Dodge Sprinter 2006 Manual page 888

8F - 28 STARTING SYSTEM
STARTING SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DIAGNOSIS AND TESTING - STARTING
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SPECIFICATIONS
TORQUE - STARTER - DIESEL
SPECIFICATIONS - STARTER MOTOR -
DIESEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
START I N G SY ST EM
DESCRIPTION
Th e st a r t in g syst em con sist s of:
• St a r t er r ela y
• St a r t er m ot or (in clu din g a n in t egr a l st a r t er sole-
n oid)
Ot h er com pon en t s t o be con sider ed a s pa r t of st a r t -
in g syst em a r e:
• Ba t t er y
• Ba t t er y ca bles
• Ign it ion swit ch a n d key lock cylin der
• P a r k/n eu t r a l posit ion swit ch (a u t om a t ic t r a n s-
m ission )
• Wir e h a r n esses a n d con n ect ion s.
Th e Ba t t er y, St a r t in g, a n d Ch a r gin g syst em s oper-
a t e in con ju n ct ion wit h on e a n ot h er, a n d m u st be
t est ed a s a com plet e syst em . F or cor r ect oper a t ion of
st a r t in g/ch a r gin g syst em s, a ll com pon en t s u sed in
t h ese 3 syst em s m u st per for m wit h in specifica t ion s.
Wh en a t t em pt in g t o dia gn ose a n y of t h ese syst em s, it
is im por t a n t t h a t you keep t h eir in t er depen den cy in
m in d.
Th e dia gn ost ic pr ocedu r es u sed in ea ch of t h ese
gr ou ps in clu de t h e m ost ba sic con ven t ion a l dia gn ost ic
m et h ods, t o t h e m or e soph ist ica t ed On -Boa r d Dia g-
n ost ics (OBD) bu ilt in t o t h e E n gin e Con t r ol Modu le
(E CM). Use of a n in du ct ion -t ype m illia m per e a m m e-
t er, volt /oh m m et er, ba t t er y ch a r ger, ca r bon pile r h eo-
st a t (loa d t est er ), a n d 12-volt t est la m p m a y be
r equ ir ed.
Cer t a in st a r t in g syst em com pon en t s a r e m on it or ed
by t h e E CM a n d m a y pr odu ce a Dia gn ost ic Tr ou ble
Code (DTC).
OPERA TION
Th e st a r t in g syst em com pon en t s for m t wo sepa r a t e
cir cu it s. A h igh -a m per a ge feed cir cu it t h a t feeds t h e
st a r t er m ot or h igh -a m per a ge, a n d a low-a m per a ge
START I N G SY ST EM
TABLE OF CONTENTS
page
STARTER MOTOR
DIAGNOSIS AND TESTING - STARTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION
STARTER MOTOR RELAY
. . . . . . . . . . . 33 DESCRIPTION
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION
con t r ol cir cu it t h a t oper a t es on less t h a n 20 a m per es.
Th e h igh -a m per a ge feed cir cu it com pon en t s in clu de
t h e ba t t er y, t h e ba t t er y ca bles, t h e con t a ct disc por-
t ion of t h e st a r t er solen oid, a n d t h e st a r t er m ot or
it self. Th e low-a m per a ge con t r ol cir cu it com pon en t s
in clu de t h e ign it ion swit ch , t h e pa r k/n eu t r a l posit ion
swit ch (a u t om a t ic t r a n sm ission ), t h e st a r t er r ela y,
t h e elect r om a gn et ic win din gs of t h e st a r t er solen oid,
a n d t h e con n ect in g wir e h a r n ess com pon en t s.
m ission , ba t t er y volt a ge is su pplied t h r ou gh t h e low-
a m per a ge con t r ol cir cu it t o t h e coil ba t t er y t er m in a l
of t h e st a r t er r ela y wh en t h e ign it ion swit ch is
t u r n ed t o t h e m om en t a r y St a r t posit ion . Th e pa r k/
n eu t r a l posit ion swit ch is in st a lled in ser ies bet ween
t h e st a r t er r ela y coil gr ou n d t er m in a l a n d gr ou n d.
Th is n or m a lly open swit ch pr even t s t h e st a r t er r ela y
fr om bein g en er gized a n d t h e st a r t er m ot or fr om
oper a t in g u n less t h e a u t om a t ic t r a n sm ission gea r
select or is in t h e Neu t r a l or P a r k posit ion s.
m a lly open r ela y con t a ct s close. Th e r ela y con t a ct s
con n ect t h e r ela y com m on feed t er m in a l t o t h e r ela y
n or m a lly open t er m in a l. Th e closed r ela y con t a ct s
en er gize t h e st a r t er solen oid coil win din gs.
n oid plu n ger. Th e solen oid plu n ger pu lls t h e sh ift
lever in t h e st a r t er m ot or. Th is en ga ges t h e st a r t er
over r u n n in g clu t ch a n d pin ion gea r wit h t h e st a r t er
r in g gea r on t h e m a n u a l t r a n sm ission flywh eel or on
t h e a u t om a t ic t r a n sm ission
t or qu e con ver t er dr ive pla t e.
t r a vel, t h e solen oid con t a ct disc com plet es t h e h igh -
a m per a ge st a r t er feed cir cu it a n d en er gizes t h e sole-
n oid plu n ger h old-in coil. Cu r r en t n ow flows bet ween
t h e solen oid ba t t er y t er m in a l a n d t h e st a r t er m ot or,
en er gizin g t h e st a r t er.
t ect s t h e st a r t er m ot or fr om da m a ge by a llowin g t h e
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
. . . . . . . . . . . . . . . . . . . . . . . . . 35
. . . . . . . . . . . . . . . . . . . . . . . . . 35
. . . . . . . . . . . . . . . . . . . . . . . . . 36
If t h e veh icle is equ ipped wit h a n a u t om a t ic t r a n s-
Wh en t h e st a r t er r ela y coil is en er gized, t h e n or-
Th e en er gized solen oid pu ll-in coil pu lls in t h e sole-
As t h e solen oid plu n ger r ea ch es t h e en d of it s
On ce t h e en gin e st a r t s, t h e over r u n n in g clu t ch pr o-
VA
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t or qu e con ver t er or