Component Tests and General Diagnostics

COMPONENT TESTS

Starter Motor - Voltage Drop Test

WARNING: When repairing the starter motor or carrying out other underhood work in the vicinity of the starter motor, be aware that the heavy gauge battery input lead at the starter solenoid is "electrically hot" at all times.

CAUTION: A new protective cap or boot, which is provided over the battery input terminal on all vehicle lines, must be installed after repairs. Be sure to disconnect the battery ground cable before repairing the starter motor.

Always connect the 73 digital multimeter at the component terminal rather than at the wiring end connector. Making a connection at the wiring end connector could result in false readings because the meter will not pick up a high resistance between the wiring connector and the component.

Starter Motor - Motor Feed Circuit
1. Make sure the battery is fully charged;
2. Disconnect the inertia fuel shutoff switch (IFS switch).
3. Connect a remote starter switch between the starter motor solenoid S-terminal and the battery positive (+) terminal.

Motor Feed Circuit:

4. Connect the 73 digital multimeter positive lead to the battery positive (+) post. Connect the negative lead to the starter motor solenoid M-terminal.
5. Engage the remote starter switch. Read and record the voltage. The voltage reading should be 0.5 volts or less.
6. If the voltage reading is 0.5 volts or less, go to the Starter Motor - Motor Ground Circuit Component Test.
7. If the voltage reading is greater than 0.5 volts, indicating excessive resistance, move the 73 Digital Multimeter negative lead to starter motor solenoid B-terminal and repeat the test. If the voltage reading at the B-terminal is lower than 0.5 volts, the concern is either in the connections at the starter motor solenoid or in the starter motor solenoid contacts.
8. Remove the cables from the starter motor solenoid B-, S- and M-terminals. Clean the cables and connections and reinstall the cables to the correct terminals. Repeat Steps 3 through 6. If the voltage drop reading is still greater than 0.5 volts when checked at the M-terminal or less than 0.5 volts when checked at the B-terminal, the concern is in the solenoid contacts. Install a new starter motor.
9. If the voltage reading taken at starter motor solenoid B-terminal is still greater than 0.5 volts after cleaning the cables and connections at the solenoid, the concern is either in the positive (+) battery cable connection or in the positive battery cable itself.
10. By moving the 73 digital multimeter negative lead toward the battery and checking each mechanical connection point, the excessive voltage drop can be located. When the high reading disappears, the last mechanical point that was checked is the concern. Repair or install a new connection as required.

Starter Motor - Motor Ground Circuit
A slow cranking condition can be caused by resistance in the ground or return portion of the cranking circuit. Check the voltage drop in the ground circuit as follows:
1. Disconnect the inertia fuel shutoff switch.
2. Connect a remote starter switch between starter motor solenoid S-terminal and the battery positive (+) terminal.

Motor Ground Circuit:

3. Connect the 73 digital multimeter positive lead to the starter motor housing (the connection must be clean and free of rust or grease). Connect the negative lead to the negative (-) battery terminal.
4. Engage the remote starter switch and crank the engine. Read and record the voltage reading. The reading should be 0.2 volts or less.
5. If the voltage drop is more than 0.2 volts, clean the negative cable connections at the battery and body connections, and retest.
6. If the voltage drop is greater than 0.2 volts, determine which way the current is flowing in the cable. Connect the 73 digital multimeter positive lead to the end of the cable nearest battery positive.
7. Connect the multimeter negative lead to the terminal at the other end of the cable.
8. Crank the engine and observe the voltage reading. The voltage reading should be 0.2 volts or lower. If the voltage drop is too high, clean the terminal ends. Retest, and if still high, install a new cable. If the voltage reading is less than 0.2 volts and the engine still cranks slowly, install a new starter motor.