1999 DODGE NEON Service Repair Manual

(3) Rinse soda solution from battery with clear
water and blot battery dry with paper toweling. Dis-
pose of toweling in a safe manner. Refer to the
WARNINGS on top of battery.
(4) Inspect battery case and cover for cracks, leak-
age or damaged hold down ledge. If battery is dam-
aged replace it.
(5) Inspect battery tray for damage caused by acid
from battery. If acid is present, clean area with bak-
ing soda solution.
(6) Clean battery posts with a battery post clean-
ing tool (Fig. 13).
(7) Clean battery cable clamps with a battery ter-
minal cleaning tool (Fig. 14). Replace cables that are
frayed or have broken clamps.
REMOVAL AND INSTALLATION
BATTERY
REMOVAL
(1) Make sure ignition switch is in OFF position
and all accessories are OFF.
(2) Remove battery negative cable then the posi-
tive cable (Fig. 4).
(3) Remove battery thermoguard cover (Fig. 15).
WARNING: TO PROTECT THE HANDS FROM BAT-
TERY ACID, A SUITABLE PAIR OF HEAVY DUTY
RUBBER GLOVES, NOT THE HOUSEHOLD TYPE,
SHOULD BE WORN WHEN REMOVING OR SERVIC-
ING A BATTERY. SAFETY GLASSES ALSO SHOULD
BE WORN.(4) Remove battery hold down clamp (Fig. 16) and
battery from vehicle.
INSTALLATION
(1) Install battery in vehicle making sure that it is
properly positioned on battery tray.
Fig. 12 Cleaning BatteryFig. 13 Cleaning Battery Post
Fig. 14 Cleaning Battery Cable Terminal
8A - 8 BATTERYPL
SERVICE PROCEDURES (Continued)

(2) Install battery hold down clamp, making sure
that it is properly positioned on battery.
(3) Place thermoguard cover over the battery and
snap it together with battery tray (Fig. 17). The bat-
tery tray pencil strut may have to be loosened on one
end to install the thermoguard cover. After the ther-
moguard cover is in place, tighten pencil strut as
necessary.(4) Connect battery cable clamps to battery posts
and making sure top of clamp is flush or below with
top of post (Fig. 18). Install battery positive cable
first.
(5) Tighten clamp nuts securely.
BATTERY TRAY
REMOVAL
(1) Remove battery, refer to Battery Removal.
(2) Remove battery tray pencil strut. Remove bat-
tery tray, refer to (Fig. 17).
INSTALLATION
For installation reverse above procedures.
FRESH AIR INLET TUBE REMOVAL
REMOVAL
(1) Ensure that the ignition switch and all acces-
sories are OFF
(2) Remove battery negative cable first then the
positive cable (Fig. 4).
(3) Remove battery thermoguard cover (Fig. 15).
Fig. 15 Battery Thermoguard
Fig. 16 Battery Hold-Down
Fig. 17 Battery Tray Removal
Fig. 18 Remove and Install Battery Cables
PLBATTERY 8A - 9
REMOVAL AND INSTALLATION (Continued)

WARNING: TO PROTECT THE HANDS FROM BAT-
TERY ACID, A SUITABLE PAIR OF HEAVY DUTY
RUBBER GLOVES, NOT THE HOUSEHOLD TYPE,
SHOULD BE WORN WHEN REMOVING OR SERVIC-
ING A BATTERY. SAFETY GLASSES ALSO SHOULD
BE WORN.
(4) Squeeze the sides of the tube at the pull strap
lock tabs and push down through the hole in the bat-
tery tray (Fig. 19). DO NOT push directly down on
the pull strap itself.
(5) Remove the tube from the radiator closure
panel by squeezing the lock tabs and pushing from
the front side (Fig. 16).INSTALLATION
For installation reverse above procedures. Ensure
that the lock tabs are properly seated in the radiator
panel and to the bottom of battery tray (Fig. 19).
Ensure that the tube opening is properly aligned
with hole before pulling on strap.
SPECIFICATIONS
BATTERY SPECIFICATIONS
COLD CRANK RATING
The current battery can deliver for 30 seconds and
maintain a terminal voltage of 7.2 volts or greater at
±18É C (0É F).
RESERVE CAPACITY RATING
The length of time a battery can deliver 25 amps
and maintain a minimum terminal voltage of 10.5
volts at 27ÉC (80ÉF).
TORQUE
DESCRIPTION TORQUE
Battery Hold Down Bolt
Clamp Bolt.................9N´m(75in.lbs.)
Fig. 19 Air Inlet Tube Pull Strap
Load Test Cold
CrankingReserve
(Amps) Rating @
-18ÉC (0ÉF)Capacity
225 Amp 450 Amp 85 Minutes
8A - 10 BATTERYPL
REMOVAL AND INSTALLATION (Continued)

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.............. 1STARTING 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:
²Ignition switch
²Starter relay
²Neutral starting and back up switch
²Clutch pedal position switch
²Wiring harness
²Battery
²Starter 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 perma-
nent magnets. The starter system consists of two
separate circuits:
²A high amperage supply to feed the starter
motor.
²A low amperage circuit to control the starter
solenoid.
SUPPLY CIRCUIT AND CONTROL CIRCUIT
The starter system consists of two separate cir-
cuits:
²A high amperage supply to feed the starter
motor.
²A low amperage circuit to control the starter
solenoid.
DIAGNOSIS AND TESTING
STARTER CONTROL CIRCUIT
The starter control circuit has:
²Starter solenoid
²Starter relay²Neutral starting and back up switch with auto-
matic transmissions
²Clutch pedal position switch with manual trans-
mission
²Ignition switch
²Battery
²All related wiring and connections
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
Fig. 1 Starting System
PLSTARTING 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 follow-
ing tests.
(1) To disable the ignition and fuel systems, dis-
connect 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, 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. 2). 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.
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 bat-
tery 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 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.
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 STARTINGPL
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, dis-
connect 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 PARKposition 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).
²If 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.
²If voltage reads 12.4 volts or greater and amper-
age reads 0 to 10 amps, check for corroded cables
and/or bad connections.
²Voltage 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
PLSTARTING 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:
²Battery- 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 Group 8A, Battery
for more information.²Ignition Switch- Visually inspect the ignition
switch for indications of physical damage and loose
or corroded wire harness connections.
²Clutch Pedal Position Switch- Visually
inspect the clutch pedal position switch for indica-
tions of physical damage and loose or corroded wire
harness connections.
²Park/Neutral Position Switch- Visually
inspect the park/neutral position switch for indica-
tions of physical damage and loose or corroded wire
harness connections.
²Starter Relay- Visually inspect the starter
relay for indications of physical damage and loose or
corroded wire harness connections.
²Starter- Visually inspect the starter for indica-
tions of physical damage and loose or corroded wire
harness connections.
²Starter Solenoid- Visually inspect the starter
solenoid for indications of physical damage and loose
or corroded wire harness connections.
²Wiring- Visually inspect the wire harness for
damage. Repair or replace any faulty wiring, as
required.
8B - 4 STARTINGPL
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.
PLSTARTING 8B - 5
DIAGNOSIS AND TESTING (Continued)