starter and alternator technical videos

TS-051: No start / No A/C / Rough idle

VEJICLES AFFECTED:
2000-2001 Infiniti I30

SYMPTOMS:
No start.
MIL “On” and/or DTC stored in Self-Diagnosis.
Other system malfunction such as A/C inop, A/C idle-up inop, rough idle, oil pressure light inop.

CAUSE:
The cause may be wire breakage in the engine control harness where it bends over the right rear of the engine next to the right strut tower.

SOLUTION:
Please refer to Infiniti TSB #ITB01-72A, issued 1/9/2002, and follow the diagnostic and repair procedures.

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REMY QUICK TECH TIP: TA-066 (Check Gauges lamp may come on, battery charging gauge reading in the 11-volt range)

VEHICLES AFFECTED:
2006-2007 Dodge Ram Truck w/ 5.9L Diesel Engine

SYMPTOMS:
The “Check Gauges” lamp on the instrument panel cluster may come on. Further inspection may show the battery charging gauge reading in the 11 volt range rather than the normal 14 volt range. However, the “Check Engine / Malfunction Indicator Lamp” (MIL) may not come on.

CAUSE:
Diagnostic Trouble Codes (DTC #’s P2502, P2503, P2509) may be stored in the Power Control Module (PCM).

SOLUTION:
Refer to Chrysler/Dodge TSB# 18-001-07 for instructions to clear trouble codes and reprogram the Power Control Module (PCM) with the latest software.

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REMY QUICK TECH TIP: TA-065 (Battery drain is caused by a defective M280 (MP3) audio receiver)

VEHICLES AFFECTED:
2006-2007 Hyundai Tucson

SYMPTOMS:
Discharged or dead battery if vehicle is left parked, without being started or driven, for 2-3 days or more.

CAUSE:
Battery drain is caused by a defective M280 (MP3) audio receiver that may be installed in some models between 8/25/2005 and 7/12/2006.

SOLUTION:
Determine that the alternator and starter are operating properly. If problem remains, a remanufactured audio receiver (00201-T5000-FLT) should be installed as per Hyundai TSB# 10-BE-003.

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REMY QUICK TECH TIP: TA-064 (Crank pulley loosening on the crank causing a misalignment)

VEHICLES AFFECTED:
1994-1999 Dodge Ram Pickup w/ 8.0L engine

SYMPTOMS:
Some vehicles may exhibit belt noise and/or excessive belt wear.

CAUSE:
The drive belt can become damaged on the inboard edge of the belt. This can be caused by the crank pulley loosening on the crank and causing a misalignment.

SOLUTION:
Inspect drive belt for fraying or unusual wear on the inboard edge. Sight the crank pulley with other accessory drives or use a straight edge to detect misalignment. If the crank pulley is misaligned or the bolt is loose, perform the repair procedure as per Dodge TSB# 09-04-98.

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REMY QUICK TECH TIP: TA-063 (Battery goes dead due to the glove box lamp remaining on when glove box door is closed)

VEHICLES AFFECTED:
1998 Dodge Ram Pickup

SYMPTOMS:
Battery goes dead due to the glove box lamp remaining on when glove box door is closed.

CAUSE:
This condition may be due to the glove box lamp switch bracket not being properly aligned to the instrument panel glove box opening upper reinforcement.

SOLUTION:
Follow the repair procedure and install 2 metal spacers (06100876) as per Chrysler TSB# 08-35-97.

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REMY QUICK TECH TIP: TA-062 (Malfunctioning Indicator, Diagnostic Trouble Codes & Possible Low Battery Rate of Charge)

VEHICLES AFFECTED:
2005 Ford Crown Victoria
2005 Lincoln Town Car
2005 Mercury Grand Marquis

SYMPTOMS:
Malfunctioning indicator light (MIL), Multiple Diagnostic Trouble Codes and Possible Low Battery Rate of Charge.

CAUSE:
Some 2005 vehicles may experience one or more of the following DTC’s: PO316, PO30X and PO606.

SOLUTION:
Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 47.9 and higher or 48.2 and higher. This calibration also includes a strategy to optimize the battery charging capability. This new calibration is not included in the VCM 2007.3 DVD.

Refer to Ford TSB # 07-6-2 for further information.

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REMY QUICK TECH TIP: TA-061 (Belt squeal, serpentine belt comes off pulleys)

VEHICLES AFFECTED:
1996-1999 Chrysler Town & Country
1996-1999 Dodge Caravan
1996-1999 Plymouth Voyager

FOR VEHICLES EQUIPPED WITH 3.0L ENGINE
SYMPTOMS:
Belt squeal, serpentine belt comes off of pulleys.

CAUSE:
Driving through deep snow allows snow to enter the engine compartment and force the serpentine belt off the pulleys.

SOLUTION:
Install belt tensioner snow shield (05003480AA) and serpentine belt (05281275) as referenced in Chrysler TSB# 07-01-99.

FOR VEHICLES EQUIPPED WITH 3.3L or 3.8L ENGINE
SYMPTOMS:
Serpentine belt slips off of pulleys

CAUSE:
Driving through deep snow or standing water allows snow or water to knock the serpentine belt off the idler pulley.

SOLUTION:
Check for proper alignment between belt and idler pulley per Chrysler TSB # 07-02-99. If alignment cannot be corrected, install a new engine mounting bracket (04612412) that attaches to the idler pulley, and reinstall idler pulley to new bracket. Also, install a new belt (04861322).

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REMY QUICK TECH TIP: TA-060 (Intermittent flickering of the charging system warning indicator)

VEHICLES AFFECTED:
2003-2004 Ford Expedition
2003-2004 Lincoln Navigator

SYMPTOMS:
Some vehicles may experience the following symptoms in any combination:
1. Intermittent flickering of the charging system warning indicator.
2. Malfunction indicator lamp (MIL) on with DTC’S PO620 and/or PO320 in memory.
3. Intermittent Driveability Concerns.

CAUSE:
These conditions may be caused either by chafing or corrosion of the 14305 harness, or an interaction of the PCM with the charging system.

SOLUTION:
Reprogram the PCM to the latest calibration using WDS release B32.2 or higher and replace the 14305 harness.

Refer to Ford TSB # 04-14-9 for further information.

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REMY QUICK TECH TIP: TA-059 (The front-end accessory drive belt may exhibit noise when starting the engine cold)

VEHICLES AFFECTED:
2003-2004 Ford Excursion w/6.0L Diesel Engine
2003-2004 Ford F-Series Super Duty w/6.0L Diesel Engine

SYMPTOMS:
Some vehicles with the 6.0L diesel engine built before 6/1/2004 may experience belt noise.

CAUSE:
The front end accessory drive (FEAD) belt may exhibit noise when starting the engine cold. The noise is described as a squeal or squawk.

SOLUTION:
Replace the front end accessory drive (FEAD) belt with updated Ford belt.

Refer to Ford TSB # 04-14-12 for further information.

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REMY QUICK TECH TIP: TA-058 (Battery warning lamp illuminated and a diagnostic trouble code of P1246)

VEHICLE AFFECTED
2003 Lincoln Town Car

SUMPTOMS:
Some 2003 Lincoln Town Car vehicles may experience the battery warning lamp illuminated and a diagnostic trouble code (DTC) of P1246 (Generator Load Input Failed) in the powertrain control module (PCM).

CAUSE:
The may be caused when the vehicle is started and immediately placed into gear and driven, without allowing the engine to return to normal idle. When this takes place the PCM will not command the alternator to charge, which results in the illumination of the battery warning lamp and a P1246 DTC.

SOLUTION:
Check to make sure that the battery is fully charged and all wiring connections are secure.  Reprogram the PCM to the latest calibration using WDS B28.3 or higher.

Refer to Ford TSB # 03-24-4 for further information.

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REMY QUICK TECH TIP: TA-057 (Front-end accessory drive belt slips off the water pump pulley when splashed with water)

VEHICLE AFFECTED:
2001-2002 Ford Crown Victoria 4.6L
2001-2002 Ford Mustang 4.6L
2001-2002 Lincoln Town Car 4.6L
2001-2002 Mercury Grand Marquis 4.6L

SYMPTOMS:
Front end accessory drive (FEAD) belt slips off the water pump pulley when splashed with water.

CAUSE:
On some vehicles equipped with the 4.6 L engine, the front end accessory drive (FEAD) belt may hydroplane on the water pump pulley when the belt is splashed with water. This may cause the belt to track forward on the tensioner pulley and the belt may then slip off the tensioner pulley.

SOLUTION:
Replace the water pump pulley and tensioner assembly as necessary. Refer to Ford TSB # 02-5-4 for further information for vehicle specific service and part replacement procedures.

FORD PART #’s
XR3Z-6B209-AB (Tensioner)
3W7Z-8509-AA (Pulley-Water pump)
1W7Z-8620-AA (FEAD belt-Town Car, Crown Victoria, Grand Marquis)
1R3Z-8620-BA (FEAD belt Mustang)

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REMY QUICK TECH TIP: TA-056 (Belt noise and possible charging problems)

VEHICLES AFFECTED:
2001 Hyundai XG300
2002 Hyundai XG350

SYMPTOMS:
Belt noise and possible charging problems.

CAUSE:
This condition may be due to improper drive belt tension.

SOLUTION:
Drive belt tension should be adjusted to 110-130 lbs. tension for a new belt or 70-90 lbs. tension for a used belt as per Hyundai TSB# 02-20-005.

Adjustment of the drive belt will help ensure proper operation of the charging system.

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REMY QUICK TECH TIP: TA-055 (Charge lamp illumination in cold ambient temperatures)

VEHICLES AFFECTED:
2001 Ford Escape 2.0L Zetec engine (built 7/8/2000 through 2/12/2001 only.)

SYMPTOMS:
Some vehicles may experience a red charge lamp illumination in cold ambient temperatures below -6 ºC (20 ºF).

CAUSE:
This may be caused by the calibration of the powertrain control module (PCM).

SOLUTION:
If normal diagnostics cannot resolve condition, reprogram the powertrain control module (PCM) with the latest calibration.

Refer to Ford TSB # 01-5-5 for further information.

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REMY QUICK TECH TIP: TA-054 (Charge lamp illumination, loss of power or discharged battery during high electrical loads with A/C on)

VEHICLES AFFECTED:
2001 Ford Escape 3.0L engine (produced before 7/27/2001)

SYMPTOMS:
Some vehicles may experience charge lamp illumination, loss of power or discharged battery during high electrical loads with A/C on.

CAUSE:
This may be caused by the A/C condenser airflow requirements exceeding the low speed capability of the cooling fans, causing high A/C head pressure, which triggers high speed fan operation. The high speed engine cooling fan requirement (approximate 56 amps for dual 320W fans) exceeds the output capability of the electrical charging system.

SOLUTION:
Replace the dual 320 Watt cooling fans with dual 220 Watt cooling fan assembly.

Ford Part # (2L8Z-8C607-GA) 220 Watt Cooling Fan Assembly

Refer to Ford TSB # 01-20-2 for further information.

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REMY QUICK TECH TIP: TA-053 (Cut or chafed “L” terminal wire)

VEHICLES AFFECTED:
1998 4.3L Chevy S10/T10
1998 4.3L Oldsmobile Bravada

SYMPTOMS:
Weak battery, alternator not charging, battery malfunction lamp on.

CAUSE:
GM TSB # 76-64-07 advises the vehicle’s “L” (lamp) wire (CKT225, RED) feeding into the voltage regulator plug may be cut or chafed, causing an open circuit. The problem occurs a few inches from the regulator plug, where the harness rubs against the heater hose support bracket that is attached to the back of the alternator.

SOLUTION:
Repair the wiring per service manual instructions, adding slack, and reroute the wiring away from the heater hose bracket.

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REMY QUICK TECH TIP: TA-052 (Flickering condition of the headlamps, interior cluster, radio, or interior lights)

VEHICLES AFFECTED:
1999-2000 Mercury Cougar with the 2.5 L engine

SYMPTOMS:
Some vehicles may experience a flickering condition of the Headlamps, interior cluster, radio or interior lights during engine startup and this may continue during the first several minutes of engine idle.

CAUSE:
This may be caused by excessive electrical resistance in the battery voltage sensing circuit.

SOLUTION:
Reroute the battery sense line from the engine compartment power distribution box to the B+ terminal on the alternator.

Refer to Mercury TSB # 00-25-6 for further information.

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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.

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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.

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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.

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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.

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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.

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REMY QUICK TECH TIP: TA-051 (Radio interference similar to problems generally associated with alternator interference)

VEHICLES AFFECTED:
1999 Hyundai Sonata w/ 2.4L engine

SYMPTOMS:
Sonata vehicles produced before 12/14/98 may experience radio interference similar to problems generally associated with alternator interference. This is not an alternator related issue.

CAUSE:
This vehicle may not have an ignition harness condenser installed at the camshaft position sensor mounting bolt.

SOLUTION:
To correct this condition, install a noise suppression condenser (27325-38000) to the control harness as outlined in Hyundai TSB#99-90-007.

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REMY QUICK TECH TIP: TA-050 (Faulty O-rings at the alternator inlet and outlet coolant pipes)

VEHICLES AFFECTED:
2004-2005 VW Phaeton
2004-2005 VW Touareg

SYMPTOMS:
Alternator appears to be leaking
Alternator Coolant Pipe Leak

CAUSE:
Volkswagen TSB #97-07-05 advises that the above vehicles are prone to coolant leaks. This is often due to faulty O-rings at the alternator inlet and outlet coolant pipes.

SOLUTION:
It is highly recommended that new O-rings are installed any time that the alternator is replaced. Replacement O-rings are available from Volkswagen by ordering VW part # N 907834 01.

For further information please refer to VW TSB #97-07-05.

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REMY QUICK TECH TIP: TA-049 (Battery light illuminates in wet weather, increased steering effort)

VEHICLES AFFECTED:
1995-1998 Ford Contour
1995-1998 Mercury Mystique

SYMPTOMS:
Battery light illuminates in wet weather Increased steering effort.

CAUSE:
The front end accessory drive (FEAD) belt may slip at the crankshaft pulley in wet weather conditions or driving through puddles while turning.

SOLUTION:
Install revised FEAD belt, revised steel idler pulley, and new two-piece splash kit.

Ford Part #’s:
F5RZ-6316-CA (Crankshaft Damper)
F83Z-6C348-AA (Steel Idler Pulley)
F83Z-8620-AA (FEAD Belt A/C)
F83Z-8620-BA (FEAD Belt Non A/C)
F8RZ-6775-CA (Splash Shield Kit)

Refer to Ford TSB # 97-11-2 for further information.

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REMY QUICK TECH TIP: TA-048 (Blown fuse, wiring problem, defective choke heater, or a defective EFE heater control)

VEHICLES AFFECTED:
1984-1989 Honda Accord

SYMPTOMS:
Charge lamp on / alternator is functioning properly.

CAUSE:
This condition can be caused by a blown fuse, wiring problem, defective choke heater, or a defective EFE heater control.

SOLUTION:
Check for a blown No. 8 fuse in the relay panel or an open in the white/green wire between the relay box and the alternator. Repair if necessary. If the charge light still remains on, continue with the following tests.

On Carbureted Engines:
1) Stop the engine and disconnect the choke heater connector. If the lamp goes out with the engine running, check for a defective choke heater.
2) Stop the engine and disconnect the 7 terminal connector from the EFE heater control. If the lamp goes out check for a defective EFE heater control.
3) If the lamp remains on check for a short to ground in the blue/white wire between the charge warning lamp and the choke heater or the EFE heater control unit.

On Fuel Injected Engines:
1) Stop engine and disconnect the electrical connector from the back of the alternator.
2) Turn on ignition. If the lamp remains on check for short to ground in the harness between the alternator and the charge warning lamp.

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REMY QUICK TECH TIP: TA-047 (Anti feedback diode damage)

VEHICLES AFFECTED:
1990-1992 Nissan Pickup 2.4L

SYMPTOMS:
Discharged battery
No alternator output.

CAUSE:
The lamp circuit wiring harness in the above application’s include an inline anti feedback diode that is secured with a wire tie.  Many of these vehicles were built with the wire tie attached to the wire and not the diode. Vehicle
vibration can cause damage to the wire and prevent the alternator from charging at less than 3600 RPM.

SOLUTION:
Before condemning the alternator, check the yellow/black “L” wire at “Diode 59E” between the alternator and the charge lamp. To repair, correct any damaged wires and secure the diode with a new wire tie.

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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

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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

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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.

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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.

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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.

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REMY QUICK TECH TIP: TA-046 (Low capacity battery)

VEHICLES AFFECTED:
1986-1989 Nissan Maxima

SYMPTOMS:
Prolonged high current output Short alternator life

CAUSE:
Batteries often “assist” the alternator in meeting the vehicle’s overall electrical load demand.  The above vehicles were originally equipped with smaller capacity batteries, which often overburdened the alternator and resulted in a (heat related) no charge condition.

SOLUTION:
It is recommended to upgrade the vehicle with a battery rated at 450-500 cold cranking amps.

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REMY QUICK TECH TIP: TA-044 (Poor ground at alternator mounting bracket to the engine)

VEHICLES AFFECTED:
1987-1988 Pontiac 6000 with 2.8L engines
1987-1988 Pontiac Grand Prix with 2.8L engines

SYMPTOMS:
Low Alternator Voltage

CAUSE:
Pontiac TSB # 88-6-17 states that the above condition may be caused by the black (phosphate coated) studs which connect the alternator mounting bracket to the engine. Due to this coating the studs provide a poor ground path.

SOLUTION:
To fix the situation GM suggests that the retaining nuts be removed and discarded. Clean the studs with a wire brush down to bare metal. Replace the nuts with standard plated ones.

Please refer to Pontiac TSB # 88-6-17 for further information.

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REMY QUICK TECH TIP: TA-043 (Intermittent Charge Lamp Illumination)

VEHICLES AFFECTED:
1991 Buick Park Avenue

SYMPTOMS:
Intermittent Charge Lamp Illumination

CAUSE:
GM TSB # 91-6D-1 states that a faulty instrument cluster can cause the charge lamp to illuminate. This condition will usually occur at idle with heavy electrical loads.

SOLUTION:
If a complete electrical system check indicates no problems, a faulty cluster circuit may be to blame and should be repaired or replaced.

Please refer to GM TSB # 91-6D-1 for further information.

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REMY QUICK TECH TIP: TA-042 (Trunk lamp can remain on after the lid has been closed)

VEHICLES AFFECTED:
1994-95 Oldsmobile 88

SYMPTOMS:
Intermittent Discharged Battery

CAUSE:
The trunk lamp can remain on after the lid has been closed. The contacts for the lamp can make contact with the surrounding sheet metal grounding the circuit allowing the lamp to remain on.

SOLUTION:
Remove the lamp from the rear of the trunk.  Insulate the lamp contacts from the rear shelf sheet metal by wrapping the terminals with electrical tape and reinstall.

For further information please refer to General Motors TSB# 53-82-07.

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REMY QUICK TECH TIP: TA-041 (Cooling fans may continue to run with the ignition switch off)

VEHICLES AFFECTED:
1993 Cadillac Fleetwood

SYMPTOMS:
Discharged Battery

CAUSE:
Cooling fans may continue to run with the ignition switch off.

SOLUTION:
If fans remain running with the ignition off, new fan relays along with diodes should be installed.

Please refer to GM TSB# 31-62-01 for further information.

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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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