Initial Inspection and Diagnostic Overview

DIAGNOSIS AND REPAIR WORK FLOW


Work Flow


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 DIAGNOSTIC STATION
Perform the starting system test with multitasking battery diagnostic station. 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 - Starter motor is OK. 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 specification.





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 - Starter motor is OK. Inspection End.
NO - GO TO 7.
7. "B" TERMINAL CIRCUIT INSPECTION
Check "B" terminal circuit. Refer to B Terminal Circuit.
Is "B" terminal circuit normal?
YES - GO TO 8.
NO - Repair as needed.
8. "S" CONNECTOR CIRCUIT INSPECTION
Check "S" connector circuit. Refer to S Connector Circuit.
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. Refer to EM or TM sections. Once resolved, perform battery test again. Refer to diagnostic station instruction manual.