Use a J 39200 to measure the voltage of the battery.

Is the voltage greater than or equal to the specified value?

12 V

Go to Step 5

Go to Step 2

1. Ensure the battery terminals and terminal bolts are free from corrosion.
2. Charge the battery. Refer to Battery Charging .
3. For gasoline engines, remove the fuel pump relay. For diesel engines, disconnect the engine shutoff solenoid.
4. Attempt to crank the engine.

Does the engine crank normally?

--

Go to Step 3

Go to Step 5

1. Install the fuel pump relay if it was previously removed, or connect the engine shutoff solenoid for diesel vehicles.
2. Verify that the charging system is operating correctly. Refer to Charging System Check .

Is the charging system OK?

--

System OK

Go to Step 4

Repair the charging system.

Is the repair complete?

--

System OK

--

1. For gasoline engines, remove the fuel pump relay. For diesel engines, disconnect the engine shutoff solenoid. Do not install the fuel pump relay or connect the engine shutoff solenoid until all cranking tests are completed.
2. Turn the ignition switch to the START position.
3. Use a J 39200 DMM to measure the voltage between the battery terminals while cranking the engine for 15 (fifteen) seconds.

Notice: Never operate the starter motor for more than 30 seconds at a time. Allow it to cool at least two minutes before cranking again. Excessive cranking can cause overheating, which will cause serious damage to the starter motor.

Does the voltage drop below the specified value while the starter is cranking the engine?

9.5 V

Go to Step 6

Go to Step 9

Load test the battery. Refer to Battery Not Operating Properly .

Is the battery OK?

--

Go to Step 8

Go to Step 7

Replace the battery. Refer to Battery Replacement .

Is the repair complete?

--

System OK

--

Replace the starter motor. Refer to Starter Motor Replacement .

Is the repair complete?

--

System OK

--

Use a J 39200 DMM to measure the voltage between the battery negative (-) terminal and the engine block while cranking the engine.

Notice: Never operate the starter motor for more than 30 seconds at a time. Allow it to cool at least two minutes before cranking again. Excessive cranking can cause overheating, which will cause serious damage to the starter motor.

Is the voltage greater than the specified value?

0.5 V

Go to Step 10

Go to Step 13

1. Inspect the battery and negative (-) battery cable to determine if there is a high-resistance connection at either end.
2. Ensure that there is a clean connection between the starter mounting surface and the engine block.

Was a high-resistance connection found?

--

Go to Step 11

Go to Step 12

Repair the high-resistance connection.

is the repair complete?

--

System OK

--

Replace the negative (-) battery cable. Refer to Battery Cable Replacement .

Is the repair complete?

--

System OK

--

1. Inspect the starter to determine if there is a high-resistance connection at the starter B terminal.
2. If the battery positive (+) terminal was not previously inspected, examine the positive (+) terminal and terminal bolt for corrosion which would indicate a high-resistance connection.

Was there a high-resistance connection found?

--

Go to Step 14

Go to Step 15

1. Repair the high-resistance connection.
2. Install the fuel pump relay if it was previously removed, or connect the engine shutoff solenoid on diesel vehicles.

Is the repair complete?

--

System OK

--

Replace the positive (+) battery cable. Refer to Battery Cable Replacement .

Is the repair complete?

--

System OK

--