Question

Difficulty: HardStarting and Charging Systems

A technician is diagnosing a vehicle with a no-crank condition. When the ignition switch is turned to the START position, a single distinct click is heard from the starter solenoid, but the engine does not turn over. A digital multimeter connected directly across the battery posts reads 12.6 V12.6\text{ V} at rest and drops slightly to 12.2 V12.2\text{ V} when the key is held in the START position. However, measuring between the starter motor's main positive battery terminal (BB-terminal) and the starter case ground shows 12.5 V12.5\text{ V} at rest, but drops to 0.4 V0.4\text{ V} during the crank attempt. Which of the following is the most likely root cause of this failure?

  1. A
    A discharged 12-volt battery unable to supply high cranking amperage
  2. High resistance in the positive battery cable or its terminal connectionsAnswer
  3. C
    An internal short circuit across the alternator stator windings
  4. D
    A seized starter motor armature drawing locked-rotor current

Answer

High resistance in the positive battery cable or its terminal connections
The correct answer is high resistance in the positive battery cable or its terminal connections. When the ignition switch activates the starter solenoid, the heavy internal contact disc closes to connect the battery feed to the starter motor windings. Because high resistance exists along the cable or connection (due to corrosion, looseness, or damaged strands), the attempted current draw causes a massive voltage drop across the resistance point, leaving only 0.4 V0.4\text{ V} at the starter motor. The battery itself maintains 12.2 V12.2\text{ V}, proving the voltage drop is strictly isolated to the feed circuit.

Step-by-Step Solution

1
Analyze the battery state of charge and battery post voltage under load.
The battery post voltage is 12.6 V12.6\text{ V} open circuit and stays at 12.2 V12.2\text{ V} during the crank attempt, confirming the battery is fully charged and not under excessive total load.
A healthy, fully charged automotive lead-acid battery maintains >9.6 V>9.6\text{ V} during starting.
2
Evaluate the voltage drop between the battery and the starter motor main terminal.
Voltage at the starter drops from 12.5 V12.5\text{ V} down to 0.4 V0.4\text{ V} during the attempt, indicating an unwanted voltage drop of over 11.8 V11.8\text{ V} (12.2 V−0.4 V12.2\text{ V} - 0.4\text{ V}) across the supply line.
According to Ohm's law (V=IRV = IR), when current flows through high unwanted resistance (corrosion, loose terminal, frayed cable), voltage drops significantly across that point instead of reaching the load.
3
Differentiate between an open supply path, a shorted/locked starter, and a cable resistance fault.
The single click confirms the solenoid pull-in coil activates and closes the internal disc contacts, but the supply cable cannot deliver current due to excessive series resistance.
The failure is isolated to the primary current-carrying feed between the battery positive post and the starter terminal.

Key Concept

Starting circuit voltage drop diagnosis and series circuit resistance behavior under heavy electrical loads.
Estimated Time:1m 30s
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