QuestionQUESTION: I've got an '89 Caravan 4cyl. 2.5liter non turbo with a starter electrical problem.The starter seized tight without warning and my attempt to start it one morning led to a puff of smoke.Removed starter and confirmed it was seized, replaced it with a reconditioned unit.Now my problems begin.When I turn the key to the "ON"position the OIL light comes on for a fraction of a second then appears very Dim,the fuel pump runs continuously and the starter relay contacts clatter on and off repeatedly.Turning the key to the "start" position produces nothing from the replacement starter.The radio works as does the heater fan,rear defrost,turn signals,seat belt light and battery gauge.All fusible links appear to be intact.A 9.6 volt reading from brown wire to starter and starter relay contacts no longer close.Any help with this issue would be greatly appreciated.
ANSWER: Hi Rod,
The starter relay shouldn't click at all when you turn the key to the run position, nor should the fuel pump run continuously. That starter relay should not be activated until you turn the key to the start position, and the ASD relay should only activate for about 1 second when you turn the key to the run position, then activate again when you try the starter and continue to activate once the engine idles on its own. Do you recall from whence the puff of smoke came from when the starter lock up occured? I would look over the starter motor relay wiring but I don't see how it could impact the system in the 'run' position, unless somehow there is a short of voltage to the relay even in the run position due to the puff of smoke.
What is reading of the battery in the off position, and what is the reading of the battery in the on position of the ignition switch (is that the 9.6V)? if so, there appears to either be a weak battery or a short to ground in the 'on' position of the ignition switch.
The 'on' position of the switch energizes many fuses but also sends power directly to the activation coils of the autoshutdown relay, the field coils of the alternator, the engine controller. There might be a short in the ignition switch itself.
I'll await your response.
Roland
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---------- FOLLOW-UP ----------
QUESTION: After reading your reply I decided to inspect/test the entire under hood wiring harness.Everything was in order except for the 9.6volts from the starter relay running to the starter solenoid.Re-read your reply and found you said it may be "... a short to ground in the 'on' position of the ignition switch".Ground being the operative word; I now checked all under hood ground connections and found the braided copper ground strap running from the firewall to the engine (to the right of the power steering pump)to be burned black and hanging by a thread! Replaced the ground strap and tuned the key and... Voila! Houston we have Ignition!!!
PS Sometimes the simplest answers offer the most information.Thanx for getting my Mind back on track.
Thanx Rod
AnswerHi Rod,
Thanks for the report. We often assume that every item has a return path to 'ground', and when it doesn't of course that becomes an issue. I am glad to learn of your discovery. That braided strap may have been the source of the smoke which probably was caused when the starter shorted and the battery pumped alot of current through starter motor and then back through the engine-to-chassis strap.
Roland
PS: Feel free to rate this or my previous answer if you would be so kind. Thank you
