Dodge Dakota (R1). Manual — part 309
(4) While supporting starter motor, remove bolt
securing starter motor to transmission housing.
(5) If equipped with automatic transmission, slide
transmission cooler tube bracket forward on tubes far
enough for starter motor to be removed from lower
mounting stud.
(6) Lower starter motor from front transmission
housing far enough to access and remove nut secur-
ing battery cable eyelet to starter solenoid stud.
Always support starter motor during this process. Do
not let starter motor hang from wire harness.
(7) Remove solenoid wire solenoid terminal stud.
(8) Disconnect battery cable solenoid wire from
receptacle on starter solenoid.
(9) Remove starter motor from transmission hous-
ing.
4.7L With Automatic Transmission
(1) Disconnect and isolate negative battery cable.
(2) Raise and support vehicle.
(3) Remove bolt and washer (rearward facing)
securing starter motor to the transmission housing
(Fig. 13).
(4) While supporting starter motor, remove bolt
and washer (rearward facing) securing starter motor
to the transmission housing.
(5) Lower starter motor from front of transmission
housing far enough to access and remove nut secur-
ing battery positive cable eyelet terminal to the
starter solenoid B(+) terminal stud. Always support
starter motor during this process. Do not let starter
motor hang from wire harness.
(6) Remove battery cable eyelet terminal from sole-
noid B(+) terminal stud.
Fig. 11 Starter Motor Remove/Install - 2.5L Engine
1 - SCREW AND WASHER
2 - EYELET TERMINAL
3 - NUT
4 - BATTERY POSITIVE CABLE WIRE HARNESS
5 - WIRE HARNESS CONNECTOR
6 - SCREW AND WASHER
7 - STARTER MOTOR
Fig. 12 Starter Motor Remove/Install - All 3.9L/5.9L,
or 4.7L Engine with Man. Trans.
1 - EYELET TERMINAL
2 - NUT
3 - BRACKET
4 - STUD
5 - STARTER MOTOR
6 - LOCK WASHER
7 - WIRE HARNESS CONNECTOR
8 - NUT
9 - SCREW AND WASHER
Fig. 13 Starter Motor Remove/Install - 4.7L Engine
with Automatic Transmission
1 - EYELET TERMINAL
2 - NUT
3 - SCREW AND WASHER (2)
4 - STARTER MOTOR
5 - WIRE HARNESS CONNECTOR
8Fa - 18
STARTING
R1
STARTER MOTOR (Continued)
(7) Disconnect battery cable solenoid terminal wire
harness connector from receptacle on starter sole-
noid.
(8) Remove starter motor from transmission hous-
ing.
REMOVAL - 2.5L DIESEL
(1) Disconnect and isolate negative battery cable.
(2) Raise vehicle on hoist.
(3) Remove
(2)
right
engine
mount
insulator
retaining nuts (Fig. 14).
(4) Position jack stand and slightly raise and sup-
port engine assembly. Raise engine just enough to
remove weight from engine mount bracket.
(5) Remove (4) engine mount bracket retaining
bolts from engine block. Remove engine mount and
bracket from vehicle as assembly.
(6) Remove starter motor support bracket (Fig.
14).
(7) Disconnect turbocharger oil return hose from
engine block (Fig. 14).
WARNING: HEAT SHIELD IS VERY SHARP. WEAR
GLOVES TO PREVENT INJURY.
(8) Remove starter motor heat shield (Fig. 14).
(9) Disconnect starter motor electrical.
(10) Remove (3) starter motor retaining bolts
(11) Remove starter from vehicle.
INSTALLATION
2.5L Engine
(1) Position starter motor to transmission housing.
(2) Connect battery cable solenoid terminal wire
harness connector to connector receptacle on starter
solenoid. Always support starter motor during this
process. Do not let starter motor hang from wire har-
ness.
(3) Install battery cable eyelet terminal onto sole-
noid B(+) terminal stud.
(4) Install and tighten nut securing battery cable
eyelet terminal to starter solenoid B(+) terminal
stud. Tighten nut to 13.6 N·m (120 in. lbs.).
(5) Position starter motor and install bolts/wash-
ers. Tighten bolts to 54.2 N·m (40 ft. lbs.).
(6) Lower vehicle.
(7) Connect negative battery cable.
All 3.9L/5.9L, or 4.7L With Manual Trans.
(1) Position starter motor to transmission housing.
(2) Connect battery cable solenoid terminal wire
harness connector to connector receptacle on starter
solenoid. Always support the starter motor during
this process. Do not let the starter motor hang from
the wire harness.
(3) Install battery cable eyelet terminal onto sole-
noid B(+) terminal stud.
(4) Install and tighten nut securing battery cable
eyelet terminal to starter solenoid B(+) terminal
stud. Tighten nut to 13.6 N·m (120 in. lbs.).
(5) Position starter motor over stud on transmis-
sion housing.
(6) If equipped with automatic transmission, slide
automatic transmission cooler tube bracket rearward
on tubes and into position over starter motor flange.
(7) Loosely install the washers, bolt, and nut to
starter. Tighten bolt and nut to 67.8 N·m (50 ft. lbs.).
(8) Lower vehicle.
(9) Connect negative battery cable.
4.7L With Automatic Trans.
(1) Position starter motor to transmission housing.
(2) Connect battery cable solenoid terminal wire
harness connector to connector receptacle on starter
solenoid. Always support the starter motor during
this process. Do not let the starter motor hang from
the wire harness.
(3) Install battery cable eyelet terminal onto sole-
noid B(+) terminal stud.
(4) Install and tighten nut securing battery cable
eyelet terminal to starter solenoid B(+) terminal
stud. Tighten nut to 13.6 N·m (120 in. lbs.).
Fig. 14 Starter Motor
1 - STARTER MOTOR HEATSHIELD
2 - TURBOCHARGER OIL RETURN LINE
3 - RIGHT ENGINE MOUNT RETAINING NUTS
4 - STARTER MOTOR SUPPORT BRACKET
5 - STARTER MOTOR
R1
STARTING
8Fa - 19
STARTER MOTOR (Continued)
(5) Position starter motor to transmission housing
and loosely install two bolts/washers.
(6) Tighten bolts to 67.8 N·m (50 ft. lbs.).
(7) Lower vehicle.
(8) Connect negative battery cable.
INSTALLATION - 2.5L DIESEL
(1) Position starter motor on engine.
(2) Install (3) starter motor retaining bolts. Leave
bolts loose until all bolts are started. Torque bolts to
24 N·m (213 in. lbs.).
(3) Connect starter motor electrical. Torque B+ ter-
minal nut to 10 N·m (90 in. lbs.).
WARNING: HEAT SHIELD IS VERY SHARP. WEAR
GLOVES TO PREVENT INJURY.
(4) Install starter motor heat shield (Fig. 16).
(5) Connect turbocharger oil return hose on engine
block (Fig. 15).
(6) Install starter motor support bracket (Fig. 15).
Position bracket over stater motor studs and torque
retaining bolt in engine block to 47 N·m (35 ft. lbs.).
Torque starter support bracket retaining nuts to 11
N·m (98 in. lbs.).
(7) Position
engine
mount
and
engine
mount
bracket in vehicle and install (4) engine mount
bracket retaining bolts in engine block. Leave bolts
loose at this time.
(8) Install (2) engine mount insulator retaining
nuts (Fig. 15). Leave bolts loose at this time.
(9) Torque engine mount bracket retaining bolts to
61 N·m (45 ft. lbs.).
(10) Torque engine mount insulator nuts to 65 N·m
(48 ft. lbs.).
(11) Remove jack stand.
(12) Lower vehicle on hoist.
(13) Connect negative battery cable.
STARTER MOTOR RELAY
DESCRIPTION
The starter relay is an electromechanical device
that switches battery current to the pull-in coil of the
starter solenoid when ignition switch is turned to
Start position. The starter relay is located in the
Power Distribution Center (PDC) in the engine com-
partment. See PDC cover for relay identification and
location.
The starter relay is a International Standards
Organization (ISO) relay. Relays conforming to ISO
specifications have common physical dimensions, cur-
rent capacities, terminal patterns, and terminal func-
tions.
The starter relay cannot be repaired or adjusted
and, if faulty or damaged, it must be replaced.
Fig. 15 Starter Motor
1 - STARTER MOTOR HEATSHIELD
2 - TURBOCHARGER OIL RETURN LINE
3 - RIGHT ENGINE MOUNT RETAINING NUTS
4 - STARTER MOTOR SUPPORT BRACKET
5 - STARTER MOTOR
Fig. 16 Starter Heat shield
1 - STARTER MOTOR
2 - HEATSHIELD
8Fa - 20
STARTING
R1
STARTER MOTOR (Continued)
OPERATION
The ISO relay consists of an electromagnetic coil, a
resistor or diode, and three (two fixed and one mov-
able) electrical contacts. The movable (common feed)
relay contact is held against one of the fixed contacts
(normally closed) by spring pressure. When electro-
magnetic coil is energized, it draws the movable con-
tact away from normally closed fixed contact, and
holds it against the other (normally open) fixed con-
tact.
When electromagnetic coil is de-energized, spring
pressure returns movable contact to normally closed
position. The resistor or diode is connected in parallel
with electromagnetic coil within relay, and helps to
dissipate voltage spikes produced when coil is de-en-
ergized.
DIAGNOSIS AND TESTING - STARTER RELAY
The starter relay (Fig. 17) is located in Power Dis-
tribution Center (PDC). Refer to PDC cover for relay
identification and location. For complete starter relay
wiring circuit diagrams, refer to 8, Wiring Diagrams.
(1) Remove starter relay from PDC.
(2) A relay in 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 faulty relay.
(3) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 75 ± 5 ohms. If OK, go to Step
4. If not OK, replace faulty relay.
(4) Connect 12V 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 Relay Circuit Test that fol-
lows. If not OK, replace faulty relay.
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 open cir-
cuit to fuse in PDC 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 common feed terminal (30) in the energized
position. This terminal supplies battery voltage to
starter solenoid field coils. There should be continu-
ity between cavity for relay terminal 87 and starter
solenoid terminal at all times. If OK, go to Step 4. If
not OK, repair open circuit to starter solenoid as
required.
(4) The coil battery terminal (86) is connected to
electromagnet in relay. It is energized when ignition
switch is held in Start position. On vehicles with
manual transmission, clutch pedal must be fully
depressed for this test. Check for battery voltage at
cavity for relay terminal 86 with ignition switch in
Start position, and no voltage when ignition switch is
released to On position. If OK, go to Step 5. If not
OK with automatic transmission, check for open or
short circuit to ignition switch and repair, if required.
If circuit to ignition switch is OK, refer to Ignition
Switch and Key Lock Cylinder. If not OK with a
manual transmission, check circuit between relay
and clutch pedal position switch for open or a short.
If circuit is OK, refer to Clutch Pedal Position
Switch in 6 , Clutch.
(5) The coil ground terminal (85) is connected to
the electromagnet in the relay. On vehicles with
manual transmission, it is grounded at all times. On
vehicles with automatic transmission, it is grounded
through park/neutral position switch only when gear-
shift selector lever is in Park or Neutral positions.
Check for continuity to ground at cavity for relay ter-
minal 85. If not OK with manual transmission,
repair circuit to ground as required. If not OK with
automatic transmission, check for pen or short circuit
to
park/neutral
position
switch
and
repair,
if
required. If circuit to park/neutral position switch is
OK, refer to Park/Neutral Position Switch in 21,
Transmission.
Fig. 17 Starter Relay
TERMINAL LEGEND
NUMBER
IDENTIFICATION
30
COMMON FEED
85
COIL GROUND
86
COIL BATTERY
87
NORMALLY OPEN
87A
NOT USED
R1
STARTING
8Fa - 21
STARTER MOTOR RELAY (Continued)
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст