Component Tests
WARNING:
Before beginning any service procedure in this service information, refer to Safety Warnings in SERVICE INFORMATION
WARNING:
Always disconnect the battery ground cable at the battery before disconnecting the starter motor battery terminal lead. If a tool is shorted at the starter motor battery terminal, the tool can quickly heat enough to cause a skin burn. Failure to follow this instruction may result in serious personal injury.
Always make the Fluke 77-IV Digital Multimeter connections 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 - Feed Circuit Test
- 1.
Make sure the battery is fully charged. Refer to Battery, Mounting and Cables .
- 2.
Carry out a battery drain test. Refer to Battery, Mounting and Cables .
- 3.
Connect a remote starter switch between starter solenoid S-Terminal and the battery positive terminal.
- 4.
Connect the Digital Multimeter positive lead to the battery positive post. Connect the negative lead to the starter solenoid "M" terminal.
- 6.
Engage the remote starter switch. Read and record the voltage. The voltage reading should be 0.5 volt or less.
- 7.
If the voltage reading is 0.5 volt or less, go to the Starter Motor - Ground Circuit Test in Component Tests
- 8.
A voltage reading greater than 0.5 volt is an indication of excessive resistance in the starter connections, the positive battery cable or in the starter solenoid. Remove the cables from solenoid "B", "S", and "M" terminals. Clean the cable connections and reinstall the cables to the correct terminals. Repeat Steps 3 through 7.
- 9.
If the voltage reading is still greater than 0.5 volt when checked at the "M" terminal, move the Digital Multimeter negative lead to the starter solenoid B-Terminal and repeat step 6.
- 10.
If the voltage reading at the B-Terminal is lower than 0.5 volt, the concern is in the connections at the starter solenoid or in the solenoid contacts. Install a new starter motor. Refer to Starter Motor - 3.5L GTDI or Starter Motor - 3.5L Ti-VCT .
- 11.
If the voltage reading taken at the solenoid B-Terminal is still greater than 0.5 volt 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.
- 12.
Clean the positive battery cable connections. If this does not solve the problem, install a new positive battery cable. Refer to Battery, Mounting and Cables .
Starter Motor - Ground Circuit Test
WARNING:
Before beginning any service procedure in this service information, refer to Safety Warnings in SERVICE INFORMATION
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.
Connect a remote starter switch between starter solenoid S-Terminal and the battery positive terminal.
- 2.
Connect the 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 0.5 volt or less.
- 5.
If the voltage drop is greater than 0.5 volt, clean the negative cable connections at the battery, the body ground connections and the starter ground connection. Retest.
- 6.
If the voltage drop is greater than 0.5 volt, install new battery cables. Refer to Battery, Mounting and Cables . If the voltage reading is less than 0.5 volt and the engine still cranks slowly, install a new starter motor. Refer to Starter Motor - 3.5L GTDI or Starter Motor - 3.5L Ti-VCT .