I would be checking. Starter motor wiring connections. Ignition switch for faults/sticking. You could also check neutral safety switch connections? Let me know if you need any diagrams listed? .
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.
CRANKING TEST
NOTE:Ensure engine is at normal operating temperature. High viscosity oil, extreme cold temperatures, or tight engine will increase amperage draw.
Using a battery load tester, connect positive and negative leads to battery. Connect inductive ammeter pick-up to positive battery cable. Ensure all lights and accessories are off. Place A/T in Park or M/T in Neutral. Apply parking brake.
Crank engine and observe voltmeter reading. If voltage drops below 9.6 volts, recharge and test battery. If voltage remains above 9.6 volts, observe amperage reading. Replace starter if amperage draw is more than specified. See STARTER SPECIFICATIONS.
CAUTION:During cranking, DO NOT draw battery voltage down to less than 9.6 volts. Use care not to overheat starter.
If starter cranks engine freely, but problem with starter is still suspected, engage starter several times while observing volt/ammeter readings. A starter that has a problem should fail when performing this procedure.
CIRCUIT RESISTANCE TESTS
NOTE:If excessive resistance is not found in circuits being tested, remove starter and proceed to BENCH TESTING.
NOTE:A voltmeter accurate to one tenth of a volt will be needed for the following tests.
Battery Connection Resistance Tes
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 greater than 0.2 volt, 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 voltage is greater 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
Remove starter heat shield (if equipped) to gain access to starter solenoid connections. Connect voltmeter negative lead to starter solenoid battery terminal and voltmeter positive lead to positive battery post.
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 under ON-VEHICLE TESTING before testing starter relay circuit and starter relay. Ensure A/T is in Park or M/T is in Neutral and parking brake is applied.
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.
Connect a remote starter switch or jumper wire between starter relay connector terminal No. 87 and positive battery post. See Fig. 1. If engine cranks, solenoid and starter are good. Go to STARTER RELAY CIRCUIT TEST.
If engine fails to crank, or if solenoid chatters, check wiring and connectors from starter relay connector to starter solenoid terminal for loose or corroded connections. Clean and retest. If engine still fails to crank, remove starter and proceed to SOLENOID TEST under BENCH TESTING.
Fig. 1: Identifying Starter Relay Terminals
Courtesy of CHRYSLER CORP.
STARTER RELAY TEST
NOTE:Perform SOLENOID CIRCUIT TEST under ON-VEHICLE TESTING before testing starter relay.
Remove starter relay from Power Distribution Center (PDC). PDC is located in engine compartment. Refer to PDC label for starter relay identification.
Using an ohmmeter, check for continuity between starter relay terminals No. 30 and 87A. See Fig. 1. If no continuity exists, replace starter relay. Check for continuity between starter relay terminals No. 30 and 87. If continuity exists, replace starter relay. If relay tests as specified, go to next step.
Check resistance between starter relay terminals No. 85 and 86. If resistance is not 70-80 ohms, replace starter relay. If resistance is okay, go to next step.
Connect a 12-volt power source to starter relay terminals No. 85 and 86. Continuity should exist between starter relay terminals No. 30 and 87. No continuity should exist between starter relay terminals No. 30 and 87A. Replace starter relay if it does not test as specified. If starter relay tests as specified, go to STARTER RELAY CIRCUIT TEST.
STARTER RELAY CIRCUIT TEST
NOTE:Perform SOLENOID CIRCUIT TEST under ON-VEHICLE TESTING before testing starter relay circuit.
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.
Connect a jumper wire between starter relay connector terminals No. 30 and 87. See Fig. 1. If engine does not crank, go to SOLENOID TEST. If engine cranks, go to next step.
Turn ignition on. Check for battery voltage at starter relay connector terminal No. 30. If voltage is not present, repair open in wiring from starter relay connector to battery.
If voltage is present at starter relay connector terminal No. 30, ensure battery voltage is also present at starter relay connector terminal No. 86. Check for voltage with ignition switch in START position. If voltage is not present, go to next step. If voltage is present, circuit is okay. Go to step 6).
If voltage is not present at starter relay connector terminal No. 86, repair open or short in wiring from ignition switch to starter relay connector. If circuit to ignition switch is okay, check ignition switch. See IGNITION SWITCH TEST under ON-VEHICLE TESTING.
Check for continuity to ground at starter relay connector terminal No. 85. If continuity exists, circuit is okay. If continuity does not exist, go to next step.
If vehicle is equipped with an A/T, check for an open or short to neutral safety switch. See NEUTRAL SAFETY SWITCH under ON-VEHICLE TESTING. If vehicle is equipped with a M/T, repair circuit to ground as required.
IGNITION SWITCH TEST
WARNING:Deactivate air bag system before performing any service operation involving steering column components. See appropriate AIR BAG RESTRAINT SYSTEM article in the ACCESSORIES/SAFETY EQUIPMENT section.
NOTE:For additional information, refer to TEST NS-1A in appropriate TESTS W/CODES article in ENGINE PERFORMANCE section.
Disconnect negative battery cable. Remove ignition switch. See STEERING COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT. With ignition switch in ON position, check for continuity between ignition switch terminals No. 1 and 7. See WIRING DIAGRAMS. If continuity exists, replace ignition switch. If continuity does not exist, go to next step.
With ignition switch in START position, check for continuity between ignition switch terminals No. 1 and 7. See WIRING DIAGRAMS. If continuity exists, ignition switch is okay. If continuity does not exist, replace ignition switch.
Sunday, January 18th, 2009 AT 9:47 AM