DIAGNOSIS AND REPAIR WORKFLOW
Work Flow (With GR8-1200 NI)
STARTING SYSTEM DIAGNOSIS WITH GR8-1200 NI
To test the starting system, use the following special service tool:
NOTE: Refer to the diagnostic station Instruction Manual for proper starting system diagnosis procedures.
OVERALL SEQUENCE
DETAILED FLOW
NOTE: To ensure a complete and thorough diagnosis, the battery, starter motor and generator test segments must be done as a set from start to finish.
1.DIAGNOSIS WITH MULTITASKING BATTERY AND ELECTRICAL DIAGNOSTIC STATION GR8-1200 NI
Perform the starting system test with Multitasking battery and electrical diagnostic station GR8-1200 NI. For details and operating instructions, refer to diagnostic station Instruction Manual.
Test result CRANKING NORMAL>>GO TO 2.
LOW VOLTAGE>>GO TO 5.
CHARGE BATTERY>>Perform the slow battery charging procedure. (Initial rate of charge is 10A for 12 hours.) Perform battery test again. Refer to diagnostic station instruction manual.
REPLACE BATTERY>>Before replacing battery, clean the battery cable clamps and battery posts. Perform battery test again. Refer to diagnostic station instruction manual. If second test result is “REPLACE BATTERY”, then do so. Perform battery test again to confirm repair.
2.CRANKING CHECK
Check that the starter motor operates properly.
Does the engine crank normally? YES >> GO TO 3.
NO >> GO TO 4.
3.ENGINE START CHECK
Check that the engine starts.
Does the engine start? YES >> Inspection End.
NO >> Perform further diagnosis of engine mechanical or engine control system. Refer to EM and EC sections. Once resolved, perform battery test again.
4.STARTER MOTOR ACTIVATION
Check that the starter motor operates.
Does the starter motor turn? YES >> Check ring gear and starter motor drive pinion. Once resolved, perform battery test again.
NO >> GO TO 7.
5.COMPARISON BETWEEN ENGINE COOLANT AND CRANKING VOLTAGE
Compare the engine coolant temperature and verify the cranking voltage is within specifications.
Minimum Specification of Cranking Voltage Referencing Coolant Temperature
Engine coolant temperature [°C (°F)] | Voltage [V] |
−30 to −20 (−22 to −4) | 8.6 |
−19 to −10 (−2 to 14) | 9.1 |
−19 to −10 (−2 to 14) | 9.5 |
More than 1 (More than 34) | 9.9 |
Is the voltage less than the specified value? YES >> GO TO 7.
NO >> GO TO 6.
6.STARTER OPERATION
Check the starter operation.
Does the starter motor turn smoothly? YES >> Inspection End.
NO >> GO TO 7.
7.“B” TERMINAL CIRCUIT INSPECTION
Check “B” terminal circuit. Refer to STR-17, "Diagnosis Procedure".
Is “B” terminal circuit normal? YES >> GO TO 8.
NO >> Repair as needed.
8.“S” CONNECTOR CIRCUIT INSPECTION
Check “S” connector circuit. Refer to STR-19, "Diagnosis Procedure"
Is “S” connector circuit normal? YES >> GO TO 9.
NO >> Repair as needed.
9.ENGINE ROTATION STATUS
Check that the engine can be rotated by hand.
Does the engine turn freely by hand? YES >> Replace starter motor.
NO >> Perform further diagnosis of engine mechanical or powertrain mechanism. Once resolved, perform battery test again using Multitasking battery and electrical diagnostic station GR8-1200 NI.
Refer to the diagnostic station Instruction Manual for proper testing procedures.
Work Flow (Without GR8-1200 NI)
OVERALL SEQUENCE
DETAILED FLOW
NOTE: If any malfunction is found, immediately disconnect the battery cable from the negative terminal.
1.CHECK ENGINE START
Crank the engine and check that the engine starts.
Does the engine start? YES >> GO TO 2.
2.CHECK THAT THE STARTER MOTOR STOPS
Check that the starter motor stops after starting the engine.
Does the starter motor stop? YES >> Inspection End.
NO >> Replace starter motor. Refer to STR-21, "Removal and Installation".
3.CHECK THAT THE ENGINE TURNS WHEN CRANKING
Check that the engine turns when cranking.
Does engine turn when cranking? YES >> GO TO 4.
NO >> GO TO 5.
4.CHECK THE ENGINE SPEED WHEN CRANKING
Check that the engine speed is not low when cranking.
Does engine turn normally? YES >> Check ignition/fuel system.
NO >> Check charge condition, corrosion and connection condition of the battery.
5.CHECK STARTER MOTOR ACTIVATION
Check that the starter motor runs at cranking.
Does starter motor turn? YES >> Replace starter motor. Refer to STR-21, "Removal and Installation".
NO >> GO TO 6.
6.CHECK POWER SUPPLY CIRCUIT
Check the following conditions:
Are these inspection results normal? YES >> GO TO 7.
NO >> Repair as needed.
7.CHECK STARTING SYSTEM WIRING
Check the following:
Are the inspection results normal? YES >> Replace starter motor. Refer to STR-21, "Removal and Installation".
NO >> Repair as needed.
Engine control system
Symptom Table
SYSTEM — BASIC ENGINE CONTROL SYSTEM
1 - 6: The numbers refer to the order of inspection.
(continued on next table)
SYSTEM — ENGINE MECHANICAL & OTHER
1 - 6: The numbers refer to the order of inspection. ...
Exterior and interior lights
Item
Wattage (W)
Bulb No.
Headlight assembly*
High
65
H9
Low
55
H11
Park
5
W5W
Turn
28/8
7444
Sidemarker
5
WY5W
Front fog lights (if so equipped)
55
H11
...
Refrigerant
Description
CONNECTION OF SERVICE TOOLS AND EQUIPMENT
Shut-off valve
A/C service valve
Recovery/recycling/recharging
equipment
Refrigerant container (HFC-134a)
Weight scale
Vacuum pump
Manifold gauge set
Preferred (best) method
Alternative method
&n ...