Starter Circuit Troubleshooting
NOTE:
  • Air temperature must be between 15 and 38 °C (59 and 100 °F) during this procedure.
  • After this inspection, you must reset engine control module (ECM), otherwise the ECM will continue to stop the fuel injectors from functioning.
  • The battery must be in good condition and fully charged.
  1. Hook up the this equipment:
    • Ammeter, 0−400 A
    • Voltmeter, 0−20 V (accurate within 0.1 V)
  1. Turn the ignition switch ON (II).
  1. Select PGM-FI, INSPECTION, then ALL INJECTORS OFF on the HDS.
  1. Set the parking brake, then turn the ignition switch ON (II), and press the engine start switch.
Did the starter crank the engine normally?
YES -
The starting system is OK. Go to Step 11 .
NO -
Go to Step 7 .
  1. Check the battery condition. Check electrical connections at the battery, the negative battery cable to body, the engine ground cables, and the starter for looseness and corrosion. Then try cranking the engine again.
Did the starter crank the engine?
YES -
Repairing the loose connection corrected the problem. The starting system is OK. Go to Step 13 .
NO -
Based on the following symptoms, take the appropriate action:
  • If the starter will not crank the engine at all, go to Step 8 .
  • If the starter cranks the engine erratically or too slowly, go to Step 10 .
  • If the starter does not disengage from the flywheel ring gear when you release the switch, replace the starter, or remove and disassemble it, and check for the following:
    • -
    Solenoid plunger and switch malfunction
    -
    Dirty drive gear or damaged overrunning clutch
  1. Make sure the transmission is in Neutral, and set the parking brake. Disconnect the starter subharness 1P connector (A) from the main wire harness 1P connector (B). Connect a jumper wire from the battery positive terminal to the starter subharness 1P connector.
Did the starter crank the engine?
YES -
Go to Step 9 .
NO -
Check the BLK/WHT wire between the starter subharness 1P connector and the starter. If the wire is OK, remove the starter, and repair or replace, as necessary.■
  1. Check the following items in the order listed until you find the open circuit:
    • The WHT wire and connectors between the under-dash fuse/relay box and the starter cut relay 2.
    • The RED wire and connectors between the starter cut relay 2 and the main wire harness 1P connector.
  1. While cranking the engine, check the cranking voltage and the current draw.
Is the cranking voltage greater than or equal to 8.5 V and the current draw less than or equal to 380 A?
YES -
Go to Step 11 .
NO -
Replace the starter, or remove and disassemble it, and check for the these problems:■
  • Drag in the starter armature
  • Shorted armature winding
  • Excessive drag in the engine
  1. Check the engine speed while cranking the engine.
Is the engine speed above 100 rpm (min −1 )?
YES -
Go to Step 12 .
NO -
Replace the starter, or remove and disassemble it, and check for the these problems:■
  • Open circuit in the starter armature commutator segments
  • Excessively worn starter brushes
  • Open circuit in the commutator brushes
  • Dirty or damaged helical splines or drive gear
  • Faulty drive gear clutch
  1. Remove the starter, and inspect its drive gear and the flywheel ring gear for damage. Replace any damaged parts.
  1. Select ECM reset to cancel ALL INJECTORS OFF on the HDS.