Starting System: Diagnosis Chevrolet Prizm I

TROUBLE SHOOTING

Note. See TROUBLE SHOOTING article in GENERAL INFORMATION.

ON-VEHICLE TESTING

Note. Before testing, ensure battery is fully charged, battery cables and terminal ends are clean and tight, and engine grounds are good.

IGNITION SWITCH TEST

See ENGINE DOES NOT CRANK & STARTER SOLENOID DOES NOT CLICK .

Solenoid Pull-In & Hold-In Test

1. Remove starter. Disconnect starter-to-solenoid field lead terminal. (Scheme 1) Ensure field lead does not touch starter housing. Connect negative lead of 12-volt battery to solenoid field lead terminal.
2. Connect another lead from negative battery terminal to starter drive housing. Connect lead from positive battery terminal to solenoid "S" terminal.
3. Pinion gear should extend quickly and completely when solenoid is energized. If pinion gear operates as specified, go to next step. If pinion gear does not operate as specified, replace solenoid.
4. Disconnect negative battery lead from solenoid field lead terminal. If pinion gear remains extended, go to next step. If pinion gear does not remain extended, replace solenoid.
5. Disconnect lead from starter drive housing. If pinion returns quickly to de-energized position, go to «NO-LOAD TEST»(ref-665-S13009542142000031300000). If pinion does not operate as specified, repair or replace starter.

Scheme 1

NO-LOAD TEST

Note. Perform SOLENOID TESTS before performing NO-LOAD TEST.

1. Remove starter. Connect ammeter in series with starter motor and fully charged 12-volt battery. (Scheme 2) Connect voltmeter across battery terminals and observe voltage draw readings.
2. Connect remote starter or jumper wire to battery and starter terminal of solenoid. Crank starter for maximum of 5 seconds. Starter drive pinion should extend completely and quickly. Starter should spin rapidly and smoothly. See «STARTER SPECIFICATIONS»(ref-665-S27663363882000031300000) for current draw specification. If current draw is not as specified, repair or replace starter.

Scheme 2

ARMATURE TEST

1. Using ohmmeter, check continuity between commutator and armature core, and between commutator and shaft. Continuity should not exist. If continuity exists in either test, replace armature.
2. Ensure continuity exists between any 2 commutator segments. If continuity does not exist, replace armature.

COMMUTATOR TEST

1. Using "V" blocks and dial indicator, check commutator runout (out-of-round). See «STARTER SPECIFICATIONS»(ref-665-S27663363882000031300000) . Replace commutator/armature if runout (out-of-round) is not within specifications.
2. Check commutator diameter. If commutator is less than specification, replace armature. See «STARTER SPECIFICATIONS»(ref-665-S27663363882000031300000) .
3. Ensure continuity exists between any 2 commutator segments. If continuity does not exist, replace armature.
4. Clean commutator segment surfaces with No. 400 grit sandpaper (if necessary). If surface is scored, out-of-round, or pitted, replace commutator/armature assembly.
5. Measure undercut depth of insulating mica. See «STARTER SPECIFICATIONS»(ref-665-S27663363882000031300000) . If mica depth is not within specification, replace armature.