If all connections are good clean and tight the first thing I would look at is the starter. This can be tested with a simple test light. There is a control wire that goes to the solenoid on starter check at it for voltage when trying to start if you have voltage there and no crank then you have a starter problem if you don't have voltage there then you have a circuit problem. Here is a diag. procedure for checking starter system. It is pretty complex procedure the test light will give you the basic answers. I don't see many neutral or ignition switch problems so I figure you will find either a connection problem or a starter failure.
Before commencing with the starting system diagnostics, verify:
- The battery posts/terminals are clean.
- The alternator drive belt tension and condition is correct.
- The battery state-of-charge is correct.
- The battery cable connections at the starter and engine block are clean and free from corrosion.
- The wiring harness connectors and terminals are clean and free from corrosion.
- The circuit is properly grounded.
Fig. 1: This is the type of volt-ampere tester required for this type of testing
Images available only to Customers.
Fig. 2: Proper connection for the volt-ampere tester
Images available only to Customers.
CAUTION
The ignition and fuel systems must be disabled to prevent engine start while performing the tests.
- Connect a volt-ampere tester to the battery terminals. Refer to the operating instructions provided with the tester.
- Disable the ignition and fuel systems by disconnecting the Automatic Shutdown (ASD) relay, located in the Power Distribution Center (PDC) in the engine compartment.
- Verify that all lights and accessories are OFF, and the transaxle shift selector is in PARK. Set the parking brake.
- Rotate and hold the ignition switch in the START position. Observe the volt-ampere tester:
- If the voltage reads above 9.6 volts, and the amperage draw reads above 280 amps, check for engine seizing or a faulty starter, then go to the starter feed circuit resistance test.
- If the voltage reads 12.4 volts or greater and the amperage reads 0–10 amps, check for corroded cables and/or bad connections.
- If the voltage reads below 9.6 volts and the amperage draw reads above 300 amps, the trouble is within the starter.
WARNING
Do not overheat the starter motor or draw the battery voltage below 9.6 volts during cranking operations.
- After the starting system problems have been corrected, verify the battery's state of charge, and charge the battery if necessary. Disconnect all of the testing equipment and connect the ASD relay. Start the vehicle several times to assure the problem was corrected.
The following test will require a voltmeter, which is capable of accuracy to within 0.1 volt.
CAUTION
The ignition and fuel systems must be disabled to prevent engine start while performing the tests.
- Disable the ignition and fuel systems by disconnecting the Automatic Shutdown (ASD) relay, located in the Power Distribution Center (PDC) in the engine compartment.
- With all wiring harnesses and components properly connected, perform the following:
Fig. 3: Testing the battery connection resistance
Images available only to Customers.
- Connect the negative (-) lead of the voltmeter to the negative battery post, and the positive (+) lead to the negative battery cable clamp. Rotate and hold the ignition switch in the START position. Observe the voltmeter. If voltage is detected, correct the poor contact between the cable clamp and battery post.
Fig. 4: Testing the ground circuit resistance
Images available only to Customers.
- Connect the positive (+) lead of the voltmeter to the positive battery post, and the negative (-) lead to the positive battery cable clamp. Rotate and hold the ignition switch key in the START position while observing the voltmeter. If voltage is detected, correct the poor contact between the cable clamp and battery post.
- Connect the negative lead of the voltmeter to the negative (-) battery terminal, and the positive lead to the engine block near the battery cable attaching point. Rotate and hold the ignition switch in the START position. If the voltage reads above 0.2 volt, correct the poor contact at the ground cable attaching point. If the voltage reading is still above 0.2 volt after correcting the poor contact, replace the negative ground cable with a new one.
Fig. 5: Testing the starter motor ground
Images available only to Customers.
Fig. 6: Testing the battery positive cable resistance
Images available only to Customers.
- Connect the positive (+) voltmeter lead to the starter motor housing and the negative (-) lead to the negative battery terminal. Hold the ignition switch key in the START position. If the voltage reads above 0.2 volt, correct the poor starter to engine ground.
- Connect the positive (+) voltmeter lead to the positive battery terminal, and the negative lead to the battery cable terminal on the starter solenoid. Rotate and hold the ignition key in the START position. If the voltage reads above 0.2 volt, correct the poor contact at the battery cable to the solenoid connection. If the reading is still above 0.2 volt after correcting the poor contact, replace the positive battery cable with a new one.
- If the resistance tests did not detect feed circuit failures, replace the starter motor.
Edited by crazi429 on July 8 2006 at 1:32 PM
I hope I have been helpful. If more info is needed just ask.
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Thanks Tim