Inspection Procedure 4: Starting Impossible (starter not operative)




















OPERATION



  • The power source is supplied from the battery to the starter (B-112 terminal No. 1).
  • The battery voltage is applied to the starter relay (terminal No. 4).
  • When the ignition switch-ST signal is input to the engine-ECU (terminal No. 105), the engine-ECU (terminal No. 106) turns ON the power transistor inside the unit, and makes the current flow into the starter relay (terminal No. 2) to turn ON the relay.
  • When the starter relay is turned ON, the current flows into the starter (B-111 terminal No. 1) from the starter relay (terminal No. 3) to drive the starter motor.

COMMENTS ON TROUBLE SYMPTOM



  • The failure could possibly be caused by the malfunction of the starter or starter system circuits.

PROBABLE CAUSES



  • Failed battery
  • Failed ignition switch
  • Failed starter relay
  • Failed starter motor
  • Open/short circuit or harness damage in starter system circuit or loose connector contact.
  • Failed shift lever
  • Failed ETACS-ECU
  • Failed engine-ECU

DIAGNOSIS PROCEDURE

STEP 1. Check battery.

  • Check battery (Refer to GROUP 54A - Battery - On-vehicle Service - Battery Test ).

Q. Is the check result normal?
Go to Step 2.
Replace the battery.

STEP 2. M.U.T.-III data list

  • Item 79: Cranking signal
OK:
    ON (ignition switch: ST)
    OFF (ignition switch: ON)

Q. Is the check result normal?
Go to Step 15.
Go to Step 3.

STEP 3. Connector check: B-09 engine-ECU connector

Q. Is the check result normal?
Go to Step 4.
Repair or replace the connector.

STEP 4. Perform voltage measurement at B-09 engine-ECU connector.

  • Disconnect connector, and measure at harness side.
  • Ignition switch: ST
  • Voltage between terminal No. 105 and earth.
OK: System voltage

Q. Is the check result normal?
Go to Step 10.
Go to Step 5.

STEP 5. Connector check: C-304 and C-315 ETACS-ECU connectors

Q. Are the check results normal?
Go to Step 6.
Repair or replace the connector.

STEP 6. Perform voltage measurement at C-315 ETACS-ECU connector.

  • Disconnect connector, and measure at harness side.
  • Ignition switch: ST
  • Voltage between terminal No. 7 and earth.
OK: System voltage

Q. Is the check result normal?
Go to Step 9.
Go to Step 7.

STEP 7. Connector check: C-212 ignition switch connector

Q. Is the check result normal?
Go to Step 8.
Repair or replace the connector.

STEP 8. Check ignition switch itself.

  • Check ignition switch itself (Refer to GROUP 54A - Ignition Switch - Inspection - Ignition Switch Continuity Check ).

Q. Is the check result normal?

    Check and repair harness between C-212 (terminal No. 5) ignition switch connector and C-315 (terminal No. 7) ETACS-ECU connector.

    • Check power supply line for open/short circuit.
Replace the ignition switch.

STEP 9. Continuity check on C-304 and C-315 ETACS-ECU connectors

  • Disconnect connectors, and measure at ETACS-ECU side.
  • Continuity check between terminal No. 7 (C-315) and No. 15 (C-304)
OK: Continuity

Q. Is the check result normal?

    Check and repair harness between C-304 (terminal No. 15) ETACS-ECU connector and B-09 (terminal No. 105) engine-ECU connector.

    • Check power supply line for open/short circuit.
Replace the ETACS-ECU.

STEP 10. Connector check: C-212 ignition switch connector and C-304 and C-315 ETACS-ECU connectors

Q. Are the check results normal?
Go to Step 11.
Repair or replace the connector.

STEP 11. Continuity check on C-304 and C-315 ETACS-ECU connectors

  • Disconnect connectors, and measure at ETACS-ECU side.
  • Continuity check between terminal No. 7 (C-315) and No. 15 (C-304)
OK: Continuity

Q. Is the check result normal?
Go to Step 12.
Replace the ETACS-ECU.

STEP 12. Check harness between C-212 (terminal No. 5) ignition switch connector and C-315 (terminal No. 7) ETACS-ECU connector.

  • Check power supply line for damage.

Q. Is the check result normal?
Go to Step 13.
Repair the damaged harness wire.

STEP 13. Check harness between C-304 (terminal No. 15) ETACS-ECU connector and B-09 (terminal No. 105) engine-ECU connector.

  • Check power supply line for damage.

Q. Is the check result normal?
Go to Step 14.
Repair the damaged harness wire.

STEP 14. M.U.T.-III data list

  • Item 79: Cranking signal
OK:
    ON (ignition switch: ST)
    OFF (ignition switch: ON)

Q. Is the check result normal?
Intermittent malfunction (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points - How to Cope with Intermittent Malfunctions ).
Replace the engine-ECU.

STEP 15. Connector check: A-27X starter relay connector

Q. Is the check result normal?
Go to Step 16.
Repair or replace the connector.

STEP 16. Check starter relay itself.

  • Check starter relay itself (Refer to GROUP 16 - Starting System - On-vehicle Service - Starter Relay Continuity Check ).

Q. Is the check result normal?
Go to Step 17.
Replace the starter relay.

STEP 17. Perform resistance measurement at A-27X starter relay connector.

  • Remove relay, and measure at relay box side.
  • Resistance between terminal No. 1 and earth.
OK: Continuity (2 Ω or less)

Q. Is the check result normal?
Go to Step 18.

    Check and repair harness between A-27X (terminal No. 1) starter relay connector and body earth.

    • Check earthing line for open circuit and damage.

STEP 18. Perform voltage measurement at A-27X starter relay connector.

  • Remove relay, and measure at relay box side.
  • Transmission: P or N range
  • Ignition switch: ST
  • Voltage between terminal No. 2 and earth.
OK: System voltage

Q. Is the check result normal?
Go to Step 26.
Go to Step 19.

STEP 19. Connector check: C-58 shift lever connector

Q. Is the check result normal?
Go to Step 20.
Repair or replace the connector.

STEP 20. Check harness between C-58 (terminal No. 5, No. 15) shift lever connector and A-27X (terminal No. 2) starter relay connector.

  • Check power supply line for open/short circuit.

Q. Is the check result normal?
Go to Step 21.
Repair the damaged harness wire.

STEP 21. Connector check: B-09 engine-ECU connector

Q. Is the check result normal?
Go to Step 22.
Repair or replace the connector.

STEP 22. Check harness between B-09 (terminal No. 106) engine-ECU connector and C-58 (terminal No. 7) shift lever switch connector.

  • Check power supply line for open/short circuit.

Q. Is the check result normal?
Go to Step 23.
Repair the damaged harness wire.

STEP 23. Connector check: B-08 engine-ECU connector

Q. Is the check result normal?
Go to Step 24.
Repair or replace the connector.

STEP 24. Check harness between B-08 (terminal No. 6) engine-ECU connector and A-27X (terminal No. 2) starter relay connector.
note Before checking harness, check intermediate connector A-70, and repair if necessary.

  • Check output line for short circuit.

Q. Is the check result normal?
Go to Step 25.
Repair the damaged harness wire.

STEP 25. Replace the shift lever.

  • After replacing the shift lever, re-check the trouble symptoms.

Q. Does the trouble symptom persist?
Replace the engine-ECU.
Check end.

STEP 26. Perform voltage measurement at A-27X starter relay connector.

  • Remove relay, and measure at relay box side.
  • Voltage between terminal No. 4 and earth.
OK: System voltage

Q. Is the check result normal?
Go to Step 27.

    Check and repair harness between battery and A-27X (terminal No. 4) starter relay connector.

    • Check power supply line for open/short circuit.

STEP 27. Connector check: B-111 starter connector

Q. Is the check result normal?
Go to Step 28.
Repair or replace the connector.

STEP 28. Perform voltage measurement at B-111 starter connector.

  • Disconnect connector, and measure at harness side.
  • Transmission: P or N range
  • Ignition switch: ST
  • Voltage between terminal No. 1 and earth.
OK: System voltage

Q. Is the check result normal?
Go to Step 34.
Go to Step 29.

STEP 29. Check harness between A-27X (terminal No. 3) starter relay connector and B-111 (terminal No. 1) starter connector.
note Before checking harness, check intermediate connectors A-70 and B-119, and repair if necessary.

  • Check output line for open/short circuit.

Q. Is the check result normal?
Go to Step 30.
Repair the damaged harness wire.

STEP 30. Connector check: C-58 shift lever connector

Q. Is the check result normal?
Go to Step 31.
Repair or replace the connector.

STEP 31. Check harness between C-58 (terminal No. 5, No. 15) shift lever connector and A-27X (terminal No. 2) starter relay connector.

  • Check power supply line for damage.

Q. Is the check result normal?
Go to Step 32.
Repair the damaged harness wire.

STEP 32. Connector check: B-09 engine-ECU connector

Q. Is the check result normal?
Go to Step 33.
Repair or replace the connector.

STEP 33. Check harness between B-09 (terminal No. 106) engine-ECU connector and C-58 (terminal No. 7) shift lever connector.

  • Check power supply line for damage.

Q. Is the check result normal?
Replace the shift lever.
Repair the damaged harness wire.

STEP 34. Check harness between battery and A-27X (terminal No. 4) starter relay connector.

  • Check power supply line for damage.

Q. Is the check result normal?
Go to Step 35.
Repair the damaged harness wire.

STEP 35. Check harness between A-27X (terminal No. 3) starter relay connector and B-111 (terminal No. 1) starter connector.
note Before checking harness, check intermediate connectors A-70 and B-119, and repair if necessary.

  • Check output line for damage.

Q. Is the check result normal?
Go to Step 36.
Repair the damaged harness wire.

STEP 36. Connector check: B-112 starter connector

Q. Is the check result normal?
Go to Step 37.
Repair or replace the connector.

STEP 37. Perform voltage measurement at B-112 starter connector.

  • Disconnect connector, and measure at harness side.
  • Voltage between terminal No. 1 and earth.
OK: System voltage

Q. Is the check result normal?
Go to Step 38.

    Check and repair harness between battery and B-112 (terminal No. 1) starter connector.

    • Check power supply line for open/short circuit.

STEP 38. Check harness between battery and B-112 (terminal No. 1) starter connector.

  • Check power supply line for damage.

Q. Is the check result normal?
Replace the starter.
Repair the damaged harness wire.