Starter Circuit Troubleshooting

NOTE:

Air temperature must be between 15° and 38°C (59° and 100°F) during this procedure.
After this inspeciton, you must select engine control module (ECM)/powertrain control module (PCM) reset using the Honda PGM Tester or the Honda Diagnostic System (HDS) otherwise ECM/PCM continues to stop the fuel injectors.
The battery must be in good condition and fully charged.

Recommended Procedure:

Use a starter system tester.
Connect and operate the equipment in accordance with the manufacturer's instructions.

Alternate Procedure

1.	Hook up the following equipment: Ammeter, 0-400A Voltmeter, 0-20 V (accurate within 0.1 volt)

2.	Connect the Honda PGM Tester or the HDS to the data link connector (DLC).

3.	Select PGM-FI, select inspection, then select the ALL INJECTORS OFF function on the Honda PGM Tester or the HDS.

4.	With the shift lever in [N] or [P] (A/T), turn the ignition switch to start (III). Did the starter crank the engine normally? YES - The starting system is OK. Select ECM/PCM reset to cancel the ALL INJECTORS OFF function, then perform the ECM/PCM idle learn procedure.n NO - Go to 5.

Check the battery condition. Check electrical connections at the battery, the negative battery cable to body, the engine ground cables and the starter for looseness and corrosion. Then try starting the engine again.

Did the starter crank the engine?

YES - Repairing the loose connection fixed the problem. The starting system is OK.n

NO - If the starter will not crank the engine at all, go to 6. If it cranks the engine erratically or too slowly, go to 9. If it won't disengage from the flywheel or torque converter ring gear when you release the key, check for the following until you find the cause.

Solenoid plunger and switch malfunction
Dirty drive gear or damaged overrunning clutch

Make sure the transmission is in neutral, then disconnect the BLK/WHT wire (A) from the starter solenoid (B). Connect a jumper wire from the battery positive terminal to the solenoid terminal.

MITSUBISHI:

MITSUBA:

DENSO:

Did the starter crank the engine?

YES - Go to 8.

NO - Remove the starter, and repair or replace as necessary.n

Check the following items in the order listed until you find the open circuit.

Check the BLK/WHT wire and connectors between the under-dash fuse/relay box and the ignition switch, and between the under-dash fuse/relay box and the starter.
Check the ignition switch.
Check the transmission range switch and connector (A/T).
Check the starter cut relay.

Check the cranking voltage and current draw.

Is cranking voltage greater than or equal to 8.0 V (DENSO 1.0 kW model)/8.7 V(DENSO 1.1 kW model)/8.5 V (MITSUBA)/7.7 V (MITSUBISHI),and current draw less than or equal to 200A (DENSO 1.0 kW model)/230A (DENSO 1.1 kW model)/350A (MITSUBA 1.2kW model)/380A (MITSUBA 1.6 kW model)/400A(MITSUBISHI)?

YES - Go to 9.

NO - Replace the starter, or remove and disassemble it, and check for the following until you find the cause.n

Starter armature dragging
Shorted armature winding
Excessive drag in engine

Check the engine speed while cranking the engine.

Is the engine speed above 100 rpm (min^-1)?

YES - Go to 10.

NO - Replace the starter, or remove and disassemble it, and check for the following until you find the cause.n

Open circuit in starter armature commutator segments
Excessively worn starter brushes
Open circuit in commutator brushes
Dirty or damaged helical splines or drive gear
Faulty drive gear clutch

10.	Select ECM/PCM reset to step the ALL INJECTORS OFF function on the Honda PGM Tester or the HDS.

11.	Perform the ECM/PCM idle learn procedure.

12.	Remove the starter, and inspect its drive gear and the flywheel or torque converter ring gear for damage. Replace any damaged parts.n