when the ignition switch is released to the
On position. If OK, go to Step 5. If not OK, check for
an open or short circuit to the ignition switch and
repair, if required. If the circuit to the ignition switch
is OK, see the Ignition Switch Test procedure in this
group.

(5) The coil ground terminal (86) is connected to

the electromagnet in the relay. It is grounded by the
PCM if the conditions are right to start the car. For
automatic trans. cars the PCM must see Park Neu-
tral switch low and near zero engine speed (rpm).
For manual trans. cars the PCM only needs to see
near zero engine speed (rpm) and low clutch inter-
lock input and see near zero engine speed (rpm). To
diagnose the Park Neutral switch of the trans range
sensor refer to the transaxle section. Check for conti-
nuity to ground while the ignition switch is in the
start position and if equipped the clutch pedal
depressed. If not OK and the vehicle has an auto-
matic trans. verify Park Neutral switch operation. If
that checks OK check for continuity between PCM
and the terminal 86. Repair open circuit as required.
Also check the clutch interlock switch operation if
equipped with a manual transmission. If OK, the
PCM may be defective.

SAFETY SWITCHES

For diagnostics of the Transmission Range Sensor,

refer to the Transaxle section for more information.

If equipped with Clutch Interlock/Upstop Switch,

refer to Diagnosis and Testing in the Clutch section.

IGNITION SWITCH

After testing starter solenoid and relay, test igni-

tion switch and wiring. Refer to the Ignition Section
or Wiring Diagrams for more information. Check all
wiring for opens or shorts, and all connectors for
being loose or corroded.

BATTERY

For battery diagnosis and testing, refer to the Bat-

tery section for procedures.

ALL RELATED WIRING AND CONNECTORS

Refer to Wiring Diagrams for more information.

DIAGNOSIS AND TESTING - FEED CIRCUIT
RESISTANCE

Before proceeding with this operation, review Diag-

nostic Preparation and Starter Feed Circuit Tests.
The following operation will require a voltmeter,
accurate to 1/10 of a volt.

CAUTION: Ignition system also must be disabled to
prevent engine start while performing the following
tests.

(1) 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.

(2) With all wiring harnesses and components

properly connected, perform the following:

(a) Connect the negative lead of the voltmeter to

the battery negative post, and positive lead to the
battery negative cable clamp (Fig. 1). Rotate and
hold the ignition switch in the START position.
Observe the voltmeter. If voltage is detected, cor-
rect poor contact between cable clamp and post.

(b) Connect positive lead of the voltmeter to the

battery positive post, and negative lead to the bat-
tery positive cable clamp (Fig. 1). Rotate and hold
the ignition switch key in the START position.
Observe the voltmeter. If voltage is detected, cor-
rect poor contact between the cable clamp and
post.

(c) Connect negative lead of voltmeter to battery

negative terminal, and positive lead to engine
block near the battery cable attaching point (Fig.
2). Rotate and hold the ignition switch in the
START position. If voltage reads above 0.2 volt,
correct poor contact at ground cable attaching
point. If voltage reading is still above 0.2 volt after
correcting poor contacts, replace ground cable.

PL/SRT-4

STARTING

8F - 31

STARTING (Continued)