starter and alternator technical videos

REMY QUICK TECH TIP TS-039: Some vehicles may experience a long crank time and hard start condition

VEHICLES AFFECTED:
1997-1998 Ford Escort with the 2.0L SPI Engines

SYMPTOMS:
Some vehicles may experience a long crank time and hard start condition.

CAUSE:
This may be caused by interference from a ground strap attached to the alternator bracket.

SOLUTION:
Reprogram the Powertrain Control Module (PCM) and install a new ground strap. The new ground strap will reduce the possibility of interference with the PCM.

Refer to Ford TSB # 97-21-5 for further information.

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REMY QUICK TECH TIP TS-038: Engagement Noise, Slow or No Start, Rapid Starter Failure

VEHICLES AFFECTED:
Audi – Various
Volkswagen – Various

SYMPTOMS:
Engagement Noise
Slow or No Start
Rapid Starter Failure

CAUSE:
Many Audi and Volkswagen vehicles are equipped with a starter that does not have traditional drive end housing. The front shaft of the starter mounts inside a bushing in the bell housing.

SOLUTION:
This bushing must be replaced whenever the starter is replaced. Use a suitable tool to remove the old bushing and install the bushing provided to validate the warranty.

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REMY QUICK TECH TIP TS-037: No Start condition when parked with the front of the vehicle facing down an incline

VEHICLES AFFECTED:
1989 Nissan Maxima

SYMPTOMS:
No Start condition when parked with the front of the vehicle facing down an incline.

CAUSE:
When the vehicle is faced downhill, at times the green/black wire running between the inhibitor switch and the ignition switch may be stretched too tight. Added gravity and a tight wire loom tie causes an open circuit.

SOLUTION:
Visually inspect the green/black wire condition for any damage and repair as necessary.  Loosen up or replace wire tie to allow wiring loom slack.

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REMY QUICK TECH TIP TS-036: Starter intermittently clicks, but will not crank

VEHICLES AFFECTED:
1991-93 3.1L Buick Regal/Chevy Lumina/Olds Cutlass Supreme/Pontiac Grand Prix
1991-93 3.4L Chevy Lumina/Olds Cutlass Supreme/Pontiac Grand Prix

SYMPTOMS:
Starter intermittently clicks, but will not crank.

CAUSE:
GM TSB # 338113 advises the following causes:
1) Loose or corroded connections at the starter, battery or ground.
2) Added resistance from an aftermarket alarm system.

SOLUTION:
1) Check positive/negative connections at the battery, engine block to battery ground, and starter connections. Also, make sure the battery is properly charged.
2) If an alarm system is present, the alarm module circuit and/or the ignition to neutral safety switch wiring may require reworking (per manufacturer’s instructions) to heavier 10 gauge wiring. The heavier wiring flows more current to properly activate the starter solenoid.

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REMY QUICK TECH TIP TS-035: Shim no shim casting

VEHICLES AFFECTED:
1983-1997 Various General Motors Vehicles

SYMPTOMS:
Starter shimming

CAUSE:
The above applications came as original equipment with one of two types of starter nose castings. One is a “NO SHIM” casting and one is a standard casting that must be shimmed for correct clearance of the pinion to flywheel or flex plate.

SOLUTION:
Please check on the upper solenoid area of the starter drive end casting for the words “NO SHIM” cast into the part. If these markings are present, DO NOT USE ANY SHIMS with this starter.  Failure to follow these instructions will cause the starter to not function properly or fail immediately.

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REMY QUICK TECH TIP TS-034: No Start / Discharged Battery

VEHICLES AFFECTED:
1990 Lincoln Town Car

SYMPTOMS:
No Start/Discharged Battery
Intermittent No Start

CAUSE:
Ford has issued two separate TSB’s (90-6T-4 and 90-16-2) related to starting problems on this application.  TSB #90-6T-4 advises that water entry into the ABS pump motor relay can cause the contact to corrode.  The corroded contact can become stuck in the closed position causing the pump motor to run at all times, discharging the battery.  TSB #90-16-2 advises that water entry into the transmission vent can cause the neutral safety switch contacts to corrode resulting in a no start condition.

SOLUTION:
To repair the ABS problem, Ford has issued a kit (FOVY-14A303-A) that contains a new relay and the necessary hardware needed to relocate the relay.  Please refer to Ford TSB #90-6T-4 for further information.

To repair the neutral safety switch problem, Ford advises to check the transmission fluid for signs of water contamination. If fluid is milky in appearance, install a new neutral safety switch (FOVY-7A247-A).  Ford has also issued a new deflector kit (FOVY-17A500-A) to divert the water away from the transmission vent.

Please refer to Ford TSB #90-16-2 for further information.

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REMY QUICK TECH TIP TS-033: Poor connection at the main fuse

VEHICLES AFFECTED:
1986 Mazda B2000

SYMPTOMS:
No Start condition
No Dash Lights

CAUSE:
Mazda TSB #001/85 advises that some of the above vehicles may have a poor connection at the main fuse.

SOLUTION:
If this condition is present, the following repair procedure should be performed:
1. Remove the two nuts securing the main fuse block and pull the main fuse block upward from the mounting bracket.
2. Probe the connections to the main fuse block for continuity.
3. If no continuity is present, repair by tightening the connections or replacing the main fuse or main fuse block.

Please refer to Mazda TSB #001/85 for further information.

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REMY QUICK TECH TIP TS-032: Intermittent no start, low voltage at the starter “S” terminal

VEHICLES AFFECTED:
1991-1992 Hyundai Excel
1991-1992 Hyundai Scoupe

SYMPTOMS:
Intermittent no start

CAUSE:
Hyundai TSB #92-36-001 and 92-36-002 state that these vehicles may not start at times but after waiting a few minutes will start normally. This is caused by low voltage at the starter “S” terminal.

SOLUTION:
Hyundai has released a repair kit (Hyundai #91401-24Q00) consisting of a relay and a wiring harness to repair this condition. Please refer to Hyundai TSB #92-36-001 and 92-36-002 for further information.

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REMY QUICK TECH TIP TS-031: No crank when restarting during high operating temperatures

VEHICLES AFFECTED:
1983 1.6L VW Rabbit Diesel w/Automatic Transmission

SYMPTOMS:
No crank when restarting during high operating temperatures.

CAUSE:
VW TSB #83-02 suggests abnormal voltage drop due to excessive (heat related) cranking circuit resistance.

SOLUTION:
Per manufacturer’s instructions, install a kit consisting of a starter relay (VW # 171-919-505A), revised wiring harness (VW # 175-971-451), and bracket (161-972-595). Also check starter/battery cables and wires for loose or corroded connections, and repair as necessary.

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REMY QUICK TECH TIP TS-030: No crank and/or discharged battery

VEHICLES AFFECTED:
1987-88 Volkswagen Fox

SYMPTOMS:
No crank and/or discharged battery

CAUSE:
VW TSB #88-01 indicates poor wire connections at the “wire bridge” in the fuse relay panel between terminals No.36 and No. 38. A loose nut or poor connection at the starter (main B+) terminal # 30 may also exist.

SOLUTION:
Locate “wire bridge” in the fuse box and inspect for proper seating and good quality connections. Also, remove and clean starter “battery” terminal connection (terminal #30) and retorque to 7.5lbs/ft.

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REMY QUICK TECH TIP TA-040: Numerous charging problems

VEHICLES AFFECTED:
1980-1984 Volvo 240 Diesel
1983-1986 Volvo 760 Diesel
1985-1986 Volvo 740 Diesel

SYMPTOMS:
Numerous Charging Problems

CAUSE:
Volvo TSB Group 32, NO. 1 advises that the above vehicles have been shown to have a poor ground connection between the alternator and the engine block causing problems in the charging system.

SOLTUION:
An additional ground cable (Volvo #1215278-1) should be attached to the back of the alternator and connected to the alternator block mounting bracket.

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REMY QUICK TECH TIP TA-039: High RPM belt whine/noise

VEHICLES AFFECTED:
1988-1992 Jaguar XJ6, XJS

SYMPTOMS:
These vehicles may exhibit high RPM belt whine/noise.

CAUSE:
This condition may be caused by an over tensioned belt.

SOLUTION:
XJ6 Models: Make sure the belt tension is set to 115 lbs. for a used belt or 138 lbs. for a new belt.
XJS Models: Make sure the belt tension is set to 70 lbs. for a used belt or 79 lbs. for a new belt.

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REMY QUICK TECH TIP TA-038: Clamp can damage the wires, resulting in a shorted or grounded condition

VEHICLES AFFECTED:
1981-1987 Isuzu P’UP and Trooper ll

SYMPTOMS:
Various Charging problems

CAUSE:
These vehicles have a metal hold down clamp on the wires at the rear of the alternator. This clamp can damage the wires, resulting in a shorted or grounded condition.

SOLUTION:
Inspect the wires and repair as needed. Wrap the area with protective material to prevent further damage.

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REMY QUICK TECH TIP TA-036: Pulley sizes vary on different models

VEHICLES AFFECTED:
1976-1983 Honda

SYMPTOMS:
Alternator Pulley

CAUSE:
Pulley sizes vary on different models using the same alternator.

SOLUTION:
On some vehicles it may be necessary to replace the pulley provided with this alternator with the pulley from the original alternator. Check the spacing of the pulley groove from the alternator fan. If the spacing is different, change the pulley to ensure proper belt alignment.

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REMY QUICK TECH TIP TA-035: Stereo cassette radios may experience alternator whine in the left channel of the radio

VEHICLES AFFECTED:
1986 – Chevy Astro Van
1986 – GMC Safari Van
1986 – S/T 10-15

SYMPTOMS:
Some above listed models equipped with ETR AM/FM stereo cassette radios may experience alternator whine in the left channel of the radio.

CAUSE:
The ground wire used in the instrument panel harness may cause a ground loop resulting in the whine.

SOLUTION:
If this condition is present, disconnect the ground lead (black wire) from the black 4-pin connector at the back of the radio. If disconnecting the ground lead causes the condition to disappear, proceed as follows:
1. Cut the black ground wire located in the black 4-pin connector
2. Connect one end of a suitable gauge wire to chassis of the radio and the other end to a good ground near the radio.
3. Reconnect the radio.

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REMY QUICK TECH TIP TA-034: Serpentine belt chirp or excessive belt noise

VEHICLES AFFECTED:
1999-2003 Land Rover Range Rover
1999-2003 Land Rover Discovery

SYMPTOMS:
Serpentine belt chirp or excessive belt noise.

CAUSE:
The plastic idler pulley may be deformed causing uneven loads on the serpentine belt.

SOLUTION:
Replace deformed idler pulley with Land Rover part # (PQR500060).  Refer to Land Rover TSB #86/02/03/NAS for further information.

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REMY QUICK TECH TIP TA-033: Accessory drive belt squealing or drive belt jumping off the pulleys

VEHICLES AFFECTED:
2001 Chrysler Town & Country
2001 Chrysler Voyager
2001 Dodge Caravan

SYMPTOMS:
Accessory drive belt squealing or drive belt jumping off the pulleys.

CAUSE:
It is possible water may drip down from the wiper module drain tube connector and onto the drive belt.  This may cause belt squealing.  In colder regions, ice can form on the belt and cause the belt to jump off the pulleys when starting the vehicle.

SOLUTION:
Find the wiper module drain tube near the top of the right strut tower.  With the hood open, send water into the cowl grille.  If water is leaking at the wiper drain tube connector, install a new seal (05080824AA) as outlined in Chrysler TSB# 23-012-01.

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REMY QUICK TECH TIP TA-032: Malfunction Indicator Lamp may come on due to Diagnostic Trouble Codes being set for abnormal conditions which may or may not actually exist

VEHICLES AFFECTED:
2003 Chrysler 300
2003 Chrysler Concorde
2003 Dodge Intrepid

SYMPTOMS:
The Malfunction Indicator Lamp (MIL) may come on due to Diagnostic Trouble Codes (DTC’s) being set for abnormal conditions which may or may not actually exist.  One example is DTC # P0622: “Alternator Field Not Switching Properly.”

CAUSE:
A software glitch may exist in Powertrain Control Modules built prior to 10-15-02.

SOLUTION:
Refer to Chrysler/Dodge TSB# 18-032-02 for instructions to selectively erase and reprogram the Powertrain Control Module (PCM) to the latest version.

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REMY QUICK TECH TIP TA-031: Battery warning light/overcharge condition

VEHICLES AFFECTED:
2001-2003 Chrysler Town & Country Van
2001-2003 Chrysler Voyager
2001-2003 Dodge Caravan

SYMPTOMS:
On some vehicles, the battery warning light may come on and an overcharge condition may occur.  Also, a DTC code of P1594 for “Charging System Voltage Too High” may set in the vehicle’s computer.

CAUSE:
Since this type of alternator contains no voltage regulator (the vehicle’s computer performs all voltage regulation), the Powertrain Control Module (PCM) may require reprogramming.

SOLUTION:
Check for usual causes of overcharging (corroded connections, poor ground, older/defective battery).  If no obvious cause, refer to Chrysler / Dodge TSB# 18-023-03 for instructions for selectively erasing and reprogramming the PCM with updated software.

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REMY QUICK TECH TIP TA-030: Low Alternator Output

VEHICLES AFFECTED:
1988-2007 Honda

SYMPTOMS:
Low Alternator Output.

CAUSE:
The above vehicles may be equipped with an Electronic Load Detector (ELD) located in the under-hood fuse/relay box.  The ELD monitors vehicle load demands and signals the power control  module.  During low electrical current demand, the ELD/PCM switches the alternator to low output mode (12.5 volts) through the alternator’s “C” terminal.

SOLUTION:
Voltage will register approximately 12.5 volts when the alternator is in low output mode.  When testing the alternator it is advised that the brake pedal be applied, which causes the ELD to signal for normal alternator output (14-15 volts).

If the voltage remains low during the above test, the ELD/PCM may be at fault.  To test, remove the “C” terminal from the 4 pin alternator plug by releasing the locking tab with a thin bladed screwdriver.  Reinstall the plug (with “C” terminal removed) and retest.  If the alternator now tests normally the ELD/PCM should be tested and serviced by a qualified technician.

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REMY QUICK TECH TIP TA-029: Cooling fan relay contacts can become fused together, causing the cooling fan to run with the ignition key off

VEHICLES AFFECTED:
1984-1990 Buick Century
1985-1990 Buick Electra, LeSabre
1984-1990 Pontiac 6000
1987-1990 Pontiac Bonneville

SYMPTOMS:
Discharged Battery.

CAUSE:
GM TSB # 90-6D-4 states that the cooling fan relay contacts can become fused together, causing the cooling fan to run with the ignition key off. The cause for the stuck relays can either be caused by the air conditioning system or the cooling fan temperature switch.

SOLUTION:
Determine if the cooling fans cycle off with the ignition key in the off position. This test should be performed while the engine is cool. If the cooling fans remain on, the vehicles A/C system and temperature switch should be serviced. Please refer to GM TSB # 90-6D-4 for further information.

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REMY QUICK TECH TIP TA-028: Interior dome light remains on

VEHICLES AFFECTED:
1993 Suzuki Swift

SYMPTOMS:
Discharged Battery.

CAUSE:
Constantly discharged batteries on these vehicles can be caused by an interior dome light remaining on. The original door switches have a flange which can break away from the barrel of the switch causing the dome light to remain on.

SOLUTION:
Inspect the door switch for damage. If you find a suspect or damaged switch, replace it with the newer, late design switch (#37670-60A01) available from Suzuki.

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REMY QUICK TECH TIP TA-027: Broken locking tab on the vehicles alternator regulator connector

VEHICLES AFFECTED:
1985-1986 Ford Escort, Mercury Lynx with 1.9L engines

SYMPTOMS:
No Alternator Output Intermittent Alternator Output.

CAUSE:
The above conditions may be caused by a broken locking tab on the vehicles alternator regulator connector, which allows the connector to work loose.

SOLUTION:
Ford has released an improved design connector (E7DZ-14489-B) with a new plug which must be spliced into the wiring harness.

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REMY QUICK TECH TIP TA-026: Alternator Short Circuit B+ Terminal

VEHICLES AFFECTED:
1981-1987 Saab 900

SYMPTOMS:
Alternator Short Circuit.

CAUSE:
These vehicles may exhibit a short circuit in the alternator due to an unprotected “B+” terminal on the back of the alternator.

SOLUTION:
Ensure that all cables and other obstructions are routed away from the battery connection; this is especially true for the transmission kick-down cable. When performing repair work keep tools clear of the alternator battery connection.

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REMY QUICK TECH TIP TS-018: No crank or intermittent no crank. Engine oil seepage inside the starter

VEHICLES AFFECTED:
1992-2000 Ford Taurus/Mercury Sable,
1995-2003 Windstar

SYMPTOMS:
No crank or intermittent no crank.

CAUSE:
Engine oil seepage inside the starter, causing poor conductivity between the brushes and commutator.

SOLUTION:
Inspect the oil filter, engine seals, gaskets, etc. for leakage. If leakage noticed, replace starter. Tighten or replace seals, etc. as needed. Take care during oil changes to prevent seepage into the starter motor.

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REMY QUICK TECH TIP TS-029: Starter Alignment Dowels

VEHICLES AFFECTED:
Renault Various Models

STARTER ALIGNMENT DOWELS
When installing this starter, the original alignment dowel must be reused. Failure to use an alignment dowel with this starter will cause mis-alignment, non-operation, flywheel damage, or premature failure of the starter.

If a replacement dowel is needed, they are available under Renault part numbers, 770501006 for the 7.5mm, and 7705010087 for the 11.3 mm.

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REMY QUICK TECH TIP TS-025: Knocking sound while the starter is operating or starter failure

VEHICLES AFFECTED:
1999-2001 Land Rover Range Rover
1999-2001 Land Rover Discovery

SYMPTOMS:
Knocking sound while the starter is operating or starter failure

CAUSE:
The starter pinion may be coming in contact with original style drive plate balance plates during starter engagement.

SOLUTION:
New configuration drive plate balance weights have been developed to eliminate potential contact with the starter during engagement.  Refer to Land Rover TSB # 86/08/01/NAS for part replacement and service procedures.

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REMY QUICK TECH TIP TS-024: No start or an intermittent electrical problem

VEHICLES AFFECTED:
1998-2002 Land Rover Range Rover
1998-2002 Land Rover Discovery
2002 Land Rover Freelander

SYMPTOMS:
The customer may complain of a no start or an intermittent electrical problem.

CAUSE:
This may be due to a broken battery clamp bolt on either the positive or negative cable clamp.

SOLUTION:
Replace the clamp bolt and nut. (Land Rover part #YTJ000010) Battery clamp nut and bolt assembly.  Refer to Land Rover TSB #86/05/02/NAS for further information.

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REMY QUICK TECH TIP TS-022: Some vehicles may exhibit delayed engine cranking

VEHICLES AFFECTED:
2005-2006 Chrysler 300
2005-2006 Dodge Charger
2005-2006 Dodge Magnum

SYMPTOMS:
Some vehicles may exhibit delayed engine cranking or MIL illumination with DTC P0573.  This may be an intermittent condition and is not a starter related problem.

CAUSE:
Diagnostic Trouble Code (DTC) P0573 may be set if the vehicle gets rocked back and forth (transmission shifted drive to reverse to drive) to get unstuck from snow/ice – without pressing the brake pedal.

SOLUTION:
Refer to Chrysler / Dodge TSB# 18-031-06 for instructions for selectively erasing and reprogramming the Power Control Module (PCM) to eliminate the delayed cranking condition and to ensure proper starter operation.

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REMY QUICK TECH TIP TS-017: No start when hot due to corrosion or loose connections

VEHICLES AFFECTED:
1974-93 VW Cabriolet, Golf, Jetta, Rabbit with automatic transmissions.

SYMPTOMS:
No start when hot.

CAUSE:
VW TSB# 92-02 indicates low voltage may arrive at the starterʼs (#50) “ignition” terminal due to corrosion or loose connections. Voltage at this terminal should not drop below 10 volts while cranking. Vehicle age contributes to the problem.

SOLUTION:
Check voltage at the starterʼs (#50) “ignition” terminal while key is in the start position. If voltage drops below 10 volts, inspect all circuit connections. Repair as needed. If problem continues, VW offers a relay (VW # 191-911-251) to permanently correct this condition.

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REMY QUICK TECH TIP TS-016: Intermittent No Crank Condition

VEHICLES AFFECTED:
1994-1995 Dodge Caravan
1994-1995 Chrysler Town & Country Van
1994-1995 Plymouth Voyager

SYMPTOMS:
Intermittent No Crank Condition.

CAUSE:
Chrysler TSB # 08-53-94 advises that the above condition may be due to a poor connection of the battery cable at the starter. The cable connector does not sit flush on the starter terminal.

SOLUTION:
Disconnect the negative battery cable from the battery.  Remove the positive battery cable at the starter. Grind off (about 1/8” to 5/16”) of the hard plastic material off the bottom edge of the cable insulator at the end of the cable terminal to allow the terminal to sit flush on the starter terminal.

Reconnect the positive cable at the starter and check to make sure the terminal sits flush. Reconnect the negative battery cable at the battery.

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REMY QUICK TECH TIP TS-013: No crank/Crank but no start/Hesitation/Surge/Misfire/Various trouble codes set

VEHICLES AFFECTED:
• 2001-2007 Chevy Silverado/GMC Sierra with 6.6L diesel
• 2003-2007 GMC C4500/C5500 Topkick with 6.6L diesel

SYMPTOMS:
No crank/Crank but no start/Hesitation/Surge/Misfire/Various trouble codes set.

CAUSE:
GM TSB # 04-06-04-001C indicates a variety of engine faults or diagnostic trouble codes may result from backed out pins in either the C107/C113 (38 way) or C108/C119 (24 way) Engine Harness to Engine Chassis Harness Connectors.  The connectors are located where the harness is mounted to the top of the driverʼs side valve cover.

SOLUTION:
Inspect the connector terminals for broken terminal locks. If so equipped, also remove the Terminal Position Assurance comb at the back of the connector. Then, lightly push/pull on the wires in question. If the wire seems to move within the connector, and does not lock in, the connector should be replaced.

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Remy Quick Tech Tip TA-024: Drain from after-run cooling fan after engine shut down

VEHICLES AFFECTED:
1985-1987 Chrysler Vehicles with 2.2L Carbureted Engines

SYMPTOMS:
Discharged Battery.

CAUSE:
These vehicles may experience a discharged battery due to a drain from the after-run cooling fan after engine shut down.

SOLUTION:
Elimination of the ambient temperature sensor from the fan mounting bracket may be necessary to remedy this problem. Please refer to Chrysler Technical Bulletin #08-13-86 for further information.

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Remy Quick Tech Tip TA-020: Charging system warning lamp comes on, & “service battery charging system” message appears

VEHICLES AFFECTED:
2006 Buick Lucerne/Cadillac DTS/Chevy Impala/Chevy Monte Carlo – (all engine options)

SYMPTOMS:
The charging system warning lamp comes on, and a “Service battery charging system” message appears. Diagnostic trouble codes B1405 and/or B1516 may also be set in the vehicleʼs computer.

CAUSE:
GM TSB # 06-06-03-006 indicates cranking the engine during low battery voltage conditions may cause the Body Control Module (BCM) to reboot. During the reboot, the battery current sensor may draw excessive current and set either the B1405 or B1516 trouble codes in the BCM.

SOLUTION:
DO NOT automatically replace the BCM, the battery current sensor, or the alternator. If no proven battery or charging system faults exist, reprogram the BCM to the latest service calibration designed to correct this condition.

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Remy Quick Tech Tip TA-021: Frayed serpentine belt and/or belt squeal

VEHICLES AFFECTED:
1999-2003 Chevy Tracker w/2.0L engine option (prior to VIN breakpoint 36949085)

SYMPTOMS:
Frayed serpentine belt and/or belt squeal.

CAUSE:
Assuming no other typical causes of belt squeal (old/worn belts, etc.), GM TSB #01-06-01-015A indicates some power steering pump brackets may not be properly positioning the power steering pump pulley. Misalignment may result between the power steering pump pulley and the alternator pulley.

SOLUTION:
Adjust the power steering pump bracket position (and replace the serpentine belt), using service manual procedures specified for this vehicle.

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Remy Quick Tech Tip TA-022: The battery warning lamp comes on during acceleration or driving uphill

VEHICLES AFFECTED:
2006 Buick Rendezvous with 3.5L engine

SYMPTOMS:
The battery warning lamp comes on during acceleration, or driving uphill.

CAUSE:
Assuming no loose or chafing charging system wires, connections, etc., GM TSB # 06-06-03-008 indicates the problem may result from electromagnetic interference (EMI). The interference results from the closeness of the alternator to the ignition coils.

SOLUTION:
Reprogram the powertrain control module (PCM) to the latest service calibration designed to correct this condition.

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Remy Quick Tech Tip TA-023: Alternator belt noise

VEHICLES AFFECTED:
1989-1991 Chrysler Vehicles w/2.2L,
2.5L engines

SYMPTOMS:
Alternator belt noise.

CAUSE:
These vehicles may exhibit a chirping or snapping noise from the alternator belt. In extreme cases, the belt may partially walk off the pulley or come off completely.

SOLUTION:
To repair a misaligned pulley, loosen and remove the alternator pivot nut. Loosen and discard the front washer and install new service flat washers (Chrysler #6500299 and 6501752) and reinstall the pivot nut. Belt tension varies from vehicle to vehicle. Refer to Chrysler TSB # 07-02-93 for your specific requirements.  Tighten the pivot nut to 40 ft. lbs.

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Remy Quick Tech Tip TA-025: Flashing of the alternator light when driven in wet conditions

VEHICLES AFFECTED:
1984-1992 Volkswagen Golf & Jetta
1990-1993 Volkswagen Passat

SYMPTOMS:
These vehicles have been known to suffer from flashing of the alternator light when driven in wet conditions.

CAUSE:
The above condition can result from belt slippage, due to water splashing onto the alternator drive belt.

SOLUTION:
Volkswagen has issued the following splash shields for these vehicles:
Golf & Jetta: VW# 191-825-250-01C, 191-825-250A-01C
Passat: VW# 357-825-254

For further information refer to VW TSB #ʼs 91-01, 91-05 & 92-02

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Remy Quick Tech Tip TA-019: Intermittent dead battery, or battery going dead overnight

VEHICLES AFFECTED:
1989-1992 Ford Probe
1989-1992 Mazda 626 / MX6

SYMPTOMS:
Electrical malfunctions may include a discharged battery, blown fuses, overcharging and low current output at low RPM.

CAUSE:
1) Water may enter the wiring connectors in the engine compartment and in front of the radiator (wiring that joins the body and engine main harness) causing shorted and/or corroded terminals.
2) The hood micro switch may bind causing the under hood lamp to remain on.
3) Low current output at low RPM caused by pulley size.

SOLUTION:
1) Complete inspection and repair of the wiring harness as necessary is strongly recommended.  Refer to Ford TSB #91-16-6 for further information.
2) The hood light micro switch is built into the hood release handle under the dash. It is recommended that the switch be checked and shimmed as necessary to eliminate this problem.
3) Ford has issued kit # E92Z010344-D which consists of a smaller alternator pulley, larger crank pulley, drive belt, cover and gasket.

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Remy Quick Tech Tip TS-009: Milling or grinding of the starter drive pinion and flywheel teeth

VEHICLES AFFECTED:
Ford Vehicles equipped with 2 Bolt Starters

SYMPTOMS:
These vehicles can exhibit milling or grinding of the starter drive pinion and flywheel teeth.

CAUSE:
This is caused by worn crankshaft thrust bearings in the engine. The worn thrust bearing allows the flywheel to float back and forth and to contact the starter drive and actually wear through it.

SOLUTION:
Short of replacing the crankshaft bearings and rebuilding the engine, starter shims (Ford # D7TZ-11N004) are available to move starter back away from the flywheel.

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Remy Quick Tech Tip TA-018: Headlamps flicker or dim while driving

VEHICLES AFFECTED:
• 2002-2005 Chevy Trailblazer/GMC Envoy with 4.2L engine
• 2004-2005 Buick Ranier/Olds Bravada with 4.2L engine

SYMPTOMS:
Headlamps flicker or dim while driving.

CAUSE:
The flickering/dimming condition is sometimes mistaken for a faulty voltage regulator. Usually, this condition is simply a normal operating characteristic due to heavy electrical system loads. On the above vehicles, GM TSB # 05-08-42-001 indicates this normal condition may be amplified by the activation or cycling of the Secondary Air Injection Pump (due to its high current draw).

SOLUTION:
No replacement of the alternator or AIR pump should be made unless a proven fault is found. It is also important to inspect all charging system wiring for loose or corroded connections, poor grounds, etc., which may cause a good voltage regulator to temporarily malfunction.

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Remy Quick Tech Tip TA-017: Burned fusible link between the alternator and the starter solenoid

VEHICLES AFFECTED:
• 1993-1995 Chevrolet Lumina APV w/ 3.8L V6
• 1993-1995 Oldsmobile Silhouette w/3.8L V6
• 1993-1995 Pontiac Trans Sport w/3.8L V6

SYMPTOMS:
Gradual alternator output loss and discharged battery. The charge light or the check gauge light may come on.

CAUSE:
This is caused by a burned fusible link between the alternator and the starter solenoid.

SOLUTION:
GM states that the existing 14 gauge fusible link may be inadequate and should be replaced with a 12 gauge link.

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Remy Quick Tech Tip TA-016: Intermittent illumination of the charge indicator light

VEHICLES AFFECTED:
1988-1989 Chevrolet S-10
1988-1989 GMC T-10
1988 Pontiac Fiero

SYMPTOMS:
Some of these vehicles may experience an intermittent illumination of the charge indicator light on the dash. This usually happens only when the intermittent wipers are in use.

CAUSE:
This is caused by negative voltage being emitted by the wiper motor.

SOLUTION:
GM has released a diode (1H4003), or diode connector kit (12085207) which needs to be installed in the brown wire at the alternator connector to prevent the charge indicator light from coming on.

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Remy Quick Tech Tip TA-015: Corroded or blown in-line diode in the engine wiring harness

VEHICLES AFFECTED:
1992-1993 Hyundai Sonata

SYMPTOMS:
Run down or continually drained battery.

CAUSE:
This can be caused by a corroded or blown in-line diode in the engine wiring harness. This can cause the cooling fans to keep running and draining the battery.

SOLUTION:
The in-line diode “A” is located behind the battery in the engine wiring harness. Hyundai supplies a replacement diode (P/N # 91798-33000) available through the dealer.

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Remy Quick Tech Tip TA-014: Blown 80-amp sub fuse link

VEHICLES AFFECTED:
1990-1994 Plymouth Laser
1990-1994 Eagle Talon

SYMPTOMS:
No charge condition after replacing alternator.

CAUSE:
This can be caused by a blown 80 amp sub fuse link located on the right side of the engine compartment in the relay/fuse box.

SOLUTION:
Disconnect the negative battery cable.  Locate the black or clear 80 amp sub fuse link in the fuse box and replace if blown. Check to see if the fuse link is bolted from the bottom before trying to remove.

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Remy Quick Tech Tip TA-013: Alternator failure due to a failed cooling fan timer relay or ambient air temperature switch

VEHICLES AFFECTED:
• 1981-1987 Chrysler Vehicles w/2.6L engine
• 1981-1987 Dodge Vehicles w/2.6L engine
• 1981-1987 Plymouth Vehicles w/2.6L engine

SYMPTOMS:
Alternator failure.

CAUSE:
These vehicles may exhibit alternator failure due to a failed cooling fan timer relay or ambient air temperature switch. These components are attached to the “L” terminal on the back of the alternator.

SOLUTION:
Whenever the alternator is replaced it is highly recommended that both of the components listed above be checked for proper operation and replaced if necessary.

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Remy Quick Tech Tip TA-012: Early alternator failure due to water and/or road debris

VEHICLES AFFECTED:
1984-89 Toyota Van

SYMPTOMS:
These vehicles have shown early alternator failure due to water and/or road debris.

CAUSE:
Water and road debris can damage the alternator due to where the alternator is mounted in the vehicle.

SOLUTION:
Toyota has issued a shield (27029-73020) to be mounted next to the left frame rail under the alternator which will deflect most of the water and debris away from the alternator.

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Remy Quick Tech Tip TA-011: Whining or humming noise at idle that is audible from the driver’s seat

VEHICLES AFFECTED:
1991-1993 Acura Integra
1991-1993 Acura Legend

SYMPTOMS:
These vehicles exhibit a whining or humming noise at idle that is audible from the driverʼs seat.

CAUSE:
This can be misdiagnosed as a faulty alternator bearing but it is actually coming from friction between the water pump seal and the water pump shaft.

SOLUTION:
Acura has issued water pump lubricant (08798-9005) to add to the coolant to help fix this problem.

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Remy Quick Tech Tip TA-009: Electrical malfunctions – discharged battery, blown fuses, low current output at low RPM

VEHICLES AFFECTED:
1989-1992 Ford Probe
1989-1992 Mazda 626 / MX6

SYMPTOMS:
Electrical malfunctions may include a discharged battery, blown fuses, overcharging and low current output at low RPM.

CAUSE:
1) Water may enter the wiring connectors in the engine compartment and in front of the radiator (wiring that joins the body and engine main harness) causing shorted and/or corroded terminals.
2) The hood micro switch may bind causing the under hood lamp to remain on.
3) Low current output at low RPM caused by pulley size.

SOLUTION:
1) Complete inspection and repair of the wiring harness as necessary is strongly recommended.  Refer to Ford TSB #91-16-6 for further information.
2) The hood light micro switch is built into the hood release handle under the dash. It is recommended that the switch be checked and shimmed as necessary to eliminate this problem.
3) Ford has issued kit # E92Z010344-D which consists of a smaller alternator pulley, larger crank pulley, drive belt, cover and gasket.

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Remy Quick Tech Tip TA-010: Alternator warning light stays illuminated on Honda Accord

VEHICLES AFFECTED:
1990 Honda Accord

SYMPTOMS:
Alternator warning light stays on.

CAUSE:
This vehicle may have a 7 pin connector that may not be fully connected.

SOLUTION:
Locate connector C211 (a flat 7 pin connector) attached to the right front inner fender and insure that it is fully connected.

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Remy Quick Tech Tip TA-008: No charge condition on Honda Accord

VEHICLES AFFECTED:
1982-1983 Honda Accord

SYMPTOMS:
No charge condition.

CAUSE:
This condition may be due to a grounded wire to the “F” terminal of the alternator.

SOLUTION:
Unplug the harness plug from the alternator.  Connect the positive lead of a voltmeter to battery positive and the negative lead to the “F” terminal of the plug. There should be no voltage registered on the voltmeter. If voltage is present the “F” wire is grounded and must be repaired. Trace the “F” wire back towards the battery. The ground or short is usually located in the harness connection under the battery tray. Repair the wire as necessary and retest for no voltage.

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Remy Quick Tech Tip TA-007: Intermittent charging problems that are often related to engine electrical operation

VEHICLES AFFECTED:
1990-1991 Chevrolet Corvette

SYMPTOMS:
Intermittent charging problems that are often related to engine electrical operation and may be difficult to diagnose.

CAUSE:
This condition may be due to the engine electrical harness being rubbed through near the mounting clamp just below the oil pressure sensor.

SOLUTION:
To correct this condition remove the negative battery cable. Remove the harness from the clamp. Carefully inspect wires for any damage and repair as necessary. Wrap any damaged wires with electrical tape or heat shrink tubing. Wrap entire harness again after repairs are completed and secure the harness to the clamp.

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Remy Quick Tech Tip TS-012: Intermittent, extended (hot) crank time. Starter may not disengage after engine startup

VEHICLES AFFECTED:
• 2004-2006 Chevy Malibu with 3.5L engine
• 2005-2006 Buick Rendezvous/Chevy Uplander/Pontiac G6/Saturn Relay – all with 3.5L engine

SYMPTOMS:
Intermittent, extended (hot) crank time –starter may not disengage after engine startup.

CAUSE:
GM TSB # 06-06-04-049 indicates the Powertain control module (PCM) may need to be reprogrammed.

SOLUTION:
Perform service manual diagnostics related to extended cranking times during hot engine restarts. If no specific causes found (faulty sensor, etc.), reprogram the PCM to the latest calibration designed to address this condition.

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Remy Quick Tech Tip TA-004: No start/charge condition, discharged battery, intermittent charge, charge Indicator lamp on

VEHICLES AFFECTED:
1993-1994 Ford Taurus 3.2L

SYMPTOMS:
-No start/charge condition
-Discharged battery
-Intermittent charge
-Charge Indicator Lamp On

CAUSE:
The above conditions may be caused by the alternator positive (+) wiring being trapped between the right hand radiator brace and the alternator. As the engine shifts, the wiring assembly pulls at the eyelet terminal connection at the alternator. This loosens the connection and may cause a no charge condition.

SOLUTION:
To correct the above condition, secure and inspect all wire connections at the alternator and the battery. If terminals and/or wires are damaged repair or replace as necessary.

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Remy Quick Tech Tip TA-005: Ford Rangers may exhibit a no start/no charge condition due to a discharged battery

VEHICLES AFFECTED:
1993-1994 Ford Rangers

SYMPTOMS:
-Discharged Battery
-Dim Lights

CAUSE #1:
Ford TSB # 94-9-1 states that the above noted vehicles may exhibit a no start/no charge condition due to a discharged battery. This condition may be caused by the heater fan circuit energizing the alternator when the fan control is left in the on position and the ignition is in the off position.

SOLUTION #1:
To correct this condition, install jumper wire kit (Ford part # F47Z-14A411-A) in cluster according to kits instructions. For further details see Ford TSB # 94-9-1.

CAUSE #2:
Ford TSB # 94-18-8 states that the above noted vehicles may exhibit a discharged battery or dim lights. This condition may be caused by road splash entering the engine department during wet conditions. This road splash can cause the alternator belt to slip resulting in low alternator output and dim lights.

SOLUTION #2:
To correct this condition, Ford has created a new splash shield that must be installed to the left fender apron (Ford part # F37Z-16103-A).  For further details see Ford TSB # 94-18-8.

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Remy Quick Tech Tip TS-011: Milling or grinding of the starter drive pinion and flywheel teeth

VEHICLES AFFECTED:
2002-2004 Chevy Astro 2WD / GMC Safari 2WD

SYMPTOMS:
No start.

CAUSE:
GM TSB # 04-06-03-012 indicates the battery cable assembly may contact the inner tie rod and center drag link on right turns, causing a direct battery short to ground.

SOLUTION:
First, check for all the usual causes of no start/no crank conditions ( weak battery, etc.). Then, inspect the battery cable assembly near the steering linkage. If necessary, replace the entire POS/NEG battery cable assembly with GM part # 15085788 or equivalent. The new assembly features an additional retainer to prevent the cable assembly from contacting the steering linkage.

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Remy Quick Tech Tip TA-006: Repeated battery discharge on Honda Prelude

VEHICLES AFFECTED:
1988-89 Honda Preludes

SYMPTOMS:
Repeated battery discharge.

CAUSE:
Honda Technical Service Bulletin No. 89-028 states that the above models, equipped with A/C, may experience repeated battery discharge when driven for short trips at low speeds during which
there is a high current demand (A/C, headlights and/or rear window defogger are continuously on).

SOLUTION:
To correct this problem Honda has released two repair kits, One for each year affected. These kits include a new alternator belt and pulley which increases alternator RPM and thus allows for higher current output at low engine RPM.

1988 Kit – 06310-PK-2-A00
1989 Kit – 06310-PK-2-A10

If the above condition is present on your vehicle, installation of the proper kit will insure that your newly purchased alternator operates as intended.

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Remy Quick Tech Tip TS-010: Diesel engines, severe starter damage including burnout will result from excessive cranking

VEHICLES AFFECTED:
Vehicles with Diesel Engines

SYMPTOMS:
Severe starter damage including burnout will result from excessive cranking.

CAUSE:
Cranking periods of longer than 3-5 seconds are an indication of fuel delivery and/or glow circuit problems. Diesel engines have very high compression ratios. The starter will be destroyed in a short period of time if allowed to crank for more than a few seconds.

SOLUTION:
Make sure glow plugs are sufficiently hot before cranking. Dash light should indicate that glow plugs are ready. In extreme cold temperatures make sure fuel is not jelled by adding recommended anti-jelling fuel supplements. If long crank times persist, fuel injector and pump circuits must be diagnosed for the starter to operate properly.

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Remy Quick Tech Tip TA-003: Alternator noise (whine, hum, etc.) in passenger compartment

VEHICLES AFFECTED:
1999 Buick Riviera
1999-2001 Buick Park Avenue and Ultra
2000-2001 Buick LeSabre
2000-2001 Pontiac Bonneville

SYMPTOMS:
Alternator noise (Whine, Hum etc.) in passenger compartment.

CAUSE:
GM TSB # 99-06-03-005A warns that some of the above listed vehicles may have various types of noise (magnetic whine, hum etc.) that can be heard in the passenger compartment. This condition may be more pronounced at idle or other low RPM operations.

This condition can be caused by the normal magnetic pulses from the alternator being transmitted into the passenger compartment by way of the heater inlet and outlet hoses that are attached to the bracket shared by the alternator.

SOLUTION:
GM recommends replacement of the two bolts that hold the heater inlet and outlet pipe adaptor to the bracket with new isolation bolts and heater inlet and outlet pipe adapters.

Replacement of isolation bolts and pipe adapters in effected models will eliminate the noise which may otherwise be diagnosed as a defective alternator.

For further information refer to GM TSB # 99-06-005A.

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Remy Quick Tech Tip TA-002: Flickering of the charging system warning lamp on Ford Expedition & Lincoln Navigator

VEHICLES AFFECTED:
2004-2003 4.6L/5.4L Ford Expedition, Lincoln Navigator

SYMPTOMS:
Ford TSB # 04-14-9 indicates the above vehicles may experience intermittent driveability concerns, flickering of the charging system warning lamp, and/or trouble codes P0320 or P0620.

CAUSE:
The conditions may result from chafing or corrosion of vehicle wiring harness 14305, or an interaction of the vehicleʼs computer with the charging system.

SOLUTION:
The harness may need replacement, and the PCM may need to be reprogrammed. Do not replace the alternator unless workshop manual diagnostics indicate replacement is required.

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Remy New Packaging – Every Unit Tested – See Results Inside

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The Road To Remy

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Principles of Magnetism for Automobiles

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Basic Electricity for Service Techs: Ohm’s law, Current Flow, Opens & Shorts

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How to Use a Multimeter to Troubleshoot Common Problems

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Troubleshooting A Starter

There are several tests we can make when troubleshooting a starter. Tests like voltage drops, we can load test a starter, and we’ll show you how to shim a starter properly.

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Troubleshooting An Alternator

Check your battery first, do your belt inspection, check your voltage drop & then perform an output test and you can troubleshoot any alternator.

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What to Test if You Have an Alleged Warranty Starter

Learn what to test if you have an alleged warranty starter including battery state of charge, connections, noises and fluid contamination.

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What to Test if You Have an Alleged Warranty Alternator

Learn what to test if you have an alleged warranty alternator including battery state of charge, wiring/connections, noises/accessory belt drive system and fluid contamination.

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