300, 300C & Magnum 2006-2008, Charger 2006-2008

Starter

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Removal & Installation



2.7L & 3.5L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable
  4.  
  5. Install a suitable steering wheel holder to lock the steering wheel in straight-ahead position.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove the underbody splash shield.
  10.  
  11. Remove the intermediate steering shaft center bolt.

    Click image to see an enlarged view

    Fig. Remove the intermediate steering shaft center bolt-2.7L and 3.5L engines

  12.  
  13. Separate the intermediate steering shaft upper and lower shaft.

    Click image to see an enlarged view

    Fig. Separate the intermediate steering shaft upper and lower shaft-2.7L and 3.5L engines

  14.  
  15. Disconnect the electrical connection from the starter.
  16.  
  17. Remove the 3 starter mounting bolts and wiring clip.

    Click image to see an enlarged view

    Fig. Remove the 3 starter mounting bolts and wiring clip-2.7L and 3.5L engines

  18.  
  19. Pull the starter forward and down.
  20.  
  21. Maneuver the starter up and around exhaust.
  22.  
  23. Work starter past the intermediate steering shaft, then remove the starter from vehicle.

    Click image to see an enlarged view

    Fig. Remove the starter from the vehicle-2.7L and 3.5L engines



    Click image to see an enlarged view

    Fig. Starter mounting-2.7L and 3.5L engines

  24.  

To install:

  1. Work the starter up and past the transmission and exhaust.
  2.  
  3. Maneuver the starter up and past the intermediate shafts.
  4.  
  5. Angle the starter up toward engine.
  6.  
  7. Install the plastic retainer into starter dust shield. The dust shield has TOP marked on it and the plastic retainer goes in the hole.

    Click image to see an enlarged view

    Fig. Install the plastic retainer into starter dust shield. The dust shield has TOP marked on it and the plastic retainer goes in the hole -2.7L and 3.5L engines

  8.  
  9. Install the dust shield to the engine block using the plastic retainer to hold dust shield in place.
  10.  
  11. Install the starter and secure with the retaining bolts. Torque the bolts to 40 ft. lbs. (54 Nm).
  12.  
  13. Attach the electrical connection to starter.
  14.  
  15. Match flats inside the intermediate shaft with that in the intermediate shaft extension, then slide the intermediate shaft onto extension.
  16.  
  17. Align the hole in the shafts.
  18.  
  19. Install the pinch bolt fastening intermediate shaft to intermediate shaft extension. Tighten the bolt to 32 ft. lbs. (43 Nm).
  20.  
  21. Install the underbody splash shield.
  22.  
  23. Carefully lower the vehicle.
  24.  
  25. Remove the steering wheel holder, then connect the negative battery cable.
  26.  

5.7L Engines
AWD Models
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect and isolate the negative battery cable.
  4.  
  5. Raise and safely support the vehicle.
    NOTE
    The steering gear assembly must be partially lowered to gain access to starter. Do not disconnect any hydraulic hoses or remove any steering linkage.

  6.  
  7. Remove the coupling bolt (pinch bolt) securing steering gear to steering column.
  8.  
  9. Remove the three steering gear mounting bolts and slightly lower the gear. Temporarily support the steering gear.
  10.  
  11. Remove the steering gear heat-shield.
  12.  
  13. Remove the 2 starter mounting bolts.
  14.  
  15. Move the starter motor towards front of vehicle far enough for nose of starter to clear. Always support the starter motor during this process. Do not let starter motor hang from wire harness.
  16.  
  17. Remove the battery cable-to-solenoid nut.
  18.  
  19. Remove the solenoid wire from solenoid stud.
  20.  
  21. Remove the starter motor.

    Click image to see an enlarged view

    Fig. Starter motor (1) and mounting bolt (2)-AWD vehicles

  22.  

To install:

  1. Position the starter into transmission but do not install bolts.
  2.  
  3. Connect the solenoid wire to starter motor. The wire snaps onto the starter.
  4.  
  5. Position the battery cable to solenoid stud. Install and tighten battery cable eyelet nut to 97 inch lbs. (11 Nm). Do not allow starter motor to hang from wire harness.
  6.  
  7. Install and tighten both starter mounting bolts to 40 ft. lbs. (54 Nm)
  8.  
  9. Install the steering gear assembly and mounting bolts. Install steering column coupling bolt (pinch bolt) and tighten to 32 ft. lbs. (43 Nm).
  10.  
  11. Install the steering gear heat-shield.
  12.  
  13. Lower the vehicle.
  14.  
  15. Connect the negative battery cable.
  16.  

RWD Models
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect and isolate the negative battery cable.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove the 3 starter mounting bolts.
  8.  
  9. Move the starter motor towards front of vehicle far enough for nose of starter to clear. Always support the starter motor during this process. Never let starter motor hang from wire harness.
  10.  
  11. Remove the battery cable-to-solenoid nut.
  12.  
  13. Remove the solenoid wire from solenoid stud.
  14.  
  15. Remove the starter motor from the vehicle.

    Click image to see an enlarged view

    Fig. View of the starter motor mounting bolts (1) and starter (2)-RWD vehicles

  16.  

To install:

  1. Position the starter (2) into transmission but do not install bolts.
  2.  
  3. Connect solenoid wire to starter motor. The wire snaps onto the starter.
  4.  
  5. Position the battery cable to solenoid stud. Install and tighten battery cable eyelet nut to 97 inch lbs. (11 Nm). Do not allow starter motor to hang from wire harness.
  6.  
  7. Install and tighten the three mounting bolts to 40 ft. lbs. (54 Nm).
  8.  
  9. Lower the vehicle.
  10.  
  11. Connect negative battery cable.
  12.  

Testing & Troubleshooting



Control Circuit Test

The starter control circuit has:



Starter motor with integral solenoid
 
Starter relay
 
Transmission range sensor, or Park/Neutral Position switch with automatic transmissions
 
Ignition switch
 
Battery
 
All related wiring and connections
 
Powertrain Control Module (PCM)
 


CAUTION
Before performing any starter tests, the ignition and fuel systems must be disabled. To disable 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 the proper relay location.

Feed Circuit Test

Before proceeding with this operation, review Diagnostic Preparation and Starter Feed Circuit Tests. The following operation will require a voltmeter, accurate to 1/10 of a volt.


WARNING
Ignition and Fuel systems must be disabled to prevent engine start while performing the following tests.

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. Gain access to battery terminals.

  1. With all wiring harnesses and components properly connected, perform the following:
  2.  
  3. Connect the negative lead of the voltmeter to the battery negative post, and positive lead to the negative battery cable clamp. 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.
  4.  
  5. Connect positive lead of the voltmeter to the battery positive post, and negative lead to the battery positive cable clamp. 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.
  6.  
  7. Connect negative lead of voltmeter to battery negative terminal, and positive lead to engine block near the battery cable attaching point. 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.
  8.  
  9. Connect positive voltmeter lead to the starter motor housing and the negative lead to the battery negative terminal. Hold the ignition switch key in the START position. If voltage reads above 0.2 volt, correct poor starter to engine ground.
  10.  
  11. Connect the positive voltmeter lead to the battery positive terminal, and negative lead to battery cable terminal on starter solenoid. 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.
  12.  
  13. If resistance tests do not detect feed circuit failures, replace the starter motor.
  14.  

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 the open circuit to the PDC fuse as required.
  2.  
  3. 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.
  4.  
  5. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the starter solenoid field coils. There should be continuity between the cavity for relay terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the open circuit to the starter solenoid as required.
  6.  
  7. The coil battery terminal (85) is connected to the electromagnet in the relay. It is energized when the ignition switch is held in the Start position and the clutch pedal is depressed (manual trans). Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start position and the clutch pedal is depressed (manual trans), and no voltage when the ignition switch is released to the On position. If OK, go to Step 5. If not OK, check for an open or short circuit to the ignition switch and repair, if required. If the circuit to the ignition switch is OK, see the Ignition Switch Test procedure in this group.
  8.  
  9. The coil ground terminal (86) is connected to the electromagnet in the relay. It is grounded by the PCM if the conditions are right to start the car. For automatic trans. cars the PCM must see Park Neutral switch low and near zero engine speed (rpm). For manual trans. cars the PCM only needs to see near zero engine speed (rpm) and low clutch interlock input and see near zero engine speed (rpm). To diagnose the Park Neutral switch of the trans range sensor refer to the transaxle section. Check for continuity to ground while the ignition switch is in the start position and if equipped the clutch pedal depressed. If not OK and the vehicle has an automatic trans. verify Park Neutral switch operation. If that checks OK check for continuity between PCM and the terminal 86. Repair open circuit as required. Also check the clutch interlock switch operation if equipped with a manual transmission. If OK, the PCM may be defective.
  10.  

Starter Relay

CAUTION
Check to ensure that the transmission is in the park/neutral position with the parking brake applied. This may result in personal injury or death.

The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location.

Remove the starter relay from the PDC to perform the following tests:

  1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. Resistance between terminals 85 and 86 (electromagnet) should be 70-80 ohms. If OK, go to Step 3. If not OK, replace the faulty relay.
  2.  
  3. Connect a battery B+ lead to terminals 85 and a ground lead to terminal 86 to energize the relay. The relay should click. Also test for continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, refer to Relay Circuit Test procedure. If not OK, replace the faulty relay.
  4.  

Starter Solenoid

CAUTION
Check to ensure that the transmission is in the park position with the parking brake applied. This may result in personal injury or death.

  1. Verify the battery condition. Battery must be in good condition with a full charge before performing any starter tests.
  2.  
  3. Perform Starter Solenoid test BEFORE performing the starter relay test.
  4.  
  5. Perform a visual inspection of the starter/starter solenoid for corrosion, loose connections or faulty wiring.
  6.  
  7. Locate and remove the starter relay from the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location.
  8.  
  9. Connect a remote starter switch or a jumper wire between the remote battery positive post and terminal 87 of the starter relay connector.
  10.  
  11. If engine cranks, starter/starter solenoid is good. Go to the Starter Relay Test.
  12.  
  13. If engine does not crank or solenoid chatters, check wiring and connectors from starter relay to starter solenoid and from the battery positive terminal to starter post for loose or corroded connections particularly at starter terminals.
  14.  
  15. Repeat test. If engine still fails to crank properly, trouble is within starter or starter mounted solenoid, and replace starter. Inspect the ring gear teeth.
  16.  

 
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