TROUBLE SHOOTING
Note. See TROUBLE SHOOTING - BASIC PROCEDURES article in GENERAL INFORMATION section.
ON-VEHICLE TESTING
Note. Before testing, ensure battery is fully charged, battery cables and terminals are clean and tight and engine grounds are good.
CIRCUIT TEST
If starter does not operate, check voltage at starter "S" terminal with ignition switch in START position (and clutch depressed on M/T). see scheme 1 If voltage is greater than 8 volts and vehicle does not crank, repair or replace starter as required. If voltage is less than 8 volts, check ignition switch, park/neutral switch (A/T), interlock switch (M/T) and wiring.
Scheme 6
NO-LOAD TEST
Connect fully-charged 12-volt battery, voltmeter and ammeter to starter. (Scheme 6) Using remote starter wires or jumper, engage solenoid. Starter should spin smoothly. Compare readings with specifications. See NO-LOAD TEST SPECIFICATIONS table. If voltage is less than specified, amperage is more than specified or shaft speed is less than specified, disassemble and inspect starter components.
| Application | Specification | ||
|---|---|---|---|
| 4-Cylinder | |||
| Voltage (Minimum) | 11.0 | ||
| Amperage (Maximum) | 90 | ||
| Shaft Speed (Minimum RPM) | 3000 | ||
| V6 | |||
| A/T | |||
| Voltage (Minimum) | 11.0 | ||
| Amperage (Maximum) | 70 | ||
| Shaft Speed (Minimum RPM) | 2200 | ||
| M/T | |||
| Voltage (Minimum) | 11.0 | ||
| Amperage (Maximum) | 90 | ||
| Shaft Speed (Minimum RPM) | 2900 | ||
NO-LOAD TEST SPECIFICATIONS
Solenoid Pull-In Test
Connect positive battery lead to solenoid "S" terminal and negative battery lead to starter body. (Scheme 6) Starter pinion drive gear should extend outward and stop. If starter pinion drive gear does not extend, replace solenoid.
Solenoid Hold-In Test
After performing solenoid pull-in test, with positive battery lead connected to solenoid "S" terminal and negative battery lead connected to starter body, disconnect field lead ("M" terminal wire) at solenoid. Starter pinion drive gear should remain extended. If starter pinion drive gear returns, replace solenoid.
Solenoid Return Test
Disconnect field lead ("M" terminal wire) at solenoid. Connect positive battery lead to solenoid "M" terminal and negative battery lead to starter body. (Scheme 6) Using screwdriver, pry overrunning clutch pinion drive outward. Release screwdriver and ensure overrunning clutch pinion drive returns to original position.
ARMATURE TEST
- Place armature in growler. Turn on growler and hold a piece of hacksaw blade over armature. Slowly rotate armature. If hacksaw blade is attracted to core or if it vibrates, replace armature.
- Remove armature from growler. Using an ohmmeter, check continuity between commutator and core. If continuity exists, replace armature. Check continuity between commutator and shaft. If continuity exists, replace armature.
- Check continuity between each commutator segment. If an open exists between any 2 segments, replace armature.
COMMUTATOR TEST
- Clean surface and polish with No. 400 sandpaper if required. If surface is scored, out of round or pitted, turn commutator in a lathe.
- Maximum commutator runout and minimum diameter of commutator must not exceed specification after turning. See COMMUTATOR SPECIFICATIONS table.
- Commutator mica undercut depth should be .020 -.030" (.50 -.80 mm). Minimum mica undercut depth is .008" (.20 mm). If not within specification, undercut to standard depth.
| Application | Maximum Runout In. (mm) | Minimum Diameter In. (mm) |
|---|---|---|
| A/T | .004 (.10) | 1.24 (31.4) |
| M/T | .004 (.10) | 1.13 (28.8) |
COMMUTATOR SPECIFICATIONS
BRUSH TEST
- Connect one ohmmeter lead to positive brush holder and other lead to negative brush holder. If continuity exists, replace brush holder assembly.
- Check brush length. See BRUSH LENGTH SPECIFICATIONS table. If brush length is less than specified, replace brushes.
- Using brush spring scale, measure spring tension. See BRUSH TENSION SPECIFICATIONS table. If tension is less than specified, replace brush holder assembly. Ensure brushes move freely in holders.
| Application | Standard In. (mm) | Minimum In. (mm) |
|---|---|---|
| A/T | .67 (17.0) | .45 (11.5) |
| M/T | .69 (17.5) | .47 (12.0) |
BRUSH LENGTH SPECIFICATIONS
| Application | Standard Ft. Lbs. (N) | Minimum Ft. Lbs. (N) | |
|---|---|---|---|
| 4-Cylinder | 3.9-5.3 (17.6-23.6) | 1.5 (6.9) | |
| V6 | |||
| A/T | 3.7-4.9 (16.3-21.9) | 2.0 (8.8) | |
| M/T | 3.7-5.1 (16.7-22.5) | 2.1 (9.3) | |
BRUSH TENSION SPECIFICATIONS
FIELD WINDING TEST
- Connect one ohmmeter lead to field coil lead ("M" terminal wire). Connect other lead of ohmmeter to soldered portion of brush lead. If continuity does not exist, repair or replace field coil.
- Check field coil for short to ground by connecting one ohmmeter lead to field coil lead ("M" terminal wire) and other ohmmeter lead to field coil housing. If continuity exists, repair or replace field coil.