Was the Starting System Check performed?

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Go to Step 2

Go to Starting System Check .

1. Disconnect the engine shutoff solenoid connector (diesel), or the ignition coil connector (gasoline).
2. Connect a J 39200 from the battery positive (+) terminal to the battery negative (-) terminal.
3. Turn the ignition switch to the START position.
4. Crank the engine for 15 seconds.
5. Measure the voltage at the end of cranking.
6. Diesel engine vehicles have 2 (two) batteries, both of the batteries must be tested.

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 measure less than 9.6 volts?

9.6 V

Go to Step 3

Go to Step 4

1. Do the battery load test(s). Refer to Battery Not Operating Properly .
2. If the battery passes the load test, repair the starter motor. Refer to Starter Motor Overhaul .

Is the repair complete?

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System OK

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1. Ensure that the battery terminals and the battery terminal bolts are tight and are not corroded.
2. Connect a J 39200 from the negative (-) battery terminal to the engine block.
3. Turn the ignition switch to the START position.
4. Observe the voltage while cranking the engine.
5. Diesel engine vehicles have 2 (two) batteries, both of the batteries must be tested.

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 measure more than 0.5 volts?

0.5 V

Go to Step 5

Go to Step 6

1. Inspect the battery cable for a high resistance connection at the engine block.
2. If the connection is OK, replace the negative (-) battery cable. Refer to Battery Cable Replacement .

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

Is the repair complete?

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System OK

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1. Connect a J 39200 from the positive (+) battery terminal to starter solenoid terminal B.
2. Turn the ignition switch to the START position.
3. Observe the voltage while cranking.
4. Diesel engine vehicles have 2 (two) batteries, both of the batteries must be tested.

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 measure more than 0.5 volts?

0.5 V

Go to Step 7

Go to Step 8

Inspect the battery cable for a high resistance connection at the starter solenoid B terminal. If the connection is OK, replace the positive (+) battery cable. Refer to Battery Cable Replacement .

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

Is the repair complete?

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System OK

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Replace the starter motor.

Refer to Starter Motor Overhaul .

Is the repair complete?

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System OK

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