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Initial Inspection and Diagnostic Overview




The battery, starting, and charging systems operate in conjunction with one another, and must be tested as a complete system. For correct starting/charging system operation, all of the components involved in these 3 systems must perform within specifications.





INSPECTION

For complete starter wiring circuit diagrams, refer to 8, Wiring Diagrams. Before removing any unit from starting system for repair or diagnosis, perform the following inspections:

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO 8, PASSIVE RESTRAINT SYSTEMS, BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

- Battery - Visually inspect battery for indications of physical damage and loose or corroded cable connections. Determine state-of-charge and cranking capacity of battery. Charge or replace battery if required. Refer to Battery in 8, Battery.NOTE: If equipped with diesel engine, a dual battery system may be used, and both batteries must be inspected.
- Ignition Switch - Visually inspect ignition switch for indications of physical damage and loose or corroded wire harness connections. Refer to Ignition Switch and Key Lock Cylinder.
- Clutch Pedal Position Switch - If equipped with manual transmission, visually inspect clutch pedal position switch for indications of physical damage and loose or corroded wire harness connections. Refer to Clutch Pedal Position Switch in 6, Clutch.
- Park/Neutral Position Switch - If equipped with automatic transmission, visually inspect park/neutral position switch for indications of physical damage and loose or corroded wire harness connections. Refer to Park/Neutral Position Switch in 21, Transmission.
- Starter Relay - Visually inspect starter relay for indications of physical damage and loose or corroded wire harness connections.
- Starter Motor - Visually inspect starter motor for indications of physical damage and loose or corroded wire harness connections.
- Starter Solenoid - Visually inspect starter solenoid for indications of physical damage and loose or corroded wire harness connections.
- Wiring - Visually inspect wire harnesses for damage. Repair or replace any faulty wiring, as required.

COLD CRANKING TEST




For complete starter wiring circuit diagrams. The battery must be fully-charged and load-tested before proceeding. Refer to Battery in Battery.

1. Connect volt-ampere tester to battery terminals (1), (2) and (3). See instructions provided by manufacturer of volt-ampere tester being used. NOTE: Certain diesel equipped models use dual batteries. If equipped with dual battery system, tester should be connected to battery on left side of vehicle only. Also, tester current reading must be taken from positive battery cable lead that connects to starter motor.

2. Fully engage parking brake.

3. If equipped with manual transmission, place gearshift selector lever in Neutral position and block clutch pedal in fully depressed position. If equipped with automatic transmission, place gearshift selector lever in Park position.

4. Verify that all lamps and accessories are turned off.

5. To prevent a gasoline engine from starting, remove Automatic ShutDown (ASD) relay. To prevent a diesel engine from starting, remove Fuel Pump Relay. These relays are located in Power Distribution Center (PDC). Refer to label on PDC cover for relay location.

WARNING: IF EQUIPPED WITH DIESEL ENGINE, ATTEMPT TO START ENGINE A FEW TIMES BEFORE PROCEEDING WITH FOLLOWING STEP:

6. Rotate and hold ignition switch in Start position. Note cranking voltage and current (amperage) draw readings shown on volt-ampere tester.

a. If voltage reads below 9.6 volts, refer to Starter Motor in Diagnosis and Testing. If starter motor is OK, refer to Engine Diagnosis in 9, Engine for further testing of engine. If starter motor is not OK, replace faulty starter motor.
b. If voltage reads above 9.6 volts and current (amperage) draw reads below specifications, refer to Feed Circuit Test.
c. If voltage reads12.5 volts or greater and starter motor does not turn, refer to Control Circuit Testing.
d. If voltage reads 12.5 volts or greater and starter motor turns very slowly, refer to Feed Circuit Test.

NOTE: A cold engine will increase starter current (amperage) draw reading, and reduce battery voltage reading.



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