TROUBLE SHOOTING
Note. For information not covered in this article, see the TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL INFORMATION section.
TROUBLE SHOOTING HINTS
On all models, note condition of SECURITY indicator light. If indicator stays on or flashes continuously, see ANTI-THEFT SYSTEM article in ACCESSORIES & EQUIPMENT section. Check starter solenoid terminals and battery grounds. Check for proper installation of aftermarket electronic equipment. Perform self-diagnostic system test, to be certain no trouble codes are stored in PCM memory which may lead to misdiagnosis. See appropriate TESTS W/CODES article in ENGINE PERFORMANCE section
- «TESTS W/CODES»(ref-33421) - 2.2L
- «TESTS W/CODES»(ref-33422) - 4.3L
Check BATTERY 175 amp maxi-fuse. Check IGN A 40 amp fuse. Check IGN C 20 amp fuse. Check CRANK 10 amp fuse. See COMPONENT LOCATIONS table.
ON-VEHICLE TESTING
| WARNING | Vehicles are equipped with air bag supplemental restraint system. Before attempting ANY repairs involving steering column, instrument panel or related components, see SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR BAG SYSTEM in the AIR BAG RESTRAINT SYSTEM article. |
Note. The following tests assume that engine and battery are operating normally and are at operating temperatures, battery is charged, there are no engine problems that would cause a no-start condition, and no diagnostic trouble codes are present.
STARTER NO-LOAD TEST
| CAUTION | DO NOT apply more voltage than specified. Excessive voltage may cause armature to throw windings due to excessive speed. |
- Secure starter in vise. Turn carbon pile off and open switch. Connect test equipment to starter as illustrated. (Scheme 2) Turn switch on and adjust carbon pile until voltage is 10 volts. See «STARTER NO-LOAD TEST SPECIFICATIONS»(ref-33553-S38738284992001011700000) table. Check ammeter reading and pinion speed on RPM indicator. Turn off carbon pile and open switch. Compare RPM and amperage readings with specifications. Refer to the «STARTER NO-LOAD TEST SPECIFICATIONS»(ref-33553-S38738284992001011700000) table.
- If amperage and RPM readings are as specified, starter motor is okay. If test indicates low free speed and/or high current draw, unit may have tight, dirty or worn bearings or bushings, shorted or grounded armature, or a grounded field.
- High current draw with pinion moving into cranking position but no pinion rotation indicates a direct ground in field, or frozen bearings or bushings. No pinion movement and a normal current reading indicates plunger is unable to move into solenoid or drive is unable to move on armature shaft. No pinion movement and very low or no current draw indicates an open or ground in solenoid windings.
- Pinion moving into cranking position but not turning and very low current draw indicates an open in field circuit or armature windings, or no current flow between solenoid battery and motor field terminals while motor is engaged. Connect a jumper wire between solenoid battery and motor field terminal "M". If motor now turns at specified RPM, replace solenoid.
- Low no-load and low current draw indicates high internal resistance due to poor brush lead connections; a dirty commutator; an open in armature windings; broken, worn or weak brush springs; or worn, damaged or dirty brushes. High no-load speed and high current draw indicates shorted field coils or shorted armature windings. If starter vibrates or is noisy, armature may be rubbing against inside of frame and field.
Scheme 2
| Application | (1) Amps | Starter RPM |
|---|---|---|
| 2.2L (SD205) | 52-76 | 6000-12,900 |
| 4.3L (PG260) | 50-62 | 8500-10,700 |
| (1) At 10 volts. | ||
| (1) | At 10 volts. |
STARTER NO-LOAD TEST SPECIFICATIONS
ARMATURE TEST
Note. Any ball bearings that are removed from armature must be replaced with new bearings.
- Inspect solder joints between armature windings and commutator bars. If any have come loose, replace armature. If commutator is rough or damaged, replace armature. DO NOT turn commutator in lathe or undercut spaces between bars. If commutator is dirty, clean with fine grit emery cloth and blow away any copper dust.
- Using growler, check armature for shorts. Hold a flat steel strip on armature parallel to armature core or shaft. Rotate armature in growler. Steel strip will vibrate on area of short circuit.
- Using self-powered test light, place one lead on armature shaft and other lead on commutator. Test light should not illuminate. If test light illuminates, armature is shorted or grounded and must be replaced.
- If no-load test indicated armature may be rubbing against inside of frame and field assembly, inspect outside of armature for signs of rubbing. If armature is scored only on one side of laminations, armature shaft may be bent and armature should be replaced. If scoring is all around armature laminations, check frame and field assembly for an out-of-position pole or for a foreign object lodged inside. Repair or replace frame and field assembly.
| CAUTION | Some starters have a molded-type commutator. DO NOT undercut insulation as it may cause serious damage to commutator. |
FIELD COIL OPEN TEST
Remove armature from frame and field assembly. Using self-powered test light, place one lead on field lead connection and other lead on one insulated brush. (Scheme 3) Test light should illuminate. If test light does not illuminate, field coil is open. Replace field and frame assembly. Repeat test for each insulated brush.
Scheme 3
FIELD COIL GROUND TEST
Remove armature from field and frame assembly. On starters with shunt lead, separate field and shunt lead connections during test. Ensure field lead connection is NOT touching ground during test. Using self-powered test light, place one lead on grounded brush holder and other lead on one insulated brush. (Scheme 4) Test light should not illuminate. If test light illuminates, field coil is grounded. Replace field and frame assembly. Repeat test for each insulated brush.
