Neon, 2000-2005

Starter

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Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Inlet hose from the intake manifold and reposition the air cleaner box, on high output engines only
     
    Starter electrical connectors
     
    Starter-to-engine bolts
     
    Starter

    Click image to see an enlarged view

    Fig. Starter mounting-2002 Neon shown, others similar

    Starter mounting-2002 Neon shown, others similar
     

  4.  

To install:

  1. Install or connect the following:

    Starter and torque bolts to 40 ft. lbs. (54 Nm)
     
    Starter electrical connectors
     
    Intake manifold inlet hose on high output engines
     
    Negative battery cable
     

  2.  

Solenoid or Relay



The relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the underside of the PDC cover for starter relay location. Simply unplug the relay to replace it

Testing & Troubleshooting



Feed Circuit Test

CAUTION
The ignition and fuel systems must be disabled to prevent engine start while performing the tests.

  1. Connect a volt-ampere tester to the battery terminals. You can use a multi-meter if it has an inductive clamp for reading high amperage.

    Click image to see an enlarged view

    Fig. This test requires the use of a volt ampere tester

    This test requires the use of a volt ampere tester

    Click image to see an enlarged view

    Fig. Proper volt-ampere test connections

    Proper volt-ampere test connections
  2.  
  3. Disable the ignition and fuel systems by disconnecting the Automatic Shutdown (ASD) relay, located in the Power Distribution Center (PDC) in the engine compartment.
  4.  
  5. Verify that all lights and accessories are Off, and the transaxle shift selector is in Park (automatic) or Neutral (manual). Set the parking brake.
  6.  
  7. Rotate and hold the ignition switch in the START position. Observe the volt-ampere tester:
    WARNING
    Do not overheat the starter motor or draw the battery voltage below 9.6 volts during cranking operations.



    If the voltage reads above 9.6 volts, and the amperage draw reads above 250 amps, go to the starter feed circuit resistance test (following this test).
     
    If the voltage reads 12.4 volts or greater and the amperage reads 0-10 amps, refer to the starter control circuit test.
     
    If the voltage reads below 9.6 volts and the amperage draw reads above 300 amps, the trouble is within the starter.
     

  8.  
  9. After the starting system problems have been corrected, verify the battery state of charge and charge the battery if necessary. Disconnect all of the testing equipment and connect the ignition coil cable or ignition coil connector. Start the vehicle several times to assure the problem was corrected.
  10.  

Before proceeding with this test, refer to the battery tests and starter feed circuit test. The following test will require a voltmeter, which is capable of accuracy to 0.1 volt.


CAUTION
The ignition and fuel systems must be disabled to prevent engine start while performing the tests.

  1. Disable the ignition and fuel systems by disconnecting the Automatic Shutdown (ASD) relay, located in the Power Distribution Center (PDC) in the engine compartment.
  2.  
  3. With all wiring harnesses and components (except for the coils) properly connected, perform the following:
    1. Connect the negative (-) lead of the voltmeter to the negative battery post, and the positive (+) lead to the negative (-) battery cable clamp. Rotate and hold the ignition switch in the START position. Observe the voltmeter. If the voltage is detected, correct the poor contact between the cable clamp and post.

      Click image to see an enlarged view

      Fig. Testing battery connection resistance

      Testing battery connection resistance
    2.  
    3. Connect the positive (+) lead of the voltmeter to the positive battery post, and the negative (-) to the positive battery cable clamp. Rotate and hold the ignition switch key in the START position. Observe the voltmeter. If voltage is detected, correct the poor contact between the cable clamp and post.
    4.  
    5. Connect the negative lead of the voltmeter to the negative (-) battery terminal, and positive lead to the engine block near the battery cable attaching point. Rotate and hold the ignition switch in the START position. If the voltage reads above 0.2 volt, correct the poor contact at ground cable attaching point. If the voltage reading is still above 0.2 volt after correcting the poor contact, replace the negative ground cable with a new one.

      Click image to see an enlarged view

      Fig. Testing the ground circuit resistance

      Testing the ground circuit resistance
    6.  

  4.  
  5. Remove the heat shield. Refer to removal and installation procedures to gain access to the starter motor and solenoid connections. Perform the following steps:
    1. Connect the positive (+) voltmeter lead to the starter motor housing and the negative (-) lead to the negative battery terminal. Hold the ignition switch key in the START position. If the voltage reads above 0.2 volt, correct the poor starter to engine ground.

      Click image to see an enlarged view

      Fig. Starter motor ground test connections

      Starter motor ground test connections
    2.  
    3. Connect the positive (+) voltmeter lead to the positive battery terminal, and the negative lead to the battery cable terminal on the starter solenoid. Rotate and hold the ignition key in the START position. If the voltage reads above 0.2 volt, correct poor contact at the battery cable to the solenoid connection. If the reading is still above 0.2 volt after correcting the poor contacts, replace the positive battery cable with a new one.

      Click image to see an enlarged view

      Fig. Positive battery cable resistance connections

      Positive battery cable resistance connections
    4.  
    5. If the resistance tests did not detect feed circuit failures, refer to the starter solenoid test.
    6.  

  6.  

Testing Preparation

Before commencing with the starting system diagnostics, verify:



The battery top posts, and terminals are clean.
 
The alternator drive belt tension and condition is correct.
 
The battery state-of-charge is correct.
 
The battery cable connections at the starter and engine block are clean and free from corrosion.
 
The wiring harness connectors and terminals are clean and free from corrosion.
 
Proper circuit grounding.
 

 
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