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.
Combination meter
Reference Value
VALUES ON THE DIAGNOSIS TOOL
*: DDS (hill descent control)
NOTE:
Some items are not available according to vehicle specification.
TERMINAL LAYOUT
PHYSICAL VALUES
Fail-safe
The combination meter activates the fail-safe control if the CAN
communica ...
Body construction
Body Construction
Outer body side
Outer front pillar reinforcement
Upper inner front pillar
Rear hoodledge reinforcement
Side dash
Inner front pillar reinforcement
Lower front pillar hinge brace
Upper hinge plate
Weld nut
Upper dash
Upper steering membe ...
Unit removal and installationEMBER
REAR SUSPENSION M
Exploded View
Rear suspension member
Suspension member stay
(RH)
Suspension member stay (LH)
Bound bumper
Front
Removal and Installation - FWD
REMOVAL
Remove wheel and tires using power tool. Refer to WT-60, "Exploded
Vie ...