Starter System Starter System ServiceService

Chapter 33Chapter 33

Page 439Page 439

Service Begins with Checking Service Begins with Checking SystemSystem

Check the battery first –Voltage should Check the battery first –Voltage should be 12.6 and while the starter is trying be 12.6 and while the starter is trying to work, the voltage can’t drop below to work, the voltage can’t drop below 9.6 volts9.6 volts

Turn the headlights on—Turn the headlights on— If they don’t work, the battery is deadIf they don’t work, the battery is dead If they dim tremendously, the battery is near deadIf they dim tremendously, the battery is near dead If they stay on bright, then there may be a bad If they stay on bright, then there may be a bad

component (solenoid, switch, wiring problem, component (solenoid, switch, wiring problem, terminal loose) terminal loose)

Testing SystemTesting System

Disable the ignition Disable the ignition Remove center ignition wire and ground it to Remove center ignition wire and ground it to

metalmetal Disconnect the wiring harness from Disconnect the wiring harness from

distributor distributor Remove ignition fuse Remove ignition fuse

Cranking rpm should be 250 or moreCranking rpm should be 250 or more *Starters are designed for short running *Starters are designed for short running

times,times,

Don’t run it long!Don’t run it long!

Testing SystemTesting System

Voltage Drop TestVoltage Drop Test This test checks the individual This test checks the individual

components to make sure each is components to make sure each is operating properly.operating properly.

Loss of voltage = High resistance = High Loss of voltage = High resistance = High heatheat

A drop of . 1 volts or more in connections A drop of . 1 volts or more in connections and .4 volts between starter and engine and .4 volts between starter and engine needs to be cleaned and checked.needs to be cleaned and checked.

A dirty and corroded terminal to clamp A dirty and corroded terminal to clamp connection can rob up to 12 volts from connection can rob up to 12 volts from the starting circuit voltage.the starting circuit voltage.

Check Terminal to Clamp Check Terminal to Clamp ConnectionConnection

Neg

Pos

No more than .1 volts

Check Clamp to Cable Check Clamp to Cable ConnectionConnection

Neg

Pos

No more than .1 volts

Check the Battery CableCheck the Battery Cable

No more than .1 volts

Check the Ground Check the Ground

Should be 0 volts

ProblemsProblems

Heat damage from high resistance

Cable frays are going to cause high resistance

Follow a Step by Step Follow a Step by Step ProcessProcess Problem: Cranks slow.Problem: Cranks slow. Test #1Test #1 - Make the following checks first: - Make the following checks first:

      Fully charged battery      Fully charged battery      Clean battery terminals      Clean battery terminals      Inspect Pos. and Neg. cables for proper routing and clean tight connections.       Inspect Pos. and Neg. cables for proper routing and clean tight connections.

Test #2Test #2 - Measure the battery voltage before you start. Pos. lead of Voltmeter to Pos. - Measure the battery voltage before you start. Pos. lead of Voltmeter to Pos. terminal of battery and the Neg. lead of Voltmeter to Neg. terminal of battery. 12.5 volts or terminal of battery and the Neg. lead of Voltmeter to Neg. terminal of battery. 12.5 volts or better is good, if less then charge the battery first. Attempt to crank the engine and note better is good, if less then charge the battery first. Attempt to crank the engine and note battery voltage, 9 volts is minimum. Anything less indicates a poorly charged or bad battery. battery voltage, 9 volts is minimum. Anything less indicates a poorly charged or bad battery.

Test #3Test #3 - Check the ground system. This test checks the integrity of the entire ground - Check the ground system. This test checks the integrity of the entire ground system from the battery to the engine block. Leave your Neg. Voltmeter lead hooded to the system from the battery to the engine block. Leave your Neg. Voltmeter lead hooded to the Neg. battery terminal and move the Pos. lead of Voltmeter to a clean ground on the engine. Neg. battery terminal and move the Pos. lead of Voltmeter to a clean ground on the engine. Attempt to crank the engine and note the battery voltage. Any reading above 0.2 volts while Attempt to crank the engine and note the battery voltage. Any reading above 0.2 volts while cranking is bad. My reading was 1.09 volts. cranking is bad. My reading was 1.09 volts.

Test #4Test #4 - Check the Pos. side. This test checks the integrity of the entire Pos. side of the - Check the Pos. side. This test checks the integrity of the entire Pos. side of the starting system between the battery and the starter. Remove your test leads and hook the starting system between the battery and the starter. Remove your test leads and hook the Pos. Voltmeter lead to the Pos. battery terminal and hook the Neg. Voltmeter lead to the Pos. Voltmeter lead to the Pos. battery terminal and hook the Neg. Voltmeter lead to the starter motor terminal. (Cable from solenoid to starter.) Attempt to crank the engine and starter motor terminal. (Cable from solenoid to starter.) Attempt to crank the engine and note the Voltmeter readings (ignore Voltmeter reading before cranking). Any reading above note the Voltmeter readings (ignore Voltmeter reading before cranking). Any reading above 0.3 volts is bad. My reading was 3.48 volts. 0.3 volts is bad. My reading was 3.48 volts.

Test #5Test #5 - Check the starter cable. Remove Pos. Voltmeter lead from battery and hook it to - Check the starter cable. Remove Pos. Voltmeter lead from battery and hook it to the starter side of the solenoid and note Voltmeter reading while attempting to crank the the starter side of the solenoid and note Voltmeter reading while attempting to crank the engine. Any reading above 0.2 volts is bad. My reading was 2.43 volts. engine. Any reading above 0.2 volts is bad. My reading was 2.43 volts.

Test #6Test #6 - Check the solenoid contacts. Hook your Voltmeter Pos. lead to the battery terminal - Check the solenoid contacts. Hook your Voltmeter Pos. lead to the battery terminal side of the solenoid and the Voltmeter Neg. lead to the starter terminal of the solenoid side of the solenoid and the Voltmeter Neg. lead to the starter terminal of the solenoid (ignore Voltmeter reading before cranking) and note Voltmeter reading while attempting to (ignore Voltmeter reading before cranking) and note Voltmeter reading while attempting to crank the engine. Any reading above 0.1 volt is bad. My reading was 0.07 volts. crank the engine. Any reading above 0.1 volt is bad. My reading was 0.07 volts.

Test #7Test #7 - Check the battery cable to starter solenoid. Hook Voltmeter Pos. lead to Pos. - Check the battery cable to starter solenoid. Hook Voltmeter Pos. lead to Pos. battery terminal and voltmeter Neg. lead to battery side of solenoid. Attempt to crank the battery terminal and voltmeter Neg. lead to battery side of solenoid. Attempt to crank the engine and note Voltmeter readings. Any reading above 0.2 volts is bad. My reading was engine and note Voltmeter readings. Any reading above 0.2 volts is bad. My reading was 1.01 volts. 1.01 volts.

Interpreting the test results:Interpreting the test results: Test #1Test #1 will solve many starting problems. will solve many starting problems. Test #2Test #2 will test the basic integrity of your battery. will test the basic integrity of your battery. Test #3Test #3 Ground system. Result of test indicates a poor ground condition. Visual Ground system. Result of test indicates a poor ground condition. Visual

inspection revealed loose and corroded battery cable to terminal connections. Block inspection revealed loose and corroded battery cable to terminal connections. Block connection was good. The proper repair will be a new Negative battery cable. connection was good. The proper repair will be a new Negative battery cable.

Test #4Test #4 Positive side. Result of test indicates poor connections (too much resistance). Positive side. Result of test indicates poor connections (too much resistance). Test #5Test #5 Starter cable. Result of this test indicates a poor connection or cable. Visual Starter cable. Result of this test indicates a poor connection or cable. Visual

inspection confirmed a bad cable, melted insulation at terminal connector for inspection confirmed a bad cable, melted insulation at terminal connector for solenoid. This cable needs replacing. solenoid. This cable needs replacing.

Test #6Test #6 Solenoid contacts. This test indicated good solenoid contacts. No problem Solenoid contacts. This test indicated good solenoid contacts. No problem here. here.

Test #7Test #7 Battery cable. This test indicated poor connections. Visual inspection Battery cable. This test indicated poor connections. Visual inspection confirmed dirty connection between battery terminal and cable. confirmed dirty connection between battery terminal and cable.

Make the needed corrections indicated by the tests above and retest the system to Make the needed corrections indicated by the tests above and retest the system to confirm the repairs you made were effective. If it still cranks slowly, the starter motor confirm the repairs you made were effective. If it still cranks slowly, the starter motor is bad. is bad. Problem: Engine does not crank, solenoid chatters or doesn't clickProblem: Engine does not crank, solenoid chatters or doesn't click

1. Complete test #1 and #2 above. 1. Complete test #1 and #2 above. 2. Check ignition switch. This is a quick test of the circuit between the battery and the 2. Check ignition switch. This is a quick test of the circuit between the battery and the

solenoid. Remove the wire going to the solenoid "S" terminal and hook up your Should solenoid. Remove the wire going to the solenoid "S" terminal and hook up your Should be 12 volts or more.be 12 volts or more.

3. Check the solenoid ground. This test assumes your ignition switch circuit is good. 3. Check the solenoid ground. This test assumes your ignition switch circuit is good. Use your Voltmeter to perform a voltage drop test to confirm the ground. Hook the Use your Voltmeter to perform a voltage drop test to confirm the ground. Hook the Neg. lead of Voltmeter to Neg. terminal of the battery and the Pos. lead of Voltmeter Neg. lead of Voltmeter to Neg. terminal of the battery and the Pos. lead of Voltmeter to the ground lug or bolt of the solenoid. Attempt to crank engine and note the volt to the ground lug or bolt of the solenoid. Attempt to crank engine and note the volt reading on your Voltmeter. Less than 0.2 volts, good reading, no problem with reading on your Voltmeter. Less than 0.2 volts, good reading, no problem with ground. More than 0.2 volts indicates a poor ground to the solenoid. No reading ground. More than 0.2 volts indicates a poor ground to the solenoid. No reading would indicate a possible open circuit in the solenoid itself. Substitute a known good would indicate a possible open circuit in the solenoid itself. Substitute a known good solenoid or remove the solenoid and test as per your Repair guide. There should be a solenoid or remove the solenoid and test as per your Repair guide. There should be a resistance value in your Repair guide for the "S" terminal to ground. A 0 (zero) ohms resistance value in your Repair guide for the "S" terminal to ground. A 0 (zero) ohms reading would indicate a shorted winding and an (infinity reading) would indicate an reading would indicate a shorted winding and an (infinity reading) would indicate an open winding. Any other reading should be compared against the specs in your Repair open winding. Any other reading should be compared against the specs in your Repair guide. If the results of your tests confirm the solenoid is good, verify the ground cable guide. If the results of your tests confirm the solenoid is good, verify the ground cable between the battery and engine block to make sure it is good. If the solenoid tests between the battery and engine block to make sure it is good. If the solenoid tests good and the ground cable is good, then the starter motor is bad.good and the ground cable is good, then the starter motor is bad.

Neutral Safety SwitchNeutral Safety Switch

This needs to be checked if you don’t This needs to be checked if you don’t get 12 volts at the “S” terminal on get 12 volts at the “S” terminal on the solenoid. the solenoid.

Both auto and manual transmissions Both auto and manual transmissions have this safety device.have this safety device.

Check the Shop manual for location Check the Shop manual for location and repair of the neutral safety and repair of the neutral safety switch.switch.

Starter RepairStarter Repair Starter repair is almost down to just Starter repair is almost down to just

replacement!replacement! The cost is to high to try to repair or rebuild the The cost is to high to try to repair or rebuild the

starterstarter Most repairs are cleaning the terminals, Most repairs are cleaning the terminals,

replacing the solenoid, replacing the drive gear, replacing the solenoid, replacing the drive gear, and cleaning corrosion off the armature---the and cleaning corrosion off the armature---the gear and armature repairs require breaking the gear and armature repairs require breaking the starter down--- probably won’t do this anymore.starter down--- probably won’t do this anymore.

Adjusting a grinding or noisy started will involve Adjusting a grinding or noisy started will involve trying different shims between the starter and trying different shims between the starter and engine. (1% of starters need this fix)engine. (1% of starters need this fix)

Cleaning the Armature and Cleaning the Armature and Adjusting Clearance Adjusting Clearance

Your Job.Your Job.

Complete chapter Questions 1-10 Complete chapter Questions 1-10 (review) and 1-10 (ASE-style). Page 448(review) and 1-10 (ASE-style). Page 448

Write on a separate paper and write Write on a separate paper and write out the complete question and your out the complete question and your answer. ( do not write the other answer answer. ( do not write the other answer options). options).

Complete the chapter worksheet (I will Complete the chapter worksheet (I will give it out). You may write on it. give it out). You may write on it.

File all items in your note book.File all items in your note book. Notebooks will be graded in the future.Notebooks will be graded in the future.