Dodge Neon 1998 Factory Service Repair Manual

STARTING CONTENTS page page GENERAL INFORMATION BOSCH STARTER ........................ 1 INTRODUCTION ......................... 1 SUPPLY CIRCUIT AND CONTROL CIRCUIT .... 1 DIAGNOSIS AND TESTING FEED CIRCUIT RESISTANCE TEST ........... 2 FEED CIRCUIT TEST ...................... 2 STARTER CONTROL CIRCUIT .............. 1 STARTING SYSTEM TEST ................. 4 REMOVAL AND INSTALLATION SAFETY SWITCHES ...................... 6 STARTER RELAY ........................ 7 STARTER .............................. 6 SPECIFICATIONS STARTER .............................. 7 TORQUE ............................... 7 GENERAL INFORMATION INTRODUCTION The starting system (Fig. 1) has: • Ignition switch • Starter relay • Neutral starting and back up switch • Clutch pedal position switch • Wiring harness • Battery • Starter motor with an integral solenoid BOSCH STARTER The Bosch is a permanent magnet starter motor. A planetary gear train transmits power between starter motor and pinion shaft. The fields have six permanent magnets. The starter system consists of two separate circuits: • A high amperage supply to feed the starter motor. • A low amperage circuit to control the starter solenoid. SUPPLY CIRCUIT AND CONTROL CIRCUIT The starter system consists of two separate circuits: • A high amperage supply to feed the starter motor. • A low amperage circuit to control the starter solenoid. DIAGNOSIS AND TESTING STARTER CONTROL CIRCUIT The starter control circuit has: • Starter solenoid • Starter relay • Neutral starting and back up switch with automatic transmissions • Clutch pedal position switch with manual transmission • Ignition switch • Battery • All related wiring and connections CAUTION: Before performing any starter tests, the ignition and fuel systems must be disabled. Fig. 1 Starting System PL STARTING 8B - 1

To disable the 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 proper relay location. FEED CIRCUIT RESISTANCE TEST 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, disconnect the Automatic Shutdown Relay (ASD). 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. 2). Rotate and hold the ignition switch in the START position. Observe the voltmeter. If voltage is detected, correct poor contact between cable clamp and post. (b) Connect positive lead of the voltmeter to the battery positive post, and negative lead to the battery positive cable clamp (Fig. 2). Rotate and hold the ignition switch key in the START position. Observe the voltmeter. If voltage is detected, correct 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. 3). 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. (3) Connect positive voltmeter lead to the starter motor housing and the negative lead to the battery negative terminal (Fig. 4). 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 battery cable terminal on starter solenoid (Fig. 5). 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 connection. If reading is still above 0.2 volt after correcting poor contacts, replace battery positive cable. (b) If resistance tests do not detect feed circuit failures, replace the starter motor. FEED CIRCUIT TEST The following procedure will require a suitable volt-ampere tester (Fig. 6). CAUTION: Before performing any starter tests, the ignition and fuel systems must be disabled. Fig. 2 Test Battery Connection Resistance Fig. 3 Test Ground Circuit Resistance 8B - 2 STARTING PL DIAGNOSIS AND TESTING (Continued)

(1) Connect a volt-ampere tester to the battery ter- minals (Fig. 7). Refer to the operating instructions provided with the tester being used. (2) To disable the ignition and fuel systems, disconnect the Automatic Shutdown Relay (ASD). The ASD relay is located in the Power Distribution Cen- ter (PDC). Refer to the PDC cover for proper relay location. The 2.5L Diesel Engine, to disable the engine from starting, disconnect wire connector from the Fuel Solenoid. (3) 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 battery voltage below 9.6 volts during cranking operations. (4) Rotate and hold the ignition switch in the START position. Observe the volt-ampere tester (Fig. 6). • If voltage reads above 9.6 volts, and amperage draw reads above 280 amps or the Diesel engine above 450 amps, check for engine seizing or faulty starter. • If voltage reads 12.4 volts or greater and amperage reads 0 to 10 amps, check for corroded cables and/or bad connections. • Voltage below 9.6 volts and amperage draw above 300 amps or Diesel engine above 500 amps, the problem is the starter. Replace the starter refer to starter removal. (5) After the starting system problems have been corrected, verify the battery state-of-charge and Fig. 6 Volt Ampere Tester Fig. 7 Volt-Ampere Tester Connections Fig. 4 Test Starter Motor Ground Fig. 5 Test Battery Positive Cable Resistance PL STARTING 8B - 3 DIAGNOSIS AND TESTING (Continued)

charge battery if necessary. Disconnect all testing equipment and connect ASD relay or the Fuel Sole- noid. Start the vehicle several times to assure the problem has been corrected. STARTING SYSTEM TEST For circuit descriptions and diagrams, refer to 8W-21, Starting System in Group 8W, Wiring Dia- grams. WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER TO GROUP 8M - PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING 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. INSPECTION Before removing any unit from the starting system for repair or diagnosis, perform the following inspec- tions: • Battery - Visually inspect the battery for indications 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 Group 8A, Battery for more information. • Ignition Switch - Visually inspect the ignition switch for indications of physical damage and loose or corroded wire harness connections. • Clutch Pedal Position Switch - Visually inspect the clutch pedal position switch for indications of physical damage and loose or corroded wire harness connections. • Park/Neutral Position Switch - Visually inspect the park/neutral position switch 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 - Visually inspect the starter 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. 8B - 4 STARTING PL DIAGNOSIS AND TESTING (Continued)

STARTING SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSE CORRECTION STARTER FAILS TO ENGAGE. 1. Battery discharged or faulty. 2. Starting circuit wiring faulty. 3. Starter relay faulty. 4. Ignition switch faulty. 5. Park/Neutral position switch (auto trans) faulty or mis-adjusted. 6. Clutch pedal position switch (man trans) faulty. 7. Starter solenoid faulty. 8. Starter assembly faulty. 1. Refer to Group 8A, Battery. Charge or replace battery, if required. 2. Refer to Feed Circuit Resistance Test and Feed Circuit Test in this section. 3. Refer to Relay Test, in this section. Replace relay, if necessary. 4. Refer to Ignition Switch Test, in Group 8D Ignition System or Group 8W, Wiring Diagrams. Replace switch, if necessary. 5. Refer Park/Neutral Position Switch Test, in Group 21, Transaxle. Replace switch, if necessary. 6. Refer to Clutch Pedal Position Switch Test, in Group 6, Clutch. Replace switch, if necessary. 7. Refer to Solenoid Test, in this section. Replace starter assembly, if necessary. 8. If all other starting system components and circuits check OK, replace starter assembly. STARTER ENGAGES, FAILS TO TURN ENGINE. 1. Battery discharged or faulty. 2. Starting circuit wiring faulty. 3. Starter assembly faulty. 4. Engine seized. 1. Refer to Group 8A, Battery. Charge or replace battery as necessary. 2. Refer to the Feed Circuit Resistance Test and the Feed Circuit Test in this section. Repair as necessary. 3. If all other starting system components and circuits check OK, replace starter assembly. 4. Refer to Group 9 Engine, for diagnostic and service procedures. STARTER ENGAGES, SPINS OUT BEFORE ENGINE STARTS. 1. Broken teeth on starter ring gear. 2. Starter assembly faulty. 1. Remove starter. Inspect ring gear and replace if necessary. 2. If all other starting system components and circuits check OK, replace starter assembly. STARTER DOES NOT DISENGAGE. 1. Starter improperly installed. 2. Starter relay faulty. 3. Ignition switch faulty. 4. Starter assembly faulty. 1. Install starter. Tighten starter mounting hardware to correct torque specifications. 2. Refer to Relay Test, in this section. Replace relay, if necessary. 3. Refer to Ignition Switch Test, in Group 8D, Ignition System. Replace switch, if necessary. 4. If all other starting system components and circuits check OK, replace starter assembly. PL STARTING 8B - 5 DIAGNOSIS AND TESTING (Continued)

Dodge Neon 1998 Factory Service Repair Manual

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