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On-Vehicle Testing: Starter: 3.5RL

  1. Connect a voltmeter and ammeter to battery. See Figure . Connect tachometer to engine. Disconnect Ignition Control Module (ICM) 6-pin and 8-pin connectors. ICM is located at front center of engine, above power steering pump pulley. Ensure transmission is in Park or Neutral.
  2. Turn ignition switch to START position. If starter does not crank engine, go to next step. If starter cranks erratically or too slowly, go to step  5 . If starter will not disengage after cranking, go to step  8 .
  3. Check battery cables and all starter wire connectors for corrosion or looseness. Check starter relay. See STARTER RELAY  . Repair or replace as necessary. If battery cables, starter wire connections and starter relay are okay, go to next step.
  4. Ensure transmission is in Park or Neutral. Unplug terminal "S" connector (Black/White wire) from starter solenoid. Connect a fused jumper wire between positive battery terminal and solenoid terminal "S". If starter does not crank, remove starter and check for internal problems. If starter cranks, check ignition switch, starter relay or immobilizer system. See appropriate IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT. Also check for open circuit between ignition switch and starter. See WIRING DIAGRAMS  . Repair or replace as necessary.
  5. Check for damaged starter drive gear or flexplate ring gear. Check drive gear overrunning clutch for binding or slipping when armature is rotated with drive gear held in place. Repair or replace as necessary. If no problem is found, go to next step.
  6. Crank engine, and check cranking voltage and current draw. Cranking voltage should be 8.0 volts or more, and current draw should be less than 400 amps. If readings are as specified, check starter drive gear and flexplate ring gear for damage. If readings are not as specified, check for low battery charge, open circuit in starter armature commutator segments, starter armature dragging, shorted armature winding or excessive engine resistance. Repair or replace as necessary. If no problem is found, go to next step.
  7. Crank engine and check engine speed. If engine speed is 100 RPM or less, check for loose battery or starter terminals, excessively worn starter brushes, open circuit in commutator segments, dirty or damaged helical spline or drive gear, or faulty drive gear overrunning clutch.
  8. If starter cranks normally but will not disengage from flexplate when ignition switch is moved back to ON position, check for malfunctioning starter solenoid plunger or ignition switch. Also check for dirty starter drive gear or damaged overrunning clutch.
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