Engine Won't Start

If engine cranks abnormally or slowly, go to step 6). If engine does not crank, ensure starter turns. If starter does not turn, go to next step. If starter turns, ensure gear shaft turns. If gear shaft does not turn, check reduction gear, armature and gear shaft for damage, and replace as necessary. If gear shaft turns, check pinion clutch for damage, and replace as necessary.
If starter does not turn, check fuse and fusible link. Replace as necessary. If fuse and fusible link are okay, check battery for proper charge. Charge as necessary. Check battery terminals for corrosion and looseness. Service as necessary.
If battery charge and terminals are okay, check starter system components and wiring. Repair wiring or replace ignition switch, inhibitor switch or starter relay as necessary.
If starter components and wiring are okay, ensure starter solenoid movement is heard. If starter solenoid movement cannot be heard, replace solenoid. If starter solenoid movement can be heard, ensure pinion and ring gear mesh properly. If pinion and ring gear do not mesh properly, adjust pinion extension length. See PINION EXTENSION LENGTH under BENCH TESTING.
Check shift lever for defects. Check return springs and pinion for sliding condition. Replace as necessary. If pinion and ring gear mesh properly, remove starter from engine. Ensure starter turns under no-load condition. If starter does not turn, disassemble starter, and check components. If starter turns, check starter solenoid, and replace as necessary.
Check battery charge. Check terminals for looseness and corrosion. Service as necessary. Check starter draw while cranking. If starter draw is excessive, repair or replace starter as necessary. If engine continues to crank abnormally, check engine for mechanical faults.
If starter will not stop turning when ignition is turned off, repair or replace ignition switch, starter relay or starter solenoid.