Starting System Test

Fig.1 Volts-Amps Tester Connections - Typical:

COLD CRANKING TEST
1. Connect volt-ampere tester to battery terminals (Fig. 1). See instructions provided by manufacturer of volt-ampere tester being used.
2. Fully engage parking brake.
3. If equipped with manual transmission, place gearshift selector lever in Neutral position and block clutch pedal in fully depressed position. If equipped with automatic transmission, place gearshift selector lever in Park position.
4. Verify that all lamps and accessories are turned OFF.
5. To prevent a gasoline engine from starting, remove Automatic Shut Down (ASD) relay.These relays are located in Power Distribution Center (PDC). Refer to label on PDC cover for relay location.
6. Rotate and hold ignition switch in Start position. Note cranking voltage and current (amperage) draw readings shown on volt-ampere tester.
a. If voltage reads below 9.6 volts, refer to Starter Motor in Diagnosis and Testing. If starter motor is OK. If starter motor is not OK, replace faulty starter motor.
b. If voltage reads above 9.6 volts and current (amperage) draw reads below specifications, refer to Feed Circuit Test.
c. If voltage reads 12.5 volts or greater and starter motor does not turn, refer to Control Circuit Testing.
d. If voltage reads 12.5 volts or greater and starter motor turns very slowly, refer to Feed Circuit Test.

NOTE: A cold engine will increase starter current (amperage) draw reading, and reduce battery voltage reading.

FEED CIRCUIT TEST
The starter feed circuit test (voltage drop method) will determine if there is excessive resistance in high-amperage feed circuit.

When performing these tests, it is important to remember that voltage drop is giving an indication of resistance between two points at which voltmeter probes are attached.

Example: When testing resistance of battery positive cable, touch voltmeter leads to battery positive cable clamp and cable connector at starter solenoid. If you probe battery positive terminal post and cable connector at starter solenoid, you are reading combined voltage drop in battery positive cable clamp-to-terminal post connection and battery positive cable.

The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing tests, be certain that following procedures are accomplished:
- Battery is fully-charged and load-tested. Refer to Battery.
- Fully engage parking brake.
- If equipped with manual transmission, place gearshift selector lever in Neutral position and block clutch pedal in fully depressed position. If equipped with automatic transmission, place gearshift selector lever in Park position.
- Verify that all lamps and accessories are turned OFF.
- To prevent a gasoline engine from starting, remove Automatic Shut Down (ASD) relay. These relays are located in Power Distribution Center (PDC). Refer to label on PDC cover for relay location.

Fig.2 Test:

1. Connect positive lead of voltmeter to battery negative terminal post. Connect negative lead of voltmeter to battery negative cable clamp (Fig. 2). Rotate and hold ignition switch in Start position. Observe voltmeter. If voltage is detected, correct poor contact between cable clamp and terminal post.

Fig.3 Test Battery Positive Resistance - Typical:

2. Connect positive lead of voltmeter to battery positive terminal post. Connect negative lead of voltmeter to battery positive cable clamp (Fig. 3). Rotate and hold ignition switch in Start position. Observe voltmeter. If voltage is detected, correct poor contact between cable clamp and terminal post.

Fig.4 Test Battery Positive Cable:

3. Connect voltmeter to measure between battery positive terminal post and starter solenoid battery terminal stud (Fig. 4). Rotate and hold ignition switch in Start position. Observe voltmeter. If reading is above 0.2 volt, clean and tighten battery cable connection at solenoid. Repeat test. If reading is still above 0.2 volt, replace faulty battery positive cable.

Fig.5 Test Ground Circuit Resistance - Typical:

4. Connect voltmeter to measure between battery negative terminal post and a good clean ground on engine block (Fig. 5). Rotate and hold ignition switch in Start position. Observe voltmeter. If reading is above 0.2 volt, clean and tighten battery negative cable attachment on engine block. Repeat test. If reading is still above 0.2 volt, replace faulty battery negative cable.

Fig.6 Test Starter Ground - Typical:

5. Connect positive lead of voltmeter to starter housing. Connect negative lead of voltmeter to battery negative terminal post (Fig. 6). Rotate and hold ignition switch in Start position. Observe voltmeter. If reading is above 0.2 volt, correct poor starter to engine block ground contact.
6. If equipped with dual battery system, connect positive lead of voltmeter to driver side battery positive cable clamp. Connect negative lead of voltmeter to passenger side battery positive terminal post. Rotate and hold ignition switch in Start position. Observe voltmeter. If reading is above 0.2 volt, clean and tighten passenger side battery positive cable eyelet connection at driver side battery positive cable clamp bolt. Repeat test. If reading is still above 0.2 volt, replace faulty passenger side battery positive cable.

If resistance tests detect no feed circuit problems, refer to Starter Motor in the Diagnosis and Testing.

CONTROL CIRCUIT TEST
The starter control circuit components should be tested in the order in which they are listed, as follows:
- Starter Relay - Refer to Starter Relay Diagnosis and Testing.
- Starter Solenoid - Refer to Starter Motor Diagnosis and Testing.
- Ignition Switch - Refer to Ignition Switch and Key Lock Cylinder
- Wire harnesses and connections.