Starting System: Diagnosis Chevrolet Tracker II

TROUBLE SHOOTING

Note. See CHARGING SYSTEM - GENERAL TROUBLE SHOOTING article in GENERAL INFORMATION.

Verify customer complaint by operating suspected system. Visually inspect for obvious signs of mechanical and electrical damage. Inspect for blown fuses. Inspect for loose or corroded connections, damaged wiring harnesses and/or switches. Check for a broken or partially broken wire inside insulation, which could cause system malfunction but prove good in a continuity/voltage check with system disconnected. Ensure any aftermarket electronic equipment is properly installed. If fault is found, repair as necessary. If no fault is found, repair by symptom. See SYMPTOM INDEX table under SYSTEM TESTS.

BATTERY TESTING & INSPECTION

Note. Manufacturer recommends using Battery Tester (J-42000) for testing battery. Follow instructions provided with tester.

1. Inspect battery for a cracked, broken or damaged case. If battery case is okay, go to next step. If battery case is not okay, go to step 19 .
2. Compare battery cold cranking amperage and reserve capacity rating to specifications. See «BATTERY SPECIFICATIONS»(ref-126046-S40823436652001103100000) table. If battery meets or exceeds specifications, go to next step. If battery does not meet or exceed specifications, go to step 19 . BATTERY SPECIFICATIONS Application Specification With 60-Amp Generator Replacement Battery Number 26R-50S Cold Cranking Amps 390 Amps Reserve Capacity Rating 71 Minutes With 70-Amp Generator Replacement Battery Number 85-7YR Cold Cranking Amps 600 Amps Reserve Capacity Rating (1) With 85-Amp Generator Replacement Battery Number (1) Cold Cranking Amps 700 Amps Reserve Capacity Rating (1) (1) Information is not available from manufacturer.
3. Inspect battery hydrometer display. If hydrometer display shows a Yellow dot, go to next step. If hydrometer display does not show a Yellow dot, go to step 5 .
4. Using a small screwdriver, tap top of hydrometer display to dislodge any air bubbles inside. If hydrometer display still shows a Yellow dot, go to step 19 . If hydrometer display does not show a Yellow dot, go to next step.
5. Turn ignition switch to LOCK position. Attempt to rotate negative battery cable connector clockwise with light finger pressure. If negative connector rotates, go to next step. If negative connector does not rotate, go to step 7 .
6. Using an INCH lb. torque wrench, record torque value while loosening negative battery cable bolt. If torque is equal to or greater than 89 INCH lbs. (10 N.m), go to step 8 . If torque is less than 89 INCH lbs. (10 N.m), go to next step.
7. Disconnect negative battery cable and go to step 9 .
8. Disconnect negative battery cable. Inspect battery and cable terminals for corrosion and defects. Repair as necessary. Go to next step.
9. Attempt to rotate positive battery cable connector clockwise with light finger pressure. If battery cable rotates, go to next step. If battery cable does not rotate, go to step 11 .
10. Using an INCH lb. torque wrench, record torque value while loosening positive battery cable bolt. If torque is equal to or greater than 89 INCH lbs. (10 N.m), go to step 12 . If torque is less than 89 INCH lbs. (10 N.m), go to next step.
11. Disconnect positive battery cable and go to step 13 .
12. Disconnect positive battery cable. Inspect battery and cable terminals for corrosion and defects. Repair as necessary. Go to next step.
13. Clean and wire brush lead face of both battery terminals and metal contact surfaces on both cable connectors. Remove bolts from both battery cable connectors and inspect for corrosion and defects. Repair or replace as necessary. If battery and cables terminals are clean and in good condition, go to next step.
14. Connect positive battery cable to battery and tighten bolt to 11 ft. lbs. (15 N.m). Go to next step.
15. Connect negative battery cable to battery and tighten bolt to 11 ft. lbs. (15 N.m). Go to next step.
16. Ensure all electrical loads are off. Follow manufacturers instructions and install Battery Tester (J-42000) to vehicle battery. Follow any instructions displayed on battery tester. If battery tester passed battery, go to next step. If battery tester did not pass battery, go to step 18 .
17. Press CODE button on battery tester. Record displayed code on vehicle repair order for warranty purposes. Battery is okay.
18. Press CODE button on battery tester. Record displayed code on vehicle repair order for warranty purposes. Replace battery.
19. Replace battery.

TEST A: STARTER SOLENOID DOES NOT CLICK

1. Review system description and operation, and perform a visual inspection of system. See «TROUBLE SHOOTING»(ref-126046-S04745432892001101900000) . Go to next step.
2. Put gear selector in Park or Neutral (A/T) or depress clutch pedal (M/T). Turn ignition switch to START position. If starter solenoid clicks, problem is intermittent. Check wiring and connections. If starter solenoid does not click, go to next step.
3. Turn ignition switch to LOCK position. Disconnect Black/Yellow wire connector from starter solenoid. Connect a test light between Black/Yellow wire and ground. Turn ignition switch to START position. If test light illuminates, go to step 7 . If test light does not illuminate, leave test light connected and go to next step.
4. Turn ignition switch to LOCK position. Disconnect Park/Neutral Position (PNP) switch (A/T), or Clutch Pedal Position (CPP) switch (M/T) harness connector. Connect a 10-amp fused jumper wire between Black/Red wire terminal and Black/Yellow wire terminal at appropriate harness connector. Turn ignition switch to START position. If test light illuminates, go to step 8 . If test light does not illuminate, go to next step.
5. Remove jumper wire. Connect a test light between Black/Red wire terminal at PNP or CPP harness connector and ground. Turn ignition switch to START position. If test light illuminates, go to step 11 . If test light does not illuminate, go to next step.
6. Check for high resistance or an open in Black/Red wire between ignition switch, and CPP switch or PNP switch. If problem exists, repair circuit as necessary and go to step 15 . If problem does not exist, go to step 10 .
7. Inspect starter solenoid for poor connections. If problem exists, repair as necessary and go to step 15 . If problem does not exist, go to step 12 .
8. Check PNP or CPP switch for proper operation. If problem exists, repair or adjust as necessary and go to step 15 . If problem does not exist, go to next step.
9. Inspect PNP or CPP switch for poor connections. If problem exists, repair as necessary and go to step 15 . If problem does not exist, go to step 13 .
10. Inspect ignition switch for poor connections. If problem exists, repair as necessary and go to step 15 . If problem does not exist, go to step 14 .
11. Repair high resistance or open in Black/Yellow wire between starter, and CPP switch or PNP switch. See «WIRING DIAGRAMS»(ref-126046-S19765669402001101900000) . After repairs, go to step 15 .
12. Replace starter. See «STARTER»(ref-126046-S27212197802001101900000) under REMOVAL & INSTALLATION. Go to step 15 .
13. Replace PNP or CPP switch. After repairs, go to step 15 .
14. Replace ignition switch. See «STEERING COLUMN SWITCHES»(ref-121806) article in ACCESSORIES & EQUIPMENT. After repairs, go to step 15 .
15. Operate system. If condition was corrected, system is okay. If condition was not corrected, go to step 3 .

TEST B: STARTER SOLENOID CLICKS, ENGINE DOES NOT CRANK

1. Review system description and operation, and perform a visual inspection of system. See «TROUBLE SHOOTING»(ref-126046-S04745432892001101900000) . If problem exists, repair as necessary. If problem does not exist, go to next step.
2. Put gear selector in Park or Neutral (A/T) or depress clutch pedal (M/T). Turn ignition switch to START position. If starter solenoid clicks, go to next step. If starter solenoid does not click, go to «TEST A: STARTER SOLENOID DOES NOT CLICK»(ref-126046-S14506065782001101900000) .
3. Check engine and drive belt system for binding. Check generator and engine for seizing conditions. If engine and drive belt moves freely, go to next step. If engine or drive belt system does not move freely, repair as necessary. See appropriate article in ENGINES.
4. Test battery positive cable between battery and starter solenoid for high resistance. See «WIRING DIAGRAMS»(ref-126046-S19765669402001101900000) . If problem exists, repair as necessary and go to step 8 . If problem does not exist, go to next step.
5. Test ground circuit between battery and starter motor for high resistance. See «WIRING DIAGRAMS»(ref-126046-S19765669402001101900000) . If problem exists, repair as necessary and go to 8 . If problem does not exist, go to next step.
6. Inspect starter for poor connections. If problem exists, repair as necessary and go to step 8 . If problem does not exist, go to next step.
7. Replace starter. See «STARTER»(ref-126046-S27212197802001101900000) under REMOVAL & INSTALLATION. After repairs, go to next step.
8. Operate system. If condition was corrected, system is okay. If condition was not corrected, go to step 3 .

TEST C: ENGINE CRANKS SLOWLY

1. Ensure battery is in good condition. See «BATTERY TESTING & INSPECTION»(ref-126046-S25200326952001103100000) under ON-VEHICLE TESTING. If problem exists, repair as necessary. If problem does not exist, go to next step.
2. Inspect wiring for damage or poor connections at starter motor, solenoid battery and all grounds. If problem exists, repair as necessary. If problem does not exist, go to next step.
3. Ensure engine is not seized. If problem exists, repair as necessary. If problem does not exist, go to next step.
4. Replace starter motor. See «STARTER»(ref-126046-S27212197802001101900000) under REMOVAL & INSTALLATION.

TEST D: STARTER NOISE DIAGNOSIS

1. Review system description and operation, and perform a visual inspection of system. See «TROUBLE SHOOTING»(ref-126046-S04745432892001101900000) . If problem exists, repair as necessary. If problem does not exist, go to next step.
2. Start engine. If starter operates normally, check wiring system for intermittent or poor connection condition. If starter does not operate normally, go to next step.
3. Start engine while listening to starter motor turn. If there is a loud "whoop" sound, go to step 6 . If there is not a loud "whoop" sound, go to next step.
4. If there is a "rumble", a "growl", or a "knock" sound as starter is slowing down to a stop after starting engine, go to step 7 . If there is not a "rumble", a "growl", or a "knock" sound as starter is slowing down to a stop after starting engine, go to next step.
5. If there is a high pitched "whine" sound after engine cranks and starts normally, go to step 9 . If there is not a high pitched "whine" sound after engine cranks and starts normally, go to step 7 .
6. Inspect flywheel ring gear for chipped, missing, or milled gear teeth and/or if flywheel is damaged or bent. If problem exists, go to step 8 . If problem does not exist, go to step 9 .
7. Remove starter motor. See «STARTER»(ref-126046-S27212197802001101900000) under REMOVAL & INSTALLATION. Inspect starter motor bushings and clutch gear. If problem exists, go to step 9 . If problem does not exist, go to step 8 .
8. Replace flywheel. See appropriate ENGINE MECHANICAL article in ENGINE. After repairs, go to step 10 .
9. Replace starter motor. See «STARTER»(ref-126046-S27212197802001101900000) under REMOVAL & INSTALLATION. When repair is complete, go to step 10 .
10. Retest system to verify repair. If condition is corrected, system is okay. If condition is not corrected, go to step 3 .

SOLENOID PULL-IN, HOLD-IN TEST & PINION RETURN TEST

1. Remove starter from vehicle. Disconnect starter-to-solenoid field coil lead wire from solenoid terminal "M". (Scheme 1) Ensure field lead does not touch starter housing. Connect a jumper wire from negative post of 12-volt battery to solenoid field lead terminal "M". Connect another jumper wire from negative battery post to starter drive housing.
2. Connect a jumper wire from positive battery post to solenoid terminal "S". (Scheme 1)
3. Pinion gear should extend quickly and completely when solenoid is energized (pull-in test). Remove negative jumper wire from starter solenoid field lead terminal "M". Verify pinion remains completely in the energized position (hold-in test). Remove negative jumper wire from starter housing. Verify pinion returns quickly and completely to the de-energized position when jumper is removed (pinion return test).
4. If pinion does not return to the de-energized position quickly and completely, the cause is most likely a faulty starter solenoid return spring. Replace starter solenoid. If any of the above tests are not satisfactory, replace starter solenoid.

Scheme 1

SOLENOID PULL-IN & HOLD-IN RESISTANCE TEST

1. Using an ohmmeter, measure resistance between solenoid terminal "S" and terminal "M". If resistance is 5.0 ohms or less, pull-in coil is open. Replace solenoid.
2. Using an ohmmeter, measure resistance between solenoid terminal "S" and solenoid housing. If resistance is 5.0 ohms or less, hold-in coil is open. Replace solenoid.

STARTER MOTOR NO-LOAD TEST

1. Remove starter from vehicle. Connect an ammeter in series with battery and starter to measure starter motor current draw. Connect a jumper wire from negative battery post to starter motor housing. Connect another jumper wire from positive battery post to an ammeter, and from ammeter to starter solenoid positive battery terminal. (Scheme 2)
2. Starter drive pinion should extend quickly and completely and starter motor should run smoothly. Read starter motor current draw on ammeter. If current draw is not as specified, repair or replace starter. See «STARTER SPECIFICATIONS»(ref-126046-S01562021732001101900000) table under STARTER SPECIFICATIONS for current draw specification.

Scheme 2

ARMATURE TEST

1. Disassemble starter. Using No. 300 or 400 grit sandpaper, remove dirt and burn marks from commutator end of armature. Using an ohmmeter, measure resistance between commutator and armature winding bars. If resistance is 5.0 ohms or less, armature is grounded. Replace armature.
2. Measure resistance between any 2 commutator segments. If resistance is greater than 5.0 ohms at any test point, an open circuit exists in commutator. Replace armature.
3. Using outside calipers, measure diameter of commutator. If commutator diameter is less than 1.13" (28.8 mm), replace armature. Using a depth gauge, measure depth between commutator segments. If depth is less than .008" (0.2 mm), replace armature.
4. Using "V" blocks and a dial indicator, measure commutator runout. If runout exceeds .016" (0.4 mm), replace armature.

BRUSHES & SPRINGS TEST

1. Disassemble starter. Using an ohmmeter, measure resistance between positive and negative brush holders. If resistance is 5.0 ohms or less, brush holder is grounded. Replace brush holder assembly.
2. Check brushes and springs for corrosion or damage. Ensure brushes move freely in holders. Measure brush length and spring tension. If components are not within specification or defects are found, replace components as necessary. See «STARTER SPECIFICATIONS»(ref-126046-S01562021732001101900000) table under STARTER SPECIFICATIONS.

FIELD COILS TEST

Disassemble starter. Using an ohmmeter, measure resistance between field coil and field frame. If resistance is 5.0 ohms or less, field windings are grounded. Replace field frame.

OVERRUNNING CLUTCH-PINION GEAR TEST

Disassemble starter. Ensure overrunning clutch-pinion gear assembly rotates freely in one direction and locks securely in opposite direction. Inspect pinion teeth for wear. Replace as necessary.