Rotating Electric Troubleshooting Guide
Contents
1. Do not over tighten and crack insulator Be careful not to strip threads Does wire from B terminal bolt connect to a fusible link at starter solenoid If so make sure the fusible link is clean and tight B terminal Wea ea f All brackets to alternator connections should be clean oj y metal to metal Note Before removing alternator make sure battery cable is disconnected Removing either battery cable with engine running will create a damaging voltage spike This was never a valid test for an alternator Voltage spikes and arcing are poison to the electrical system Alternator and system management computers may be damaged and or destroyed OE vs Aftermarket Why doesn t the replacement alternator last as long as the OE unit Answer Poor connections and excessive voltage drop Clean and tight connections insure electrical system functions as designed A bet la at PA IN S Metal Engine chassis block Rotating Electrical Troubleshooting Guide Amperage Test Testing the alternator for AMP capacity Place AMP inductive clamp on heavy gauge AMPS VOLTS wire s coming from back half of alternator amp 30 OF 0 fa L a i a it ees a With engine at normal operating temp and at high RPM s load engine down by turning up the load on the carbon pile tester amperage reading The unit is good if AMP output is within 80 100 rated output j az pes2. Battery terminal Junction solenoid or relay Maximum v drop 0 20 Maximum v drop 0 20 Rotating Electrical Troubleshooting Guide Amperage Amperage must flow in a complete circuit Why test for excessive resistance on the side Ohm s Law states Amperage out amperage in D ai ii jii Og JO Junction solenoid or relay Bolted to engine block All amps that reach the starter motor must return to battery post Excessive resistance could be anywhere within the path The starter motor is grounded through the nose housing to engine block This connection must be clean and tight Testing Side Testing for excessive resistance on the side Must have fully charged battery To prevent engine from starting some vehicles may not start with WOT See manufacturer s service manual f Set DVOM on lowest volt scale Ca DVOM lead to clean metal spot on starter DVOM lead to battery terminal While cranking engine over record _voltage drop excessive resistance If voltage drop exceeds 0 3 volt clean all connections between battery and starter Teel Engine chassis block Tech Support 800 854 0076 Negative Side Starter motor pinpoint tests on negative side 1 Must have fully charged battery 2 To prevent engine from starting some vehicles may not start with WOT See manufacturer s service manual 3 Set DVOM on 2 volt scale or
3. engine off Dash board charging indicator does not light while key on engine off Low voltage output from alternator Lights dim at idle while all accessories are off e Drive belt broken or loose e No voltage signal to field through regulator plug e Voltage not present at alternator B terminal Blown fuse or fusible link Light bulb burned out e Corroded or loose connections e Drive belt slipping e Belt tensioner weak e Cables corroded Improper body ground Drive belt slipping or tensioner is weak Improper engine rpm s at idle e Weak or defective battery e Replace or tighten belt e Check regulator plug for corrosion or melting Replace pigtail if necessary e Check fusible links and wire going to B terminal e Check and replace fuses as needed Replace charging indicator light bulb e Clean and tighten connections and perform voltage drop test e Use test gauge on belt to determine if replacement is needed e Check tensioner alignment marks for weakness e Clean and tighten connections and perform volt drop test e Clean and tighten body ground e Check belt and tensioner for excessive wear e Refer to manufacturer s specifications and repair if needed e Test battery and replace as needed Tech Support 800 854 0076 B Terminal Is battery voltage available at B terminal iasulator Connection must be clean and tight at B terminal
4. lowest volt scale 4 Engine at normal operating temp 5 The following pinpoint tests will show you exactly where the excessive voltage drop is located Engine block am f i i Starter solenoid or relay Maximum v drop 0 20 Engine block Maximum v drop 0 30 Maximum v drop 0 00 Rotating Electrical Troubleshooting Guide Charging amp Starting System Testing Overview Key components to be tested before removing the starter motor Battery and connections Test the battery right group Check connections size state of charge load test and cables Relay Check drive belt condition Check operation of dash light tension automatic belt tensioner indicator or dash voltmeter Solenoid Battery cables Check for excessive Check charging voltage Switches parasitic draw and amp output Need Assistance Tech Support 800 854 0076 Email tes remyinc com Monday thru Friday 8AM 8PM EST Saturday 8AM 4 30PM EST Remy Remy International Inc remyinc com 600 Corporation Drive Pendleton IN 46064 USA 2012 Remy International Inc 15 121
5. 2095 watts e Volts x AMPS watts e How many amps will this starter motor now need in order to crank e 2095 watts 9 5 volts 220 AMPS Weak battery Strong battery Voltage drops to 11 2 volts while cranking e Example starter motor needs 2095 watts How many AMPS will this starter motor now need in order to crank e 2095 watts 11 2 volts 187 AMPS Strong battery Testing for excessive resistance on the side Must have fully charged battery To prevent engine from starting some vehicles may not start with WOT See manufacturer s service manual Set DVOM on lowest volt scale DVOM lead to battery post DVOM lead to battery terminal stud on starter While cranking engine over record drop excessive resistance __ voltage If voltage drop exceeds 0 5 volt clean all connections Metal Engine between battery amp starter chassis block Tech Support 800 854 0076 Positive Side Starter motor pinpoint tests on positive side 1 Must have fully charged battery 2 To prevent engine from starting some vehicles may not start with WOT See manufacturer s service manual 3 Set DVOM on 2 volt scale or lowest volt scale 4 Engine at normal operating temp 5 The following pinpoint tests will show you exactly where the excessive voltage drop is located L DCAMP DCVOLTS J o w A mA COM yQ 5 To alternator Starter terminal
6. Identify and understand the key components to the starting and charging system Alternator 7 44 yi a Starter Motor WE START THE WORLD amp KEEP IT RUNNING Rotating Electrical Troubleshooting Guide Before you start Each page contains information and instructions that are important in assisting with the repair of your starting and charging system Due to the electrical complexities of today s modern vehicles it is important to determine why the unit failed This manual will be most helpful in correctly finding the root cause of the difficulty the first time At Remy it is our goal to provide you with a product that has passed the most severe and stringent tests in the industry To insure that the starter motor and or alternator perform to your complete satisfaction we have taken the neces sary steps to provide you the guidelines to achieve that objective Our technical assistance team at Remy are ASE certified and have available the latest wiring schematics and technical information For Technical Assistance 1 800 854 0076 Mon Fri 8AM 8PM EST sat 8AM 4 30PM EST WE START THE WORLD amp KEEP IT RUNNING Contents Electrical Essentials 2 Starter Motor 11 Belts belt tensioner 0 2 Cranking circuit components 0 00 0 11 BAE hacctisheices erslenieeta fai cine pee Aftermarket vs OE a T Battery cables connections 3 Starters Where to beg
7. Note Battery must If AMP reading is low it could be a bad alternator be fully charged or excessive resistance may be in the charging circuit Alternator Tests Voltage test This procedure does not apply to computer controlled charging systems 1 With voltmeter connected to battery key and engine off record base voltage reading volts Note Battery should have minimum of 12 4 volts Start engine and bring to normal operating temperature With engine at 1500 to 2000 RPM turn on all electrical loads lights blower fan A C etc record volts ____volts Charging voltage should be at least 0 5 volt above base voltage reading If not excessive resistance could be present Engine block Tech Support 800 854 0076 Voltage at the Alternator Check charging voltage at alternator illustration to left and then again at battery below test This test will determine if there is a problem between the alternator and battery With engine running 1500 to 2000 rpm loads on 1 Measure charging voltage at alternator and record _____ volts 2 Measure open circuit voltage at battery and record _ S Its Sot 3 If the difference is greater than 1 volt there Engine block i is a problem Not charging Looking for excessive resistance on the side Voltmeter test lead to alternator B terminal Voltmeter test lead to battery post e Set voltmeter
8. an and tighten connections e Check switch operation replace as needed e Check and replace as needed e Check engine e Check service manual for system tests e Check battery state of charge e Clean and tighten connections Test starter e Diagnose engine problem and repair e Check gears for wear or damage Test starter and Magnetic switch e Check switch and circuit components e Rotate pinion by hand it should not go both ways Test motor and verify drive extension e Bench test starter if passes check external switches control circuit e Check teeth on both drive and ring gear Starter Shims Noisy grinding starter To shim or not to shim In order for starter to operate efficiently and quietly shimming may be required even if shims were not used on original installation On some applications you will have to either add shim s or remove shim s to achieve correct gap clearance Proper clearance between starter drive pinion gear and flywheel ring gear is critical for correct operation of starter See Fig 1 To achieve correct gap between ring gear and starter drive usage of one or more shims may be required on certain GM engines See Fig 2 Does your starter motor require a shim s Use your ears to listen for problem sounds Do you hear a high pitched whine or clanging sound while cranking BEFORE engine starts Problem excessive clearance Start
9. and retest for a good ground External voltage regulator Tech Support 800 854 0076 AG Ripple Voltage What is AC voltage ripple and how does it cause problems AC Voltage ripple is alternating current riding on top of DC current e Causes poor voltage source to modules ABS ECU PCM etc e Modules need quality DC voltage source to make accurate decisions on the side and side e Changing amplitude of AC voltage ripple on top Corrosion acts like a semi conductor of linear DC voltage can cause module to lose its causing DC voltage to fluctuate place in the engine run program This results in Excessive AC ripple caused by Erratic spark timing e Alternator bad diodes or stator Missing fuel injector pulses e Corrosion at the battery or any connection e Significant driveability problems Sulfated battery What is the most accurate tester to measure for AC ripple Many have used an Averaging voltmeter Some have graduated to an RMS voltmeter AC However due to changes in alternator design technology such as amount of current produced rotor shaft RPM stator windings it is far more accurate CO Ga A mA COM VO to use a Lab Scope 1 A scope will provide an actual footprint of the AC Ripple not just a voltage number Usage of a voltmeter due to the slow refresh rate is not Lab Scope an accurate test Rotating Electrical Troubleshooting Guide C
10. er must be shimmed closer into ring gear to reduce gap clearance Remove any existing shims Start with one 015 shim cut in half on outboard bolt only the bolt on outside of starter motor away from engine See Fig 3 This will move starter closer into the ring gear Starter drive Full shim Half shims Fig 2 Full shim cut in half Gap too loose Engine Block Half shim GAP t Outboard bolt Fig 3 Tech Support 800 854 0076 Starter Shims Does your starter motor require a shim s Gap too tight Use your ears to listen for problem sounds Engine Block Do you hear a high pitched whine after engine starts as key Fe is being released gt Shim Problem not enough clearance Starter must be shimmed away from ring gear to increase GAP gap clearance Install one 015 shim across both bolt holes to increase gap See Fig 4 Fig 4 t Outboard bolt OR Install one 015 shim cut in half or a substitute shim on inboard bolt only the bolt on inside of starter motor closest to engine See Fig 5 Engine Block Usage of one shim on inboard bolt only will provide greater clearance Half shim Note Do not use more than 3 shims on either side GAP When installing replacement starter motor DO NOT use an impact gun or breaker bar to tighten bolts Nose inboard boii cones are made of aluminum and are very easy to distort or crack by Fig 5 over tightening e A
11. in 0 00000 12 Excessive resistance amp OHM s Law 4 Does starter require a shim s 13 14 CONNECTIONS octets 15 Alternator 5 Cranking voltage at 2 locations 15 Alternators Where to begin 0 5 Does starter have a good ground 15 The DoS amp Don ts sete O Amp draw specs 0 E m 10 OE vs Aftermarket oo 6 Analyze cranking voltage amp amp draw 16 Amperage TOSI aeua niaie s a Weak battery Battery too small 17 Alternator tests 0 0000 7 Testing for excessive resistance side 17 Not charging Excessive resistance 8 Pinpoint tests on side 18 External voltage regulator test 9 Testing for excessive resistance side 19 Causes of amp testing for AC Ripple 10 Pinpoint tests on side 20 Overview pack cover The alternator is only as good as the belt With the engine running if dash indicator light stays Are the belts on or flashes erratically check the following Glazed shiny 1 Can pulley or fan be turned by hand due to loose Oil soaked or glazed belt Belt will slip resulting in low out Coreciensbn put dash light may stay on or flicker e Cracked Is the belt cracked or contaminated with oil ATF Misaligned coolant etc e Squealing Check for excessive noise from alternator Could be a loose worn belt or pulleys
12. lways reinstall any existing heat shields and rear support brackets e Make sure all connections at solenoid are clean and tight Add or remove shims one at a time to avoid damage Providing the proper gap will award you with a quiet starter and a longer life Rotating Electrical Troubleshooting Guide Cables and Connections Too hot to handle Check connections While cranking if either battery cable feels hot gauge of cable may be too Right small or too long or possibly a short within the starter When replacing battery cables always use shortest heaviest gauge cables possible Terminal end is pressed down Terminal end is not completely over battery post properly seated While Cranking If the difference is greater than 1 volt excessive resistance is present 10 7 volts 9 2 volts Excessive resistance could be on the or side or the side of the cranking circuit 1 5 volts To prevent engine from starting some vehicles may not start with WOT See manufacturer s service manual PROBLEM Good Ground The starter motor is grounded to engine block Engine must have a good ground through the battery cable back to battery terminal in order to crank To prevent engine from starting some vehicles may not start with WOT See manufacturer s service manual e With voltmeter test leads as shown measure and record voltage while cranking volt If voltage exceeds 0 2 volt there is a p
13. not aligned Hh Belt Tensioner Automatic belt tensioners and idler pulleys do fail Belt stretched Belt tensioner Check gauge on tensioner Is the spring tension too tight Too loose Pointer gt t tf Maximum belt Ideal belt Minimum belt length length length Battery The battery is the heart of the system Starter motor draws Pn f Crk ire Alternator generates power from the battery W sc s 7 electric current to replace a power lost and supply vehicle electrical system Rotating Electrical Troubleshooting Guide Battery Testing There are two key tests to determine condition of battery State of charge test The battery voltage must be at least 12 4 volts before load test Load test Load test simulates the electrical demands placed on the battery If load tester is not available have your alternator battery supplier test the battery 12 6 v 100 12 4v 75 12 2v 50 12 0v 25 11 8v 0 Battery condition State of Charge State of Charge State of Charge State of Charge State of Charge p lt q Electrolyte 1 Plates covered with water 3 Top of battery clean 2 Is battery secure in tray 4 Correct size for vehicle Battery Cables Cables connect your alternator and starter to the battery Carefully inspect cables for 1 Signs of cracked insulation 2 Too long or short While attempting to crank engine do ba
14. on lowest DC volt scale e With engine running at 1500 to 2000 rpm all loads on measure and record voltage drop____ Note Should not exceed 0 5 volt drop If voltage drop exceeds 0 5 volt check for e Corrosion e Frayed strands of wire e Loose connections e Battery cable gauge too small Engine block Rotating Electrical Troubleshooting Guide Still Not Charging There is resistance in the charging circuit somewhere Couldn t find the excessive resistance on the side Lets check the side e Voltmeter test lead to battery post e Voltmeter test lead to alternator case e Set voltmeter on lowest DC volt scale e With engine running at 1500 to 2000 rpm all loads on measure and record voltage drop Note Should not exceed 0 3 volt drop If voltage drop exceeds 0 3 volt check for e Corrosion e Battery cable gauge too small e Loose connections e Frayed strands of wire All alternators with external voltage regulators Regulator must have a good ground in order for alternator to function To determine if external voltage regulator is properly grounded follow these simple steps Engine running no loads on DVOM lead to the regulator metal housing DVOM lead to battery post Set DVOM on lowest DC volt scale If reading is 0 1 volt or 100mv DC or above the regulator does not have a good ground Clean
15. oor ground in cable or connections Engine block Metal chassis Tech Support 800 854 0076 Amp Draw Specs Approximate amp draw specifications Engine Size Amp Draw eed is no fixed amperage draw for every engine Cubic Inches Liters e Engine size e Weight viscosity of oil 100 to 200 1 6 to 3 2 100 to 200 l 7 l e Compression e Mechanical condition of engine 200 to 350 3 2 to 5 6 125 to 250 e Carbon buildup Design of starter motor 350 to 500 5 6 to 8 0 150 to 300 e High torque low torque gear reduction etc All have an impact on amperage draw Analyze Cranking Voltage amp Amperage 2 Problem high electrical resistance i Problem high mechanical resistance resulting in low amp draw resulting in high amp draw Volts Norma Possible causes we Loose connections e Carbon build up on top of pistons Possible causes e Frayed cables etc e Wrong weight oil e Corrosion e Cable that is shorted to ground e Cable gauge too small Bad starter resulting in high resistance Binding engine Problem A weak or undersized battery resulting in e Low cranking voltage e Slower spinning armature causing starter to draw excessive amps e Destroyed starter Rotating Electrical Troubleshooting Guide Weak Battery A weak or undersized battery will cause high amp draw Weak battery e Voltage drops to 9 5 volts while cranking Example starter motor needs
16. ranking Circuit The following components have a profound effect on the starter and its ability to crank the engine Battery Battery cables Relay solenoid e Neutral safety switch Alarm system Ignition switch Connections Why doesn t the aftermarket starter motor last as long as OE Answer Poor connections and excessive voltage drop Potential Problems Note the starter motor is only as good as each one of these connections Metal Engine chassis block Tech Support 800 854 0076 Engine will not crank Engine cranks too slow Starter keeps running Starter spins but engine will not crank Starter does not engage or disengage properly Starters Where to Begin e Dead battery e Defective fusible link e Loose connections e Defective ignition switch e Defective solenoid mag switch relay neutral start switch or clutch switch e Mechanical problem in engine e Problem in vehicle anti theft system e Weak battery e Loose or corroded connections e Defective starter motor e Mechanical problem with engine e Damaged pinion or ring gear e Defective starter or magnetic switch e Defective ignition switch or control circuit e Defective drive clutch e Defective starting motor e Defective solenoid mag switch Damaged or worn pinion gear or ring gear Rotating Electrical Troubleshooting Guide e Check battery state of charge e Replace fusible link e Cle
17. ttery cables feel warm to the touch If warm to the touch cable gauge may be too small Lower gauge number allows for greater amperage flow Which cable will carry more power to the battery oes 4 There are some cables sold with thick insulation and very little copper Look for gauge size printed on cable insulation Caution D Eg Tech Support 800 854 0076 Connections Critically important Often overlooked battery terminal ends and all cable connections are extremely vital Temporary ends can dramatically shorten life of an Temporary ends 9 alternator or starter How p y Bare strands of copper wire under steel plates bolted to lead terminal ends and exposed to 5 humidity equal corrosion e Apply correct terminal protection product Far better to use molded crimped style terminals It is important that NO bare copper wire is exposed to the environment Clean connections Side terminal Excessive Resistance The starter and alternator are only as good as the connections Until you completely eliminate excessive resistance your starter and alternator will not function properly All connections should be metal to metal clean and tight 4 possibilities for resistance Rotating Electrical Troubleshooting Guide Alternators Where to Begin No output from alternator Battery condition good Dashboard indicator light illuminates when key on
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