Starting System: Testing and Inspection
Starter TestNOTE: The air temperature must be between 59° F and 100° F (15° C and 38° C) before testing.
Recommended Procedure:
^ Use a starter system tester.
^ Connect and operate the equipment in accordance with the manufacturer's instructions.
^ Test and troubleshoot as described.
Starting System - Starter Test:
Alternate Procedure:
^ Use the following equipment:
- Ammeter, 0 - 400 A
- Voltmeter, 0 - 20 V (accurate within 0.1 Volt)
- Tachometer, 0 - 1200 rpm
^ Hook up voltmeter and ammeter as shown.
NOTE: After this test, or any subsequent repair, reset the ECM/PCM to clear any codes (See Fuel and Emissions).
Starting System - Starter Test:
Check Starter Engagement
1. Disconnect the 4P connector from the ignition coil.
2. With the at shift lever to [P], and turn the ignition switch to "Start" (III). The starter should crank the engine.
3. Check the battery, battery positive cable, ground, and the wire connections for looseness and corrosion. Test again. If the starter still does not crank the engine, go to step 4.
Starting System - Starter Test:
4. Bypass the ignition switch circuit as follows (make sure the transmission is in neutral):
Unplug the connector (BLK/WHT wire and solenoid terminal) from the starter. Then connect a jumper wire from the battery positive (+) terminal to the solenoid terminal. The starter should crank the engine.
^ If the starter still does not crank the engine, remove it, and diagnose its internal problems.
^ If the starter cranks the engine, go to step 5.
5. Check for an open in the BLK/WHT, WHT/RED wire circuit between the starter and ignition switch, and connectors.
6. Check the ignition switch.
7. Check the A/T gear position switch (neutral position switch),
starter cut relay, and connector.
Check for Wear and Damage
The starter should crank the engine smoothly and steadily. If the starter engages, but cranks the engine erratically, remove it, and inspect the starter drive gear and flywheel or torque converter ring gear for damage.
^ Check the drive gear overrunning clutch for binding or slipping when the armature is rotated with the drive gear held. If the clutch is damaged, replace the clutch assembly.
Check Cranking Voltage and Current Draw
Cranking voltage should be no less than 8.5 Volts.
Current draw should be no more than 380 Amperes.
If cranking voltage is too low, or current draw too high, check for:
^ Dead or low battery
^ Open circuit in starter armature commutator segments
^ Starter armature dragging
^ Shorted armature winding
^ Excessive drag in engine
Check Cranking rpm
Engine speed during cranking should be above 100 rpm.
If speed is too low, check for:
^ Loose battery or starter terminals
^ Excessively worn starter brushes
^ Open circuit in commutator segments
^ Dirty or damaged helical spline or drive gear
^ Defective drive gear overrunning clutch
Check Starter Disengagement
With the shift lever at [P], turn the ignition switch to "III", and release to "II". The starter drive gear should disengage from the flywheel ring gear when you release the key.
If the drive gear hangs up on the flywheel ring gear, check for:
^ Solenoid plunger and switch malfunction.
^ Dirty drive gear assembly or damaged overrunning clutch.
Starter Replacement
NOTE: The original radio has a coded theft protection circuit. Be sure to get the customer's code number before
- disconnecting the battery.
- removing the No. 39 (7.5 A) fuse from the under- hood fuse/relay box.
- removing the radio.
After service, reconnect power to the radio and turn it on. When the word "CODE" is displayed, enter the customer's 5-digit code to restore radio operation.
1. Disconnect the battery negative cable, then disconnect the positive cable.
2. Remove the engine wire harness from the starter motor.
Starter Replacement:
3. Disconnect the starter cable from the B terminal on the solenoid, then the BLK/WHT wire from the S terminal wire.
4. Remove the two mounting bolts, then remove the starter.
5. Install in the reverse order of removal.
Starter Solenoid Test
Starter Solenoid Test:
1. Remove the starter solenoid.
2. Check for continuity between the terminals in each solenoid plunger position according to the table.
Starter Brush Inspection
Starter Brush Inspection:
Measure the brush length. If not within the service limit, replace the armature housing and brush holder assembly.
NOTE: To seat new brushes after installing them in their holders, slip a strip of #500 or #600 sandpaper, with the grit side up, over the commutator, and smoothly rotate the armature. The contact surface of the brushes will be sanded to the same contour as the commutator.
Starter Brush Holder Test
1. Check that there is no continuity between the (+) and (-) brush holders.
Starter Brush Holder Test:
2. If continuity exists, replace the brush holder assembly.
Starter Brush Holder Test:
3. Insert the brush into the brush holder, and bring the brush into contact with the commutator, then attach a spring scale to the spring. Measure the spring tension at the moment the spring lifts off the brush. If it is out of specification, replace the brush holder assembly.
Armature Inspection and Test
Armature Inspection:
1. Inspect the armature for wear or damage due to contact with the field coil magnets.
Armature Inspection And Test:
Armature Inspection And Test:
2. A dirty or burnt commutator surface may be resurfaced with emery cloth or a lathe within the following specifications.
3. If the commutator runout and diameter are within limits, check the commutator for damage or for carbon dust or brass chips between the segments.
Cleaning Up The Commutator Surface:
4. If the surface is dirty, recondition it with #500 or #600 sandpaper.
Armature Inspection And Test:
5. Check the mica depth. If necessary, undercut the mica with a hacksaw blade to achieve the proper depth.
Checking For Continuity:
6. Check for continuity between the segments of the commutator. If an open circuit exists between any segments, replace the armature.
7. Place the armature on an armature tester. Hold a hacksaw blade on the armature core.
If the blade is attracted to the core or vibrates while the core is turned, the armature is shorted. Replace the armature.
Commutator And Armature Continuity Check:
8. With an ohmmeter, check that no continuity exists between the commutator and armature coil core, and between the commutator and armature shaft. If continuity exists, replace the armature.
Overrunning Clutch Inspection
1. Slide the overrunning clutch along the shaft.
Does it move freely? If not, replace it.
Overrunning Clutch Inspection:
2. Rotate the overrunning clutch both ways.
Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction or it locks in both directions, replace it.
3. If the starter drive gear is worn or damaged, replace the overrunning clutch assembly; the gear is not available separately.
4. Check the condition of the torque converter ring gear if the starter drive gear teeth are damaged.
Starter Reassembly
Reassemble the starter in the reverse order of disassembly.
Starter Brush Holder Assembly:
1. Pry back each brush spring with a screwdriver, then position the brush about halfway out of its holder, and release the spring to hold it there.
Installation Of Brush Housing Onto The Armature:
2. Install the armature in the housing. Next, pry back each brush spring again, and push the brush down until it seats against the commutator, then release the spring against the end of the brush.
Starter Reassembly:
3. Install the end cover on the brush holder.