AT 121 - Chapter 12 Automotive Starters. Service, Diagnosis, and Inspection – PART AName: _________________________________________Date: __________________________________________WARNING! This lab will have you working with live batteries. Batteries are dangerous devices and can explode if shorted. Fire and explosion can result from carelessness! Batteries also contain sulfuric acid. If skin or eyes come incontact with acid or corrosion on the battery surface flush with water and seek medical assistance!It is important to remember a few things about how a vehicle starts. Most vehicles made after 1990 have a “clutch interlock” switch. This switch prevents a manual transmission vehicle from being starter in gear. However, it is important to make sure that the vehicle is in neutral and the parking brake is set before any type of automotive inspection or service is preformed! To start the vehicle the clutch must be fully depressed. Other vehicles with an automatic transmission must be in either neutral or park in order for the vehicle to start. On most manual transmission vehicles equipped with a clutch interlock the interlock switch is located above the clutch pedal. On mostautomatics the “neutral safety switch” is located on the transmission housing and is controlled by the shifter cable or rod.  SECTION 1 Starter Inspection, Component LocationsTools you will need:Vehicle #1Electrical Component Locator (Mitchell’s or Factory Shop Manual)Wiring Diagrams (Mitchell’s or Factory Shop Manual)Year _______________________ Make ___________________ Model ______________________ Locate the following components on the vehicle and show them to your instructor; Battery Inspection (Cracks, Loose Terminals, Holdown, Corrosion) Results: ___________________________ Starter Inspection (S wire, B wire, Ground) Results: ___________________________ Ignition Switch (Wires, Connectors) Results: ___________________________ Neutral Safety or Clutch Lockout Switch (Wires, Connectors) Results: ___________________________ Starter Relay or Solenoid (Wires, Connectors) Results: _________________________ Cable from battery to starter (Wire Damage, Connectors) Results: _________________________QDraw a simple schematic of a starting system;B+ S1 M(+) (-)IGN SWSAFETYRELAYName 6 components that could fail and cause a No-Crank scenario_______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Name 2 components that could fail and cause a No-Crank scenario, but the starter “runs” and makes noise._____________________________________________________________________________________________Name 3 components that could fail and cause a noisy starter._____________________________________________________________________________________________Name 3 components that could fail and cause a starter to get “stuck on”._____________________________________________________________________________________________The ___________________ must be depressed on must manual transmission vehicles in order to start them. On most automatics __________________________ is located on the transmission housing and is controlled by the shifter cable or rod.On most manual transmission vehicles equipped with a clutch interlock the interlock switch is located ____________________________________________________________.The “S” wire is the signal from the ______________________ switch. The “B” wire is ____________________ voltage at all times to the _________________________.Instructor’s Signature _________________________________________________________________ SECTION 2 Starter Motor RemovalTools you will need:2001 Ford WindstarTool BoardWARNING: When servicing the starter motor or working underhood in the vicinity of the starter motor, note the heavy gauge input lead connected to the starter solenoid is hot at all times. Make sure the protective cap is installed over the terminal and is reinstalled after servicing. If needed lift the vehicle Disconnect the battery ground cable. Remove the bolts and lower the starter motor. Remove the caps, nuts and starter motor. WARNING! DO NOT ALLOW THE STARTER TO HANG BY ANY CABLES! IT WILL BREAK THE TERMINALS ON THE STARTER!2 Installation - To install, reverse the removal procedure. Torque all bolts on the starter relay pins to 53 In/Lbs.NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn PCM strategies.QMake sure the ___________________________ installed over the starter terminal and is reinstalled after servicing.What will happen if the starter is allowed to “hang” by it cables during service? _____________________________When the battery is disconnected and reconnected, some abnormal _____________________________ may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven ________________________ or more to relearn PCM strategies.Instructor’s Signature _________________________________________________________________ SECTION 3 On Car Starter Motor Inspection – Customer Complaint – “No Crank”3If a starter does not run, and the battery checks out, this simple test may be preformed on any vehicle. The test is broken down to inspect the most basic parts of a starter circuit. Proper power and ground must be in the right place at the right time in order for the starter to function when the driver needs it. A “No Crank” is very different from a “No Start”. A No Crank means that the starter is NOT functioning and it or the battery may be at fault. A No Start means the vehicle cranks, but will not run. This could be a base engine problem, fuel delivery or ignition system failure. Before performing this test the battery must be fully inspected and checked!WARNING: When servicing the starter motor or working underhood in the vicinity of the starter motor, note the heavy gauge input lead connected to the starter solenoid is hot at all times. Make sure the protective cap is installed over the terminal and is reinstalled after servicing.Tools you will