TROUBLE SHOOTING
Note. To ensure a complete and thorough diagnosis, the battery, starter and generator test segments must be done as a set from start to finish. For 2002 models, see GENERATORS & REGULATORS - FRONTIER article in ELECTRICAL. For 2003 models, see GENERATORS & REGULATORS - FRONTIER article in ELECTRICAL. For 2004 models, see GENERATORS & REGULATORS - FRONTIER article in ELECTRICAL.
TROUBLE DIAGNOSES WITH BATTERY/STARTING/CHARGING SYSTEM TESTER
Note. To ensure a complete and thorough diagnosis, the battery, starter and generator test segments must be done as a set from start to finish.
Note. If the starter performs normally but the engine does not start, see appropriate TROUBLE SHOOTING - NO CODES article in ENGINE PERFORMANCE. For intermittent "NO CRANK" or "NO STARTER OPERATION" incidents, see DIAGNOSTIC PROCEDURE 2, CHECK "S" TERMINAL CIRCUIT under SYSTEM TESTS.
- Turn off all loads on the vehicle electrical system.
- Perform battery test with Battery/Starting/Charging system tester. (Scheme 1)
- Press "ENTER" to begin the starting system test.
- Start the engine.
- Diagnosis result is displayed on the tester. See «DIAGNOSTIC RESULT ITEM CHART»(ref-168311-S13925215512004110500000).
Scheme 1
DIAGNOSTIC RESULT ITEM CHART
| Diagnostic Item | Service Procedure |
|---|---|
| Cranking Voltage Normal | See WORK FLOW |
| Cranking Voltage Low | See WORK FLOW |
| Charge Battery | Perform The Slow Battery Charging Procedure (Initial Rate Of Charge Is 10-amps For 12 Hours). Perform Battery Test Again With Battery/Starting/Charging System Tester, See TROUBLE DIAGNOSES WITH BATTERY/STARTING/CHARGING SYSTEM TESTER . |
| Replace Battery | Before Replacing Battery, Clean The Battery Cable Clamps & Battery Posts. Perform Battery Test Again With Battery/Starting/Charging System Tester, See TROUBLE DIAGNOSES WITH BATTERY/STARTING/CHARGING SYSTEM TESTER . If Second Test Result Is "Replace Battery", Then Do So. Perform Battery Test Again To Confirm Repair. |
DIAGNOSTIC RESULT ITEM CHART
STARTER NO-LOAD TEST
Connect starter in series with a 12-volt battery and bench tester (with 1000-amp ammeter). Operate starter. If amperage exceeds maximum specification or if RPM is less than minimum specification, repair or replace starter. See STARTER NO-LOAD TEST SPECIFICATIONS table.
| Application | Max. Amps | Min. RPM |
|---|---|---|
| Reduction | 90 | 2500 |
STARTER NO-LOAD TEST SPECIFICATIONS
DIAGNOSTIC PROCEDURE 1 (CHECK "B" TERMINAL CIRCUIT)
- Check power supply for starter motor "B" terminal by performing the following procedure. Remove the fuel pump fuse. Crank or start the engine (where possible) until the fuel pressure is released.
- Turn the ignition switch OFF. Check that the starter motor terminal "B" [E210, (Black/Yellow wire) for KA24DE models or E203, (Black/Blue wire) for VG33E and VG33ER models] connection is clean and tight.
- Check voltage between starter motor terminal "B" [E210, (Black/Yellow wire) for KA24DE models or E203, (Black/Blue wire) for VG33E and VG33ER models] and ground using a digital circuit tester. (Scheme 2) If battery voltage exists, go to next step. If battery voltage does not exist, check harness between the battery and the starter motor for open circuit.
- Check voltage between starter motor terminal "B" [E210, (Black/Yellow wire) for KA24DE models or E203, (Black/Blue wire) for VG33E and VG33ER models] and battery positive terminal using a digital circuit tester with ignition switch in START position. (Scheme 3) Voltage should be less than.5 volts. If voltage is as specified, go to next step. If voltage is not as specified, check harness between the battery and the starter motor for poor continuity.
- Check voltage between starter motor case and battery negative terminal using a digital circuit tester. (Scheme 4) Voltage should be less than.2 volts. If voltage is as specified, starter motor "B" terminal circuit is okay. Further inspection may be necessary. See «WORK FLOW»(ref-168311-S38740567582004110500000) under TROUBLE SHOOTING. If voltage is not as specified, check the starter motor case and ground for poor continuity.
Scheme 2
Scheme 3
Scheme 4
DIAGNOSTIC PROCEDURE 2 (CHECKING "S" TERMINAL CIRCUIT)
- Remove the fuel pump fuse. Crank or start the engine (where possible) until the fuel pressure is released. Turn the ignition OFF.
- Disconnect starter motor terminal "S" [E209 (Black/Red) for KA24DE models or E202 (Black/Red) for VG33E and VG33ER models] connector.
- Check voltage between starter motor terminal "S" [E209, (Black/Red) for KA24DE models or E202, (Black/Red) for VG33E and VG33ER models] and ground using a digital circuit tester. (Scheme 5) If battery voltage is present, go to next step. If battery voltage is not present, check the following: 40-amp fusible link (letter "E", located in fuse and fusible link box). Clutch Interlock relay (with M/T). Park/Neutral Position relay (with A/T). Harness for open or short.
- Connect starter motor terminal "S" [E209, (Black/Red) for KA24DE models or E202, (Black/Red) for VG33E and VG33ER models] connector.
- Check voltage between starter motor terminal "S" [E209, (Black/Red) for KA24DE models or E202, (Black/Red) for VG33E and VG33ER models] and battery positive terminal using a digital tester. (Scheme 6) If voltage is less than one volt, starter motor "S" terminal circuit is okay. Further inspection may be necessary. See «WORK FLOW»(ref-168311-S38740567582004110500000) under TROUBLE SHOOTING. If voltage is more than one volt, check harness between the battery and the starter motor "S" terminal for poor continuity.
