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02 Monte Carlo SS 3.8, Intermittent No crank
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Question
tunabreath
2002 Monte Carlo SS 3.8, no supercharger. 65k miles.
Having an intermittent no-crank condition. Sometimes the starter solenoid will click, sometimes it won't. The starter is a 2 week old reman from Advance Auto.
Here's what I have done -
-Cleaned all connections including battery terminals, grounds, leads to starter and starter housing to block.
-Tested all wires for voltage drop and high resistance, nothing abnormal found.
-Verified operation of starter cranking relay, swapped it with a known good one. Checked voltage at relay pins in junction block, all good.
-Tested all fuses and checked for loose fuses.
-jumped the battery terminal on solenoid to S terminal on solenoid. SOMETIMES it cranks, sometimes nothing, not even an arc.
-checked for voltage at S terminal while ignition in START, couldn't get reading even when starter cranks or doesn't crank. Too quick for meter to pick up?
-removed starter from vehicle, bench tested it. Can not get it to act up, works OK.
2 odd things-
Once in a while when the starter does function on the vehicle you will get a few sparks falling from near starter area, too quick to see where from.
Once, when holding ignition to START and nothing was happening, a RED/BLK wire heated up and burnt insulation off. This wire comes from the ignition module and runs to PCM. The area where it burnt up was at connector C110 located under the engine cover. It is the "LOW REFERENCE" to PCM. Why would there be that much current flowing through what is essentially a ground wire and why has it not blown a fuse? On a hunch, I swapped in a different ignition module thinking something was internally shorted inside this one (replaced it due to a phantom misfire 2 weeks ago), but no change. Back to the new module.
I'm lost. Right now the starter is off the vehicle and I am letting it sit to see if I can get it to malfunction while bench testing.
Also, no Security light flashing. Just the normal pulse when key is ON position from BATTERY to SECURITY which is normal.
Any help is appreciated!
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