1999 DODGE RAM Service Repair Manual

STA R TE R

1999 D odge P ic ku p R 1500
1999 STARTING & CHARGING SYSTEMS
CHRY - Starters - Except Avenger & Sebring Coupe
Breeze, Caravan, Cirrus, Concorde, Dakota, Durango, Intrepid,
LHS, Neon, Ram Pickup, Ram Van, Ram Wagon, Sebring
Convertible, Stratus, Town & Country, Voyager, 300M
NOTE: For models not covered in this article, see STARTERS -
AVENGER, SEBRING COUPE & TALON article.
DESCRIPTION
Bosch, Melco and Mitsubishi starters use a planetary gear
train that transmits power from starter motor to pinion shaft. Six
permanent magnets (Bosch and Melco starters) or 4 permanent magnets
(Mitsubishi starters) are used, eliminating potential field wire-to-
frame short circuits.
Nippondenso starter is a 4-field, 4-brush, 12-volt motor with
a solenoid mounted within the housing. The unit has a 2-to-1 reduction
gear set in a die cast aluminum housing. Starter has serviceable gear
and clutch assembly only. If starter solenoid fails, entire starter
motor must be replaced.
All models use a starter relay in starter circuit between the
battery and starter solenoid terminal. Automatic Transmission (A/T)
equipped vehicles use a Park/Neutral Position (PNP) switch or a
Transmission Range (TR) sensor to provide ground path for the starter
relay. Manual Transmission (M/T) equipped vehicles use a clutch pedal
position switch to provide battery voltage from ignition switch to the
starter relay. See WIRING DIAGRAMS.
STARTER APPLICATIONS - CARS









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Model Type
Breeze & Stratus 2.0L ........................................ Bosch
Cirrus, Sebring Convertible & Stratus
2.4L ................................................. Nippondenso
2.5L ....................................................... Melco
Concorde, Intrepid, LHS & 300M
2.7L ....................................................... Melco
3.3L & 3.5L .......................................... Nippondenso
Neon ......................................................... Bosch









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STARTER APPLICATIONS - TRUCKS








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Model Type
Caravan, Town & Country, & Voyager ..................... Nippondenso
Dakota & Durango
2.5L .................................................. Mitsubishi
3.9L & 5.2L .......................................... Nippondenso
Ram Pickup, Ram Van & Ram Wagon ........................ Nippondenso









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TROUBLE SHOOTING
NOTE: See TROUBLE SHOOTING article in GENERAL INFORMATION.

ON-VEHICLE TESTING
CAUTION: When battery is disconnected, vehicle computer and memory
systems may lose memory data. Driveability problems may exist
until computer systems have completed a relearn cycle. See
COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION
before disconnecting battery.
DISABLING/ENABLING IGNITION & FUEL SYSTEMS
WARNING: To prevent engine from starting while performing tests,
always disable ignition and fuel systems.
Disabling Ignition & Fuel Systems
Remove Automatic Shutdown Relay (ASD) located in Power
Distribution Center (PDC). Refer to PDC cover for proper relay
location. PDC is located in engine compartment. On 5.9L diesel
engines, also disconnect fuel shutdown solenoid connector. Solenoid is
located behind upper intake manifold. See appropriate SYSTEM &
COMPONENT TESTING article in ENGINE PERFORMANCE section.
Enabling Ignition & Fuel Systems
When testing and/or repairs have been completed, verify
battery condition. Recharge battery as necessary, after starter tests
have been completed. Disconnect all test equipment. Install ASD relay.
On 5.9L diesel engines, reconnect fuel shutdown relay connector. On
all models, start engine several times to verify malfunction has been
corrected.
CRANKING TEST
NOTE: Ensure engine is at normal operating temperature. High
viscosity oil, extreme cold temperatures, or tight engine
will increase amperage draw.
1) Using a battery load tester, connect positive and negative
leads to battery. Connect inductive ammeter pick-up to positive
battery cable. Disable ignition and fuel systems. See
DISABLING/ENABLING IGNITION & FUEL SYSTEMS.
2) Ensure all lights and accessories are off. Place A/T in
Park position or M/T in Neutral position. Apply parking brake. Crank
engine and observe voltmeter reading. If voltage is more than 9.6
volts and cranking amperage draw is more than specified amps, proceed
to CIRCUIT RESISTANCE TESTS. See STARTER SPECIFICATIONS - CARS or
STARTER SPECIFICATIONS - TRUCKS.
3) If voltage is 12.5 volts or more and cranking amperage
draw is less than specified, check starter circuit components in the
following order:
starter solenoid, starter relay, starter relay circuit, park/neutral
position switch or transmission range sensor (A/T), clutch pedal
position switch (M/T), ignition switch, wiring harness and
connections.
CIRCUIT RESISTANCE TESTS
NOTE: If excessive resistance is not found in circuits being
tested, remove starter and proceed to BENCH TESTING.
Battery Connection Resistance Test
1) Disable vehicle ignition and fuel systems. See
DISABLING/ENABLING IGNITION & FUEL SYSTEMS. A voltmeter accurate to
one tenth of a volt will be needed for the following tests.

2) Connect voltmeter positive lead to negative battery cable
clamp. Connect voltmeter negative lead to negative battery post. Crank
engine and observe voltmeter reading. If voltage is detected, repair
poor contact between cable clamp and post. Perform same procedure to
positive battery post and cable clamp.
Ground Connection Resistance Test
Connect voltmeter negative lead to negative battery post.
Connect voltmeter positive lead to engine block, near negative battery
cable grounding point. Crank engine and observe voltmeter reading. If
voltmeter reading indicates more than 0.2 volt, repair poor ground
connection or replace ground cable.
Starter Ground Connection Resistance Test
Connect voltmeter negative lead to negative battery post.
Connect voltmeter positive lead to starter housing. Crank engine and
observe voltmeter reading. If voltmeter reading indicates more than 0.
2 volt, repair poor starter-to-ground connection.
Positive Battery Cable Resistance Test
1) Remove starter heat shield (if equipped) to gain access t\
o
starter solenoid connections. Connect voltmeter negative lead to
starter solenoid battery terminal and voltmeter positive lead to
positive battery post.
2) Crank engine and observe voltmeter reading. If voltage
reads more than 0.2 volt, correct poor connection between battery
cable and starter solenoid or replace positive battery cable.
SOLENOID CIRCUIT TEST
NOTE: Perform SOLENOID CIRCUIT TEST before testing starter relay
and starter relay circuit. Ensure A/T is in Park position or
M/T is in Neutral position and parking brake is applied.
1) Disable vehicle ignition and fuel systems. See
DISABLING/ENABLING IGNITION & FUEL SYSTEMS.
2) Ensure battery is fully charged. Ensure solenoid
connections are not loose or corroded. Remove starter relay from Power
Distribution Center (PDC). Refer to PDC cover for proper relay
location. PDC is located in engine compartment.
3) Connect a remote starter switch or jumper wire between
starter relay socket terminal No. 87 and positive battery post. See
Fig. 1 or 2. If engine cranks, solenoid and starter are good. Go to
STARTER RELAY TEST.
4) If engine fails to crank, or if solenoid chatters, check
wiring and connectors from starter relay socket to starter solenoid
terminal. Repair any loose or corroded connections. If engine still
fails to crank, remove starter and proceed to SOLENOID TEST under
BENCH TESTING.
STARTER RELAY TEST
NOTE: Perform SOLENOID CIRCUIT TEST before testing starter relay.
Remove starter relay from Power Distribution Center (PDC).
Refer to PDC cover for proper relay location. PDC is located in engine
compartment. Connect 12-volt power source to starter relay terminal
No. 86 and ground terminal No. 85. See Fig. 1 or 2. Using ohmmeter,
check continuity across starter relay terminals No. 30 and 87. If
continuity is not present, replace starter relay.

Fig. 1: Identifying Starter Relay Terminals (Except Concorde,
Dakota, Durango, Intrepid, LHS, Ram Van, Ram Wagon
& 300M)
Courtesy of Chrysler Corp.

Fig. 2: Identifying Starter Relay Terminals (Concorde, Dakota,
Durango, Intrepid, LHS, Ram Van, Ram Wagon &
300M)
Courtesy of Chrysler Corp.

STARTER RELAY CIRCUIT TEST
NOTE: Perform STARTER RELAY TEST before testing starter relay
circuit.
1) Ensure battery is fully charged. Remove starter relay from
Power Distribution Center (PDC). Refer to PDC cover for proper relay
location. PDC is located in engine compartment.
2) Connect a jumper wire between starter relay socket
terminal No. 30 and terminal No. 87. See Fig. 1 or 2. If engine does
not crank, go to SOLENOID TEST under BENCH TESTING. If engine cranks,
go to next step.
3) Turn ignition on. Check voltage between ground and starter
relay socket terminal No. 30. If battery voltage is not present,
repair open in circuit between starter relay socket and battery. If
battery voltage is present, go to next step.
4) Check voltage between ground and starter relay socket
terminal No. 86 with ignition switch in START position and clutch
pedal depressed (if equipped with M/T). If battery voltage is present,\
circuit is okay. Go to step 6) if equipped with M/T or step 7) if
equipped with A/T. If battery voltage is not present, repair open in
circuit between ignition switch and starter relay socket (A/T) or go
to next step (M/T).
5) Unplug wiring connector from clutch position switch
mounted on clutch pedal bracket. Connect jumper wire between clutch
position switch connector terminals. Recheck for voltage at starter
relay socket terminal No. 86 with ignition switch in START position.
If battery voltage is present, check clutch position switch adjustment
(if applicable). Adjust switch as necessary. If switch adjustment is
okay, check clutch position switch. See CLUTCH POSITION SWITCH TEST.
If battery voltage is not present, repair wiring between ignition
switch and starter relay socket as necessary.
6) On M/T models, connect voltmeter negative lead to starter
relay socket terminal No. 85 and positive lead to terminal No. 86.
Turn ignition switch to START position and depress clutch pedal. If
battery voltage is present, starter relay socket ground circuit is
good. Replace faulty starter relay. If battery voltage is not present,
repair ground wire circuit.
7) On A/T models, connect voltmeter negative lead to starter
relay socket terminal No. 85 and positive lead to terminal No. 86.
Ensure transmission gear selector is in Park or Neutral position.
Ground circuit runs through Park/Neutral Position (PNP) switch or
Transmission Range (TR) sensor on transmission. Turn ignition switch
to START position. If battery voltage is present, starter relay socket
ground circuit is good. Replace faulty starter relay.
8) If battery voltage is not present, check PNP switch or TR
sensor for loose or damaged connections. Also, check ground to PNP
switch or TR sensor. Repair as necessary. If connections and ground
are okay, check PNP switch or TR sensor. See PARK/NEUTRAL POSITION
(PNP) SWITCH & TRANSMISSION RANGE (TR) SENSOR TEST.
PARK/NEUTRAL POSITION (PNP) SWITCH & TRANSMISSION RANGE (TR)
SENSOR TEST
NOTE: Transmission Range (TR) sensor may be also known as
Park/Neutral Position (PNP) switch or Park/Neutral switch.
NOTE: The following test is for Caravan, Ram Van, Ram Wagon and
Voyager with 3-speed transmission. All other models are
equipped with a Transmission Range (TR) sensor. If TR sensor
or sensor circuit is defective, see appropriate NTC test in
appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE
section.

1) Place gear selector in Park. Disconnect negative battery
cable. Raise and support vehicle. Disconnect PNP switch connector.
Using an ohmmeter, check for continuity between ground and PNP switch
center terminal. If continuity exists, go to next step. If continuity
does not exist, replace PNP switch.
2) Place gear selector in Reverse. Check for continuity
between ground and PNP switch center terminal. If continuity exists,
PNP switch is okay. If continuity does not exist, replace PNP switch.
CLUTCH POSITION SWITCH TEST
Disconnect negative battery cable. Disconnect clutch position
switch connector. Using an ohmmeter, check for continuity between
clutch position switch terminals. With clutch pedal released,
continuity should not exist. With clutch pedal depressed, continuity
should exist. Replace clutch position switch if continuity is not as
specified.
IGNITION SWITCH TEST
NOTE: For ignition switch testing procedures, see appropriate
STEERING COLUMN SWITCHES article in ACCESSORIES &
EQUIPMENT.
BENCH TESTING
SOLENOID TEST
1) With starter removed from vehicle, remove starter motor
field coil wire from solenoid field coil terminal. Using an ohmmeter,
check for continuity between solenoid terminal and field coil terminal
of starter solenoid. Continuity should exist.
2) Check for continuity between solenoid terminal and
solenoid housing. Continuity should exist. If continuity is not
present in either test, replace starter and solenoid as an assembly.
OVERHAUL
NOTE: Manufacturer does not recommend disassembling and servicing
starters. If starter is found defective, a new unit must be
installed.
STARTER SPECIFICATIONS
STARTER SPECIFICATIONS - CARS








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Application Specification
Cranking Amperage Draw ( 1)
Bosch 2.0L .......................................... 150-280 Amps
Melco 2.5L & 2.7L ................................... 150-280 Amps
Nippondenso 2.4L, 3.2L & 3.5L ......................... 150-280 Amps
No-Load Test At 11 Volts
Maximum Amps
Bosch 2.0L .................................................. ( 2)
Melco 2.5L & 2.7L ........................................... ( 2)
Nippondenso 2.4L, 3.2L & 3.5L ............................... ( 2)
No-Load Test At 11 Volts
Minimum RPM

Bosch 2.0L .................................................. (2)
Melco 2.5L & 2.7L ........................................... ( 2)
Nippondenso 2.4L, 2.7L & 3.5L ............................... ( 2)
Power Rating
Bosch 2.0L ............................................... 0.95 Kw
Melco 2.5L & 2.7L ......................................... 1.2 Kw
Nippondenso 2.4L, 2.7L & 3.5L ............................... 1.4 Kw
( 1) - With engine at normal operating temperature. High viscosity oil,
extreme cold temperatures, or tight engine will increase
amperage draw.
( 2) - Information is not available from manufacturer.









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STARTER SPECIFICATIONS - TRUCKS








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Application Specification
Cranking Amperage Draw ( 1)
Caravan, Town & Country & Voyager ................... 150-200 Amps
Dakota & Durango
2.5L ................................................... 130 Amps
3.9L, 5.2L & 5.9L .................................. 125-250 Amps
Ram Pickup
Diesel Engines ..................................... 450-700 Amps
Gasoline Engines ................................... 125-250 Amps
Ram Van & Ram Wagon ................................. 125-250 Amps
No-Load Test At 11 Volts
Maximum Amps
Caravan, Town & Country & Voyager ....................... 73 Amps
Dakota & Durango
2.5L .................................................. 90 Amps
3.9L, 5.2L & 5.9L ..................................... 73 Amps
Ram Pickup
Gasoline .............................................. 73 Amps
Diesel ............................................... 200 Amps
Ram Van & Ram Wagon ..................................... 73 Amps
Minimum RPM
Caravan, Town & Country & Voyager ...................... 3401 RPM
Dakota & Durango
2.5L ................................................. 2600 RPM
3.9L, 5.2L & 5.9L .................................... 3601 RPM
Ram Pickup
Gasoline ............................................. 3601 RPM
Diesel ............................................... 3000 RPM
Ram Van & Ram Wagon .................................... 3601 RPM
Power Rating
Caravan, Town & Country & Voyager ......................... 1.2 Kw
Dakota & Durango
2.5L ..................................................... 1.2 Kw
3.9L, 5.2L & 5.9L ........................................ 1.4 Kw
Ram Pickup
Gasoline ................................................. 1.4 Kw
Diesel ................................................... 2.7 Kw
Ram Van & Ram Wagon ....................................... 1.4 Kw
( 1) - With engine at normal operating temperature. High viscosity oil,
extreme cold temperatures, or tight engine will increase
amperage draw.









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TORQUE SPECIFICATIONS