More starter problems

baggins987 · Post by **baggins987** » Sat Sep 02, 2006 7:15 pm

New problem with the starter. Turning key to start, the starter clicks like the solenoid is trying to fire but the starter doesn't turn. After the first attempt there is nothing electrical working - no idiot lights, etc. If I pull the + cable off the battery and then put it back on I can get the starter to click again just one time. Measured 12V at the main starter lug with key at "On"; measured 0V at spade terminal with key at "Start". The wire to the spade terminal disappears into a wire harness that goes thru the firewall.

Removed the starter and bench tested it; it works fine.

Is it possible something is shorted in the wiring to the starter? (What I hooked up during installation).

Any suggestions on what to check?

So Cal Mark · Post by **So Cal Mark** » Sat Sep 02, 2006 8:42 pm

it sounds like you've got a voltage drop somewhere, that's why all your cluster lights go out. When you measure v at the starter lug, I'm assuming you mean the stud at the bottom of the solenoid; sending voltage into the starter motor. Did you also check voltage there with the key on "start"? Measuring voltage there with the key on, won't tell too much since there isn't much load then, only when cranking.
You should have battery voltage at the spade terminal at "start". Most Fiats have a spade connection along the left fenderwell in the wire that leads to the spade connector on the solenoid. I've seen those corroded, loose, etc. But before you trace the harness looking for that connector, see if you're losing battery voltage everywhere.

baggins987 · Post by **baggins987** » Mon Sep 04, 2006 9:31 pm

Taking the starter out & putting it back in (& reconnecting the cables) temporarily fixed the problem - I was able to turn the engine over on several attempts before the before-mentioned behavior returned.
Checking voltages again, at the stud where the battery cable connects to the solenoid - 12.5V key off; 5.5V key on; ~3.5 key at start. At the blade terminal - 0V key on, ~.5V key at start. Didn't check the other stud (power from solenoid to starter motor); figured if solenoid didn't move no power was going to the motor anyway.

One exciting moment - after clipping the + test lead to the blade terminal/red wire and the - test lead to ground, the starter/engine turned over when key was turned to start. Surprised the hell out of me and my helper. Especially me under the car with my hand near the alternator. Didn't happen on following attempts with hands at a safer distance from moving parts.

The red wire to the blade terminal (and another wire) go to a connector about 6"from the starter then into a cable harness that goes thru the firewall. The short section of red wire looks OK and continuity checks OK.

What should I check next?

So Cal Mark · Post by **So Cal Mark** » Tue Sep 05, 2006 12:14 am

you're not getting enough voltage at the battery cable connection at the solenoid. It takes a minimum of 9.6v to make the solenoid/starter to operate. If you only have 5.5 with the key on, you've got a voltage drop somewhere between the battery and starter. Just by chance, does your battery cable have one of those clamp on replacement terminals at the battery? If so, that's a common spot to have a poor connection.
What does the voltage at the battery do when you turn the key on or try to start?

baggins987 · Post by **baggins987** » Tue Sep 05, 2006 11:33 pm

Just for giggles I removed both battery cables, cleaned clamps and posts, repositioned them a bit for less strain, and reclamped. Problem solved.

So Cal Mark · Post by **So Cal Mark** » Wed Sep 06, 2006 12:08 am

it's always good to start at the beginning