Diagnosis And Testing - Starting System Test: Inspection

WARNING: This page is about a different car, the 2006 Dodge Magnum, 2006 Dodge Charger, and 2006 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.

Before removing any unit from the starting system for repair or diagnosis, perform the following inspections:

Battery - Visually inspect the battery for indications 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 the BATTERY SYSTEM for more information.
Ignition Switch - Visually inspect the ignition switch for indications of physical damage and loose or corroded wire harness connections.
Transmission Range Sensor or Park/Neutral Switch - Visually inspect the transmission range sensor for indications of physical damage and loose or corroded wire harness connections.
Starter Relay - Visually inspect the starter relay for indications of physical damage and loose or corroded wire harness connections.
Starter Motor - Visually inspect the starter motor for indications of physical damage and loose or corroded wire harness connections.
Starter Solenoid - Visually inspect the starter solenoid for indications of physical damage and loose or corroded wire harness connections.
Wiring - Visually inspect the wire harness for damage. Repair or replace any faulty wiring, as required. Check for loose or corroded wire harness connections at main engine ground and remote jump post.
Power Distribution Center (PDC) - Visually inspect the B+ connections at the PDC for physical damage and loose or corroded harness connections.

STARTING SYSTEM DIAGNOSIS

CONDITION	POSSIBLE CAUSE	CORRECTION
STARTER FAILS TO ENGAGE.	1. BATTERY DISCHARGED OR FAULTY.	1. REFER TO BATTERY SYSTEM FOR MORE INFORMATION. CHARGE OR REPLACE BATTERY, IF REQUIRED.
	2. STARTING CIRCUIT WIRING FAULTY.	2. REFER TO DIAGNOSIS AND TESTING - FEED CIRCUIT RESISTANCE TEST AND DIAGNOSIS AND TESTING - CONTROL CIRCUIT TEST .
	3. STARTER RELAY FAULTY.	3. REFER TO RELAY TEST . REPLACE RELAY, IF NECESSARY.
	4. IGNITION SWITCH FAULTY.	4. REFER TO IGNITION SWITCH IN IGNITION SYSTEM - ELECTRICAL DIAGNOSTICS OR APPROPRIATE SYSTEM WIRING DIAGRAMS ARTICLE. REPLACE SWITCH, IF NECESSARY.
	5. PARK/NEUTRAL POSITION SWITCH (AUTO TRANS) FAULTY OR MIS-ADJUSTED.	5. REFER TO PARK/NEUTRAL POSITION SWITCH TEST, FOR MORE INFORMATION. REPLACE SWITCH, IF NECESSARY.
	6. CLUTCH INTERLOCK SWITCH (MAN TRANS) FAULTY.	6. REFER TO CLUTCH PEDAL POSITION SWITCH TEST. REPLACE SWITCH, IF NECESSARY.
	7. STARTER SOLENOID FAULTY.	7. REFER TO STARTER SOLENOID . REPLACE STARTER ASSEMBLY, IF NECESSARY.
	8. STARTER ASSEMBLY FAULTY.	8. IF ALL OTHER STARTING SYSTEM COMPONENTS AND CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
	9. FAULTY TEETH ON RING GEAR.	9. ROTATE FLYWHEEL 360°, AND INSPECT TEETH AND RING GEAR REPLACED IF DAMAGED.
	10. PCM DOUBLE START OVERRIDE OUTPUT FAILURE.	10. REFER TO PCM DIAGNOSTIC. CHECK FOR CONTINUITY BETWEEN PCM AND TERMINAL 85. REPAIR OPEN CIRCUIT AS REQUIRED. IF OK, PCM MAY BE DEFECTIVE.
STARTER ENGAGES, FAILS TO TURN ENGINE.	1. BATTERY DISCHARGED OR FAULTY.	1. REFER TO BATTERY SYSTEM FOR MORE INFORMATION. CHARGE OR REPLACE BATTERY AS NECESSARY.
	2. STARTING CIRCUIT WIRING FAULTY.	2. REFER TO THE DIAGNOSIS AND TESTING - FEED CIRCUIT RESISTANCE TEST AND DIAGNOSIS AND TESTING - CONTROL CIRCUIT TEST . REPAIR AS NECESSARY.
	3. STARTER ASSEMBLY FAULTY.	3. IF ALL OTHER STARTING SYSTEM COMPONENTS AND CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
	4. ENGINE SEIZED.	4. REFER TO ENGINE ARTICLE, FOR DIAGNOSTIC AND SERVICE PROCEDURES.
	5. LOOSE CONNECTION AT BATTERY, PDC, STARTER, OR ENGINE GROUND.	5. INSPECT FOR LOOSE CONNECTIONS.
	6. FAULTY TEETH ON RING GEAR.	6. ROTATE FLYWHEEL 360°, AND INSPECT TEETH AND RING GEAR REPLACED IF DAMAGED.
STARTER ENGAGES, SPINS OUT BEFORE ENGINE STARTS.	1. BROKEN TEETH ON STARTER RING GEAR.	1. REMOVE STARTER. INSPECT RING GEAR AND REPLACE IF NECESSARY.
STARTER ENGAGES, SPINS OUT BEFORE ENGINE STARTS.	2. STARTER ASSEMBLY FAULTY.	2. IF ALL OTHER STARTING SYSTEM COMPONENTS AND CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
STARTER DOES NOT DISENGAGE.	1. STARTER IMPROPERLY INSTALLED.	1. INSTALL STARTER. TIGHTEN STARTER MOUNTING HARDWARE TO CORRECT TORQUE SPECIFICATIONS.
	2. STARTER RELAY FAULTY.	2. REFER TO RELAY TEST . REPLACE RELAY, IF NECESSARY.
	3. IGNITION SWITCH FAULTY.	3. REFER TO IGNITION SWITCH IN STEERING OR APPROPRIATE SYSTEM WIRING DIAGRAMS ARTICLE. REPLACE SWITCH, IF NECESSARY.
	4. STARTER ASSEMBLY FAULTY.	4. IF ALL OTHER STARTING SYSTEM COMPONENTS AND CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
	5. FAULTY TEETH ON RING GEAR.	5. ROTATE FLYWHEEL 360°, AND INSPECT TEETH AND RING GEAR REPLACED IF DAMAGED.