Pinpoint Test A: P0616, P0617. THE ENGINE DOES NOT CRANK
| WARNING | Beware of rotating parts. Failure to follow these instructions may result in personal injury. |
Note. Make sure the vehicle is in NEUTRAL or PARK for automatic vehicles, NEUTRAL for manual vehicles. Make sure the clutch pedal is fully depressed for Federal manual vehicles.
Note. Check that the inertia switch has not tripped.
Pinpoint Test A
A1
CHECK THE BATTERY
- Check the battery. For additional information. Refer to «Charging System - General Information»(ref-311872) article.
Is the battery OK?
YES Go to step 2 . → A2
NO INSTALL a new battery. Refer to «Battery, Mounting and Cables»(ref-311867) article. CLEAR the DTC. TEST the system for normal operation.
A2
CHECK THE STARTER RELAY
- Turn the ignition switch to the CRANK position.
Does the starter relay make an audible click?
A3
CHECK FOR CRANK SUPPLY VOLTAGE TO STARTER RELAY
- Remove the starter relay.
- Turn the ignition switch to the CRANK position, and hold.
- Measure the voltage between terminal 1 of the relay base and GROUND.
Is the voltage greater than 10 volts?
A4
CHECK FOR CRANK SUPPLY VOLTAGE TO ECM
- Disconnect the ECM electrical connector EN16.
- Turn the ignition switch to the CRANK position, and hold.
- Measure the voltage between EN16 pin 6 (Y) and GROUND.
Is the voltage greater than 10 volts?
A5
CHECK FUSE 28 IN THE ENGINE COMPARTMENT FUSE BOX.
- Check the fuse.
Is the fuse OK?
YES CHECK and repair the circuit including the power distribution fuse box, the starter relay base pin 1 and EN16 pin 6. For additional information, refer to appropriate SYSTEM WIRING DIAGRAMS. CLEAR the DTC. TEST the system for normal operation. This circuit includes the ignition switch
NO INSTALL a new fuse. TEST the circuit for cause of fuse failure. Go to step 6 . → 6
A6
CHECK ECM GROUND SIGNAL TO STARTER RELAY
- Connect the ECM electrical connector EN16.
- Turn the ignition switch to the CRANK position.
- Measure the resistance between terminal 2 of the relay base and GROUND.
Is the resistance less than 5 ohms?
YES INSTALL a new starter relay. For additional information, refer to appropriate SYSTEM WIRING DIAGRAMS. CLEAR the DTC. TEST the system for normal operation.
NO Go to step 7 . → 7
A7
CHECK ECM GROUND SIGNAL CIRCUIT FOR CONTINUITY
- Disconnect the ECM electrical connector EN16.
- Measure the resistance between terminal 2 of the starter relay base and EN16 pin 41 (GO).
Is the resistance less than 5 ohms?
YES Federal spec. manual transmission vehicles. Go to step 13 . → A13
NO REPAIR the circuit between the starter relay and the ECM. For additional information, refer to appropriate SYSTEM WIRING DIAGRAMS. CLEAR the DTC. TEST the system for normal operation.
A8
CHECK FOR IGNITION VOLTAGE TO TRANSMISSION RANGE SENSOR
- Turn the ignition switch to the ON position.
- Measure the voltage between JB156 pin 10 and GROUND.
Is the voltage greater than 10 volts?
A9
CHECK FUSE 92 IN THE CENTRAL JUNCTION FUSE BOX
- Check the fuse.
Is the fuse OK?
YES Repair the circuit between the power distribution fuse box and the transmission range switch. For additional information, refer to appropriate SYSTEM WIRING DIAGRAMS. CLEAR the DTC. TEST the system for normal operation. This circuit includes the central junction fuse box, inertia switch, ignition switch, ignition relay, and power distribution fuse box (Fuse 28, See «Visual Inspection Chart»(ref-311893-S27200160292009040700000) )
NO INSTALL a new fuse. TEST the circuit for cause of fuse failure. CLEAR the DTC. TEST the system for normal operation.
A10
CHECK THE CIRCUIT BETWEEN TRANSMISSION RANGE SENSOR AND ECM FOR CONTINUITY
- Measure the resistance between EN16 pin 31 (B) and JB156 pin 6 (B).
Is the resistance less than 5 ohms?
YES Go to step 11 . → A11
NO REPAIR the circuit between EN16 pin 31 (B) and JB156 pin 6 (B). For additional information, refer to appropriate SYSTEM WIRING DIAGRAMS. CLEAR the DTC. TEST the system for normal operation.
A11
CHECK THE TRANSMISSION RANGE SENSOR
- Disconnect the transmission range sensor electrical connector JB156.
- Select PARK or NEUTRAL.
- Measure the resistance between pins 6 and 10 of the TR sensor.
Is the resistance less than 5 ohms?
YES INSTALL a new ECM. Refer to «Electronic Engine Controls - Adding A Trailing A»(ref-311888) or «Electronic Engine Controls - Adding A Trailing A»(ref-311889) article. Before replacing a ECM, contact Dealer technical support.
NO INSTALL a new transmission range sensor. Refer to «Automatic Transmission/Transaxle»(ref-311854) article. CLEAR the DTC. TEST the system for normal operation.
A12
CHECK FOR IGNITION VOLTAGE TO ECM
- Turn the ignition switch to the ON position.
- Measure the voltage between EN16 pin 31 (B) and GROUND.
Is the voltage greater than 10 volts?
YES INSTALL a new ECM. Refer to «Electronic Engine Controls - Adding A Trailing A»(ref-311888) or «Electronic Engine Controls - Adding A Trailing A»(ref-311889) article. Before replacing a ECM, contact Dealer technical support.
NO REPAIR the circuit between the ECM and the power distribution fuse box. For additional information, refer to appropriate SYSTEM WIRING DIAGRAMS. CLEAR the DTC. TEST the system for normal operation. This circuit includes the central junction fuse box, inertia switch, ignition switch, ignition relay, and power distribution fuse box (Fuse 28, See «Visual Inspection Chart»(ref-311893-S27200160292009040700000) )
A13
CHECK FOR IGNITION VOLTAGE TO CLUTCH SWITCH; MANUAL TRANSMISSION (USA ONLY)
- Turn the ignition switch to the ON position.
- Measure the voltage between the clutch switch electrical connector PA5 pin 1 (B) and GROUND.
Is the voltage greater than 10 volts?
YES Go to step 15 . → A15
NO Repair the circuit between the power distribution fuse box and the clutch switch. For additional information, refer to appropriate SYSTEM WIRING DIAGRAMS. CLEAR the DTC. TEST the system for normal operation. This circuit includes the central junction fuse box, inertia switch, ignition switch, and power distribution fuse box (Fuse 28, See «Visual Inspection Chart»(ref-311893-S27200160292009040700000) )
A14
CHECK THE CLUTCH SWITCH CIRCUIT FOR CONTINUITY; MANUAL TRANSMISSION (USA ONLY).
- Disconnect the clutch switch electrical connector PA5.
- Disconnect the ECM electrical connector EN16.
- Measure the resistance between PA5 pin 2 (W) and EN16 pin 31 (B).
Is the resistance less than 5 ohms?
YES Go to step 15 . → A15
NO REPAIR the circuit between PA5 pin 2 (W) and EN16 pin 31 (B). For additional information, refer to appropriate SYSTEM WIRING DIAGRAMS. CLEAR the DTC. TEST the system for normal operation.
A15
CHECK THE CLUTCH SWITCH; MANUAL TRANSMISSION (USA ONLY).
- Measure the resistance between PA5 pins 1 and 2.
- Operate the clutch pedal while observing the ohmmeter reading.
Does the resistance switch between 0 ohms and 10,000 ohms as the pedal is operated?
YES INSTALL a new ECM. Refer to «Electronic Engine Controls - Adding A Trailing A»(ref-311888) or «Electronic Engine Controls - Adding A Trailing A»(ref-311889) article. Before replacing a ECM, contact Dealer technical support.
NO INSTALL a new clutch switch. CLEAR the DTC. TEST the system for normal operation.
A16
CHECK THE STARTER SOLENOID INPUT
- NOTE: The starter motor will disengage once a start is detected by the ECM.
- Turn the ignition switch to the CRANK position.
- Measure the voltage between starter motor connector ST3 and GROUND.
Is the voltage greater than 10 volts?
A17
CHECK THE STARTER SOLENOID INPUT CIRCUIT FOR CONTINUITY
- REMOVE the starter relay.
- Disconnect starter motor connector ST3
- Measure the resistance between ST3 and pin 5 of the starter relay base.
Is the resistance less than 5 ohms?
YES Go to step 18 . → A18
NO REPAIR the circuit between ST3 and pin 5 of the starter relay base. For additional information, refer to appropriate SYSTEM WIRING DIAGRAMS. CLEAR the DTC. TEST the system for normal operation.
A18
CHECK THE STARTER RELAY BASE PIN 3 FOR PERMANENT SUPPLY
- Measure the voltage between the starter relay base pin 3 and GROUND.
Is the voltage greater than 10 volts?
A19
CHECK FUSE 29 OF THE POWER DISTRIBUTION FUSE BOX
- Check the fuse.
Is the fuse OK?
YES REPAIR the circuit between the starter relay base pin 3 and the battery. For additional information, refer to appropriate SYSTEM WIRING DIAGRAMS. CLEAR the DTC. TEST the system for normal operation.
NO INSTALL a new fuse. Check the circuit for cause of fuse failure. CLEAR the DTC. TEST the system for normal operation.
A20
CHECK THE STARTER FOR BATTERY VOLTAGE
- Measure the voltage between the starter connector ST2 and GROUND.
Is the voltage greater than 10 volts?
YES Go to step 21 . → A21
NO REPAIR the starter motor permanent live supply circuit. For additional information, refer to appropriate SYSTEM WIRING DIAGRAMS. CLEAR the DTC. TEST the system for normal operation.
A21
CHECK THE STARTER GROUND
- Measure the resistance between starter outer casing and GROUND.
Is the resistance less than 2 Ohms?
YES INSTALL a new starter motor. See «Starting System»(ref-311893-S41529805962009040700000) . CLEAR the DTC. TEST the system for normal operation.
NO REPAIR starter GROUND strap or connections. For additional information, refer to appropriate SYSTEM WIRING DIAGRAMS. CLEAR the DTC. TEST the system for normal operation.
Pinpoint Test B: THE ENGINE CRANKS SLOWLY
Pinpoint Test B
B1
CHECK FOR VOLTAGE DROP
- WARNING: Beware of rotating parts. Failure to follow these instructions may result in personal injury.
- NOTE: The starter motor will disengage once a start is detected by the ECM.
- NOTE: Check battery condition before commencing this test. Refer to «Pinpoint Test A»(ref-311893-S13066701512009040700000) .
- Turn the ignition switch to the CRANK position, and hold.
- Measure the voltage between the starter motor permanent voltage supply terminal and the positive battery terminal while cranking.
Is the voltage less than 0. 5 volts?
YES Turn the ignition switch to the OFF position. Go to step 2 . → B2
NO CLEAN and TIGHTEN all positive battery cable connections. TEST the system for normal operation. If the concern persists, INSTALL a new positive battery cable. Refer to «Battery, Mounting and Cables»(ref-311867) article.
B2
CHECK FOR GROUND CONNECTION VOLTAGE DROP
- Turn the ignition switch to the CRANK position, and hold.
- Measure the voltage between the starter motor case and the battery negative terminal.
Is the voltage less than 0. 5 volts?
YES INSTALL a new starter motor. See «Starting System»(ref-311893-S41529805962009040700000) . TEST the system for normal operation.
NO CLEAN and TIGHTEN all negative battery cable connections, starter motor mounting and starter motor GROUND cable. TEST the system for normal operation. If the concern persists, INSTALL a new negative battery cable. Refer to «Battery, Mounting and Cables»(ref-311867) article.
Scheme 3
Scheme 4
Scheme 5
Scheme 6
- Disconnect the battery. Refer to «Battery Disconnect»(ref-311867-S05805567962009040700000) article.
- Remove the air deflector. Refer to «Air Deflector - 2. 0L Diesel»(ref-311846-S26564309702009040700000) article.
- Disconnect the vacuum pipes from the vacuum solenoid valves and the vacuum reservoir.
- Disconnect the vacuum solenoid valves electrical connectors.
- Detach the wiring harness from the vacuum solenoids and vacuum reservoir mount bracket.
- Remove the vacuum solenoids and vacuum reservoir mount bracket assembly.
- Detach the wiring harness retaining clips from the wiring harness support bracket.
- Remove the wiring harness support bracket.
- Detach the starter motor.
- Position the starter motor to provide access to the starter motor cables.
- Remove the starter motor solenoid cover and electrical connector retaining nut.
- Remove the starter motor. Remove the starter motor electrical connector retaining nut.