Testing
Road Service
For cases of a starter that cranks the engine very slowly, connect a 12-volt booster battery to the system.
Jump Starting
To avoid damage to the vehicle and battery or the possibility of personal harm, follow these instructions and precautions:
WARNING: HYDROGEN AND OXYGEN GASES ARE PRODUCED DURING NORMAL BATTERY OPERATION. THIS GAS MIXTURE CAN EXPLODE IF FLAMES, SPARKS OR LIGHTED TOBACCO ARE BROUGHT NEAR THE BATTERY. WHEN CHARGING OR USING A BATTERY IN AN ENCLOSED SPACE, ALWAYS PROVIDE VENTILATION AND SHIELD YOUR EYES.
WARNING: KEEP OUT OF REACH OF CHILDREN. BATTERIES CONTAIN SULFURIC ACID. AVOID CONTACT WITH SKIN, EYES OR CLOTHING. ALSO, SHIELD YOUR EYES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION. IN CASE OF ACID CONTACT WITH SKIN, EYES OR CLOTHING, FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF FIFTEEN MINUTES. IF ACID IS SWALLOWED, DRINK LARGE QUANTITIES OF MILK OR WATER, FOLLOWED BY MILK OF MAGNESIA, A BEATEN EGG, OR VEGETABLE OIL. CALL A PHYSICIAN IMMEDIATELY.
WARNING: DO NOT DISCONNECT THE BATTERY OF THE VEHICLE TO BE STARTED. DISCONNECTING THE BATTERY COULD DAMAGE THE VEHICLE'S ELECTRONIC SYSTEM.
Negative Grounded Battery
WARNING: TO AVOID ANY POSSIBILITY OF INJURY, USE PARTICULAR CARE WHEN CONNECTING A BOOSTER BATTERY TO A DISCHARGED BATTERY.
1. Position vehicles so jumper cables will reach, being careful that vehicles do not touch.
2. Turn on heater blower motor of vehicle to be started (set control on DEFROST for vehicles equipped with automatic temperature control). Turn off other switches and lamps.
3. Make jumper cable connections.
^ Connect one end of first jumper cable to positive (+) terminal of discharged battery and other end to positive (+) terminal of booster battery.
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TESTING (Continued)
^ Connect one end of second jumper cable to negative (-) terminal of booster battery. Connect other end to an engine bolthead or, good metallic contact spot on engine of vehicle to be started, NOT TO NEGATIVE (-) BATTERY TERMINAL.
WARNING: MAKING THE FINAL CABLE CONNECTION COULD CAUSE AN ELECTRICAL SPARK NEAR THE BATTERY AND COULD CAUSE AN EXPLOSION. REFER TO WARNING AT THE BEGINNING OF THE JUMP STARTING PROCEDURE.
^ Ensure jumper cables are not in way of moving engine parts.
^ Start engine of vehicle with good battery. Run engine at a moderate speed.
^ Start engine of vehicle with discharged battery. Follow starting instructions in the Owner Guide.
^ Leave all switches off except heater blower motor. Reduce engine speed to idle on both vehicles to prevent possible damage to vehicle electrical systems.
4. Remove cables in exact REVERSE sequence. Begin by removing cable from engine of vehicle that had discharged battery.
If the starter does not turn the engine over, even with the booster battery attached, refer to On-Vehicle Testing.
On-Vehicle Testing
Place transmission or transaxle in NEUTRAL or PARK. Disconnect vacuum line to Thermactor bypass valve before performing any cranking tests, if so equipped. After tests, run engine for three minutes before connecting vacuum line.
Starter Cranks Slowly
1. Battery: Use jumper cables per instructions. If this corrects problem, check condition of battery. Recharge or replace battery if necessary. Clean battery posts and cable lugs making sure to tighten connections.
2. Cables: If Step 1 does not correct problem, clean and tighten connections at starter relay and battery ground on engine. Eyelet terminals should not be easily rotated by hand. Also check for a short to ground.
3. If above does not correct problem, service or replace starter.
Starter Does Not Crank But Starter Relay Operates (Clicks)
1. Battery: Use jumper cables and check battery as outlined.
2. Cables: Clean and tighten connections at starter and relay. Ensure wire strands are secure in eyelets.
3. Starter: Connect a jumper cable across terminals B and M of starter solenoid. If starter does not operate, service or replace starter. If starter does operate, replace solenoid.
WARNING: MAKING THE JUMPER CONNECTION COULD CAUSE AN ELECTRICAL SPARK. BATTERY JUMPER CABLES OR EQUIVALENT SHOULD BE USED DUE TO HIGH CURRENT IN THE STARTING SYSTEM.
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TESTING (Continued)
Starter Does Not Crank And Relay Chatters Or Does Not Click
1. Battery: Use jumper cables. Check battery as outlined.
2. Remove push-on connector from relay S terminal (red w/blue stripe wire). Make sure connection is clean and secure and that relay bracket is grounded. If connections are good, check operation of relay with a jumper wire. Place transmission or transaxle in PARK or NEUTRAL. Remove push-on connector from relay. Using a jumper wire, jump from the now exposed terminal on starter relay to main terminal (battery side or battery positive post). If this corrects problem, check ignition switch, neutral switch or clutch switch and wiring in starting circuit for open or loose connections.
3. If a jumper wire across relay does not correct problem, replace relay.
Starter Spins (Humming Noise) But Does Not Crank Engine
Starter: Remove and check armature shaft for corrosion. Clean or replace. If no corrosion, drive assembly is slipping and must be replaced.
Starter Load Test
Conduct this test if the starter cranks slowly and it is desired to compare current to specifications.
1. Connect Rotunda Battery Tester 078-00005 or equivalent. Ensure that current is not flowing through ammeter and heavy-duty carbon pile rheostat portion of circuit (rheostat maximum counterclockwise position).
2. Place transmission or transaxle in NEUTRAL or PARK. Crank engine with ignition off, and determine exact reading on voltmeter. This test is accomplished by disconnecting push-on connector S at starter relay and by connecting a remote-control starter switch from positive battery terminal to S terminal of starter relay. (NOTE: Ensure ignition switch is in the OFF position and S terminal connector has been removed so engine does not start.)
3. Stop cranking engine, and reduce resistance of carbon pile until voltmeter indicates same reading as that obtained while starter cranked the engine. The ammeter will indicate starter current draw under load. Check this with value listed in Specifications.
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TESTING (Continued)
Bench Tests
Starter No-Load Test
The starter no-load test will uncover such conditions as open or shorted windings, rubbing armature and bent armature shaft. The starter can be tested, at no-load, on the test bench only.
1. Make test connections with Rotunda Battery Tester 078-00005 or equivalent cables connected to starter, large enough to carry high current (the same as in the vehicle). The starter will run at no-load. Be sure that no current is flowing through ammeter (rheostat at maximum counterclockwise position). Determine exact reading on voltmeter.
2. Disconnect starter from battery. Then, reduce resistance of rheostat until voltmeter indicates same reading as that obtained while starter was running. The ammeter will indicate starter no-load current draw. Refer to Specifications for a comparative value.
3. If current exceeds specification, check for rubbing armature, bent shaft, binding bearings, or shorts in armature, or brush assembly.
Armature Open Circuit Test
An open circuit armature may sometimes be detected by examining the commutator for evidence of burning. A burn spot on the commutator is caused by an arc formed every time the commutator segment, connected to the open circuit winding, passes under a brush.
Grounded Armature Test
This test will determine if the winding insulation has been damaged, permitting a conductor to touch the frame or armature core. To determine if the armature windings are grounded, check with a VOM as shown. Infinite resistance indicates a normal condition.
Starter Solenoid Test
Ensure that the solenoid is isolated electrically from the motor. Using a VOM, check for continuity between S terminal and M terminal, and between S terminal and ground (frame). If there is no continuity, the wire is broken and the solenoid should be replaced.