REMY QUICK TECH TIP: TS-050 (CHRYSLER, DODGE, PLYMOUTH – No crank or intermittent no crank)

VEHICLES AFFECTED:
1990-1995 3.0L Chrysler LeBaron; Dodge Caravan/Spirit; Plymouth Acclaim/Voyager

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 engine oil filter, gaskets, seals, 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.

REMY QUICK TECH TIP: TS-049 (JEEP – No crank or intermittent no crank)

VEHICLES AFFECTED:
1987-1998 4.0L Jeep Cherokee
1987-1992 4.0L Jeep Comanche
1993-1998 4.0L Jeep Grand Cherokee
1988-1998 4.0L Jeep Wrangler

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 starter motor.

REMY QUICK TECH TIP: TS-048 (Some vehicles may experience a no start condition)

VEHICLES AFFECTED:
2002-2005 Ford Excursion
2002-2006 Ford Super Duty F-Series Pick up

SYMPTOMS:
Some vehicles may experience a no start condition

CAUSE:
This may be due to a broken or corroded bolt on the battery terminal positive or negative side.

SOLUTION:
Replace only the bolt and nut. Do not replace the entire harness.

Ford Parts #’s
5C3Z-10756-A (Bolt)
5C3Z-18865-A (Nut)

Refer to Ford TSB # 05-20-1 for further information.

REMY QUICK TECH TIP: TS-047 (No start, starter fuse malfunction)

VEHICLES AFFECTED:
2001-2006 Mercedes Benz C-Series
2003-2006 Mercedes Benz CLK-Series
2003-2006 Mercedes Benz E-Series

SYMPTOMS:
No start

CAUSE:
Mercedes Benz TSB # P-B-15.30/55A, issued 12/22/2005, states that the starter fuse in the “Driver Signal Acquisition and Actuation Module (SAM)” may be malfunctioning.

SOLUTION:
Mercedes Benz recommends that the 15 amp fuse should be upgraded with a larger 20 amp fuse (N072581 000306).

Refer to MB TSB # P-B-15.30/55A. for further information and fuse locations.

REMY QUICK TECH TIP: TS-046 (Some vehicles may exhibit a no crank condition)

VEHICLES AFFECTED:
2006 Dodge Ram Truck w/ 5.9L Diesel Engine

SYMPTOMS:
Some vehicles may exhibit a no crank condition.

CAUSE:
DTC code P1277 may be stored in the Totally Integrated Power Module (TIPM). This code is set when the output current to the starter solenoid exceeds 75 amps, which is normal especially in cold climates. In addition, if DTC code B2215 is stored then the starter solenoid circuit over-current condition has been detected by the TIPM module more than 250 times. At this point, the current to the starter solenoid is turned off until the TIPM memory is cleared.

SOLUTION:
Refer to Chrysler/Dodge TSB# 08-021-06 REV.A for instructions to clear trouble codes and memory and update the TIPM software. The new TIPM software raises the TIPM trigger point for DTC B2215 from 75 amps to 100 amps.

REMY QUICK TECH TIP: TS-045 (No start, engine will not crank, may be due to a blown starter relay circuit fuse)

VEHICLES AFFECTED:
2000-2001 Dodge Ram Pickup
2000 Dodge Ram Van

SYMPTOMS:
No start, engine will not crank.

CAUSE:
This condition may be due to a blown starter relay circuit fuse.

SOLUTION:
On Ram Van/Wagon check starter relay circuit fuse #17 located in the fuse block. On Ram Pickup check starter relay fuse “D” located in the (PDC) Power Distribution Center.

If fuse is blown, inspect starter relay circuit for electrical shorts to ground. If no shorts are found refer to Chrysler/Dodge TSB #08-01-00 Rev. A to install a starter solenoid jumper relay/harness assembly and a new fuse.

Chrysler Part #’s: 25amp fuse: 04687835

Jumper Relay/Harness Assembly for Ram Van: 05019014AA

Jumper Relay/Harness Assembly for Ram Pickup: 05019015AA

REMY QUICK TECH TIP: TS-044 (Low battery voltage caused by excessive ignition off draw)

VEHICLES AFFECTED:
2001 Chrysler PT Cruiser

SYMPTOMS:
Vehicle will not crank or start.

CAUSE:
This can be due to low battery voltage caused by excessive ignition off draw in excess of .020 amps (20 milliamps) in vehicles that have a Mopar Subwoofer (82205894) installed.

SOLTION:
Measure ignition off draw (IOD) as per Chrysler TSB# 08-008-02. If draw exceeds .020 amps (20 milliamps) a jumper harness and relay kit for the subwoofer (05093966AA) is available from Chrysler to repair this condition

REMY QUICK TECH TIP: TS-043 (Hard or No start condition on vehicles with the 7.3L diesel engine)

VEHICLES AFFECTED:
2000-2003 Ford E-Series Van
2000-2003 Ford Excursion
2000-2003 Ford F-Series Super Duty

SYMPTOMS:
Hard or No start condition on vehicles with the 7.3L diesel engine.

CAUSE:
Some vehicles equipped with the glow plug control module (GPCM) may experience a hard or no start condition which may be attributed to the GPCM connector.

SOLUTION:
Inspect GPCM connector for damage and/or corrosion. If damage is found, install a new GPCM connector service kit (Ford part# 4C3Z12B568-AA).

Refer to Ford TSB #04-25-4 for service and repair procedures.

REMY QUICK TECH TIP: TS-042 (Some vehicles may experience a condition where the starter stays engaged after releasing the key from the start position)

VEHICLES AFFECTED:
1999-2003 Ford Excursion
1999-2003 Ford Super Duty F-Series Pick up

SYMPTOMS:
Some vehicles may experience a condition where the starter stays engaged after releasing the key from the start position, repeated starter failures or a sticking/binding ignition lock cylinder.

CAUSE:
This may be caused by the following:

1. The ignition lock cylinder is binding and not fully returning from the start position to the run position.
2. Short circuit on the starter relay circuit.
3. A sticking starter relay.
4. An internal short in the power distribution junction box.

SOLUTION:
If these conditions are present, inspect the flywheel and starter for any damage. Inspect the starter circuit and the power distribution box for any shorts and verify that the ignition lock cylinder is functioning properly.  Ford Part# 1L3Z-11582-AB Ignition Lock Cylinder

Refer to Ford TSB # 03-20-5 for further information.

REMY QUICK TECH TIP: TS-040 (No start and/or dead battery, Corrosion around the battery tray area, Front end rattle noise)

VEHICLES AFFECTED:
1998 Ford Ranger w/2.5L, 3.0L, 4.0L Engines

SYMPTOMS:
No start and/or dead battery Corrosion around the battery tray area Front end rattle noise

CAUSE:
This may be caused by weld burrs from the battery tray scraping or puncturing the battery causing the battery to fail/leak.

SOLUTION:
Grind away all burrs from the battery tray and replace battery if damaged.  Ford Part# BXT 59 (Battery)

Refer to Ford TSB # 98-17-4 for further information.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

We use remy.

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