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FIGURE 19-1 To test the voltage drop of the battery cable connection, place one voltmeter lead on the battery terminal and the
other voltmeter lead on the cable end and crank the engine. The voltmeter will read the difference in voltage between the two
leads which should not exceed 0.2 volt (200 mV).
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 19-2 Voltmeter hookups for voltage drop testing of a GM-type cranking circuit.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 19-3 Voltmeter hookups for voltage drop testing of Ford-type cranking circuit.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 19-4 A typical Ford solenoid on the left and a typical GM solenoid on the right.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 19-5 GM solenoid ohmmeter check. The reading between 1 and 3 (S terminal and ground) should be 0.4 to 0.6 ohm
(hold-in winding). The reading between 1 and 2 (S terminal and M terminal) should be 0.2 to 0.4 ohm (pull-in winding).
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 19-6 Starter trouble diagnostic chart.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 19-7 Starter current can be measured by using a high-current clamp and a digital multimeter or a specialized starting
and charging tester.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 19-8 Before disassembly of any starter, mark the location of the through bolts on the field housing. This makes
reassembly easier.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 19-9 Removing the solenoid from the starter on a GM-type starter assembly.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 19-10 Rotate the solenoid to remove it from the starter housing. (Caution: The plunger return spring exerts a force on
the solenoid and may cause personal injury if not carefully released.)
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 19-11 The brushes should be replaced if worn to less than 50% of their original length. Replace if less than 1/2 in.(13
mm) long.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 19-12 An exploded view of a General Motors starter.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 19-13 To replace the starter drive unit, the retainer and clip must be removed from the armature shaft. A box-end
wrench and a hammer can be used to pop the retainer off of the spring clip.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 19-14 Measuring an armature shaft for run-out using a dial indicator V-blocks.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 19-15 Using a growler to check for shorted armature windings.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 19-16 Replacement starter brushes should be installed so the beveled edge matches the rotation of commutator.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 19-17 A shim (or half shim) may be needed to provide the proper clearance between the flywheel teeth of the engine
and the pinion teeth of the starter.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 19-18 This simple theft deterrent circuit will prevent the engine from cranking unless the lights are turned on first. The
lights do not have to remain on after the engine starts.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
Pearson Prentice Hall - Upper Saddle River, NJ 07458