Detailed Flow
- To ensure a complete and thorough diagnosis, the battery, starter motor and alternator test segments must be done as a set from start to finish.
- If any malfunction is found, immediately disconnect the battery cable from the negative terminal.
- DIAGNOSIS WITH BATTERY AND ELECTRICAL DIAGNOSTIC ANALYZER 165-DSS - 5000P
Perform system test with battery and electrical diagnostic analyzer 165-DSS-5000P. For details and operating instructions, refer to diagnostic analyzer instruction manual.
How is the test result?
CRANKING NORMAL
GO TO 3.
LOW VOLTAGE
GO TO 2.
CHARGE BATTERY
Perform the slow battery charging procedure. (Initial rate of charge is 10 A for 12 hours.) Perform battery test again. Refer to diagnostic analyzer instruction manual.
REPLACE BATTERY
Before replacing battery, clean the battery cable clamps and battery posts. Perform battery test again. Refer to diagnostic analyzer instruction manual. If second test result is "REPLACE BATTERY", then do so. Perform battery test again to confirm repair.
- COMPARISON BETWEEN ENGINE COOLANT AND CRANKING VOLTAGE
Compare engine coolant temperature and the cranking voltage with the specifications.
Minimum Specification of Cranking Voltage Referencing Coolant TemperatureEngine coolant temperature [ deg. C (deg. F)]
Voltage [V]
-30 to -20 (-22 to -4)
8.6
-19 to -10 (-2 to 14)
9.1
-9 to 0 (16 to 32)
9.5
More than 1 (More than 34)
9.9
Is the voltage less than the specified value?
YES
GO TO 11.
NO
GO TO 3.
- CHECK ENGINE START
Check engine and check that engine starts.
Does engine start?
YES
GO TO 4.
NO
GO TO 5.
- CHECK RETURN OF PINION GEAR
Check that pinion gear returns to original position after engine starts.
Does pinion gear return?
YES
Starter motor is OK. Inspection End
NO
GO TO 11.
- CHECK ENGINE SPEED WITH CRANKING
Check that engine turns while cranking.
Does engine turn by cranking?
YES
GO TO 6.
NO
GO TO 7.
- CHECK STARTER MOTOR TURNING WITH CRANKING
Check that starter motor runs smoothly without abnormal noise at cranking.
Does starter motor turn normally?
YES
Check ignition/fuel system.
NO
Check engine mechanical and power train system.
- CHECK STARTER MOTOR SPEED WITH CRANKING
Check that starter motor turns while cranking.
Does starter motor turn at cranking?
YES
GO TO 8.
NO
GO TO 9.
- CHECK PINION GEAR AND RING GEAR ENGAGEMENT
Check condition of pinion and ring gear engagement.
Is inspection result normal?
YES
Check engine mechanical and power train system.
NO
Check pinion protrusion length. Refer to STARTER MOTOR : Inspection (with PR25DD engine) or STARTER MOTOR : Inspection (with KR20DDET engine).
- CHECK POWER SUPPLY CIRCUIT
Check the following conditions:
- Fuse and fusible link.
- Charge condition, corrosion and connection condition of battery. Refer to Work Procedure .
Are these inspection results normal?
YES
GO TO 10.
NO
Repair as needed.
- CHECK STARTING SYSTEM WIRING
Check the following:
- "B" terminal circuit. Refer to Diagnosis Procedure (with PR25DD engine) or Diagnosis Procedure (with KR20DDET engine).
- "S" terminal circuit. Refer to Diagnosis Procedure .
Are these inspection results normal?
YES
GO TO 11.
NO
Repair as needed.
- CHECK MAGNETIC SWITCH OPERATION
Check magnetic switch operation. Refer to STARTER MOTOR : Inspection (with PR25DD engine) or STARTER MOTOR : Inspection (with KR20DDET engine).
Does magnetic switch operate normal?
YES
GO TO 12.
NO
Replace magnetic switch or stater motor.
- CHECK PINION TURNING
- Remove starter motor.
- Check that pinion turns smoothly by hand.
Does pinion turn normally?
YES
Perform no-load test of starter motor. Refer to STARTER MOTOR : Inspection (with PR25DD engine) or STARTER MOTOR : Inspection (with KR20DDET engine).
NO
Check pinion clutch. Refer to Inspection (with PR25DD engine) or STARTER MOTOR : Inspection (with KR20DDET engine).