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For 1990-2009 cars only

Starter Solenoid Clicks, Engine Does Not Crank Gasoline

Step

Action

Value(s)

Yes

No

¹This vehicle is equipped with dual batteries. Test accordingly.

1

  1. Disconnect the gray connector at the ignition coil.
  2. Connect a J 39200 to the outboard battery positive and negative terminals.
  3. Turn the ignition switch to the START position for 15 seconds.
  4. Observe the voltmeter indication.
  5. Turn the ignition switch to the OFF position.

Does the voltage measure greater than the specified value?

9.6 V

Go to Step 2

Go to Step 3

2

  1. Connect a J 39200 to the inboard battery positive and negative terminals.
  2. Turn the ignition switch to the START position for 15 seconds.
  3. Observe the voltmeter indication.
  4. Turn the ignition switch to the OFF position.

Does the voltage measure less than the specified value?

9.6 V

Go to Step 3

Go to Step 6

3

Perform the battery load test(s).¹ Refer to Charging System Check .

Does the battery pass the load test?

--

Go to Step 4

Go to Step 5

4

  1. Verify engine is not seized.
  2. If engine spins freely, replace the starter motor.

Is the repair complete?

--

System OK

--

5

Replace the failed battery.

Is the repair complete?

--

System OK

--

6

  1. Connect a J 39200 between the outboard battery negative terminal and the engine block.
  2. Turn the ignition switch to the START position.
  3. Observe the voltage.

Does the voltage measure greater than the specified value?

0.5 V

Go to Step 7

Go to Step 8

7

Repair the high resistance in negative cable CKT 50 (BLK) between the battery and battery ground G400.

Is the repair complete?

--

System OK

--

8

  1. Connect a J 39200 between the inboard battery negative terminal and the engine block.
  2. Turn the ignition switch to the START position.
  3. Observe the voltage.

Does the voltage measure greater than the specified value?

0.5 V

Go to Step 9

Go to Step 10

9

Repair the high resistance in negative cable CKT 50 (BLK) between the battery and battery ground G400.

Is the repair complete?

--

System OK

--

10

  1. Connect a J 39200 between the outboard battery positive terminal and starter solenoid terminal B.
  2. Turn the ignition switch to the START position.
  3. Observe the voltage.

Does the voltage measure greater than the specified value?

0.5 V

Go to Step 11

Go to Step 12

11

Repair the high resistance in positive cable CKT 1 (BLK) between the battery and the starter.

Is the repair complete?

--

System OK

--

12

  1. Connect a J 39200 between the inboard battery positive terminal and starter solenoid terminal B.
  2. Turn the ignition switch to the START position.
  3. Observe the voltage.

Does the voltage measure greater than the specified value?

0.5 V

Go to Step 13

Go to Step 14

13

Repair the high resistance in positive cable CKT 1 (BLK) between the battery and the starter.

Is the repair complete?

--

System OK

--

14

Repair or replace the starter motor.

Is the repair complete?

--

System OK

--

Starter Solenoid Clicks, Engine Does Not Crank Cat Diesel

Starter Solenoid Clicks and the Engine Will Not Crank or Cranks Slowly (Cat® Diesel Engine)

Step

Action

Value(s)

Yes

No

1

  1. Disconnect the harness connector at the fuel shutoff solenoid valve.
  2. Connect a DMM J 39200 to the outboard battery positive and negative terminals.
  3. Place the ignition switch in the START position for 15 seconds.
  4. Observe the voltage reading on the J 39200 .
  5. Place the ignition switch in the OFF position.

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

9.6 V

Go to Step 2

Go to Step 3

2

  1. Connect a DMM J 39200 to the inboard battery positive and negative terminals.
  2. Place the ignition switch in the START position for 15 seconds.
  3. Observe the voltage reading on the J 39200 .
  4. Place the ignition switch in the OFF position.

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

9.6 V

Go to Step 4

Go to Step 3

3

Perform the Battery Load Test(s). Refer to Charging System Check . This vehicle is equipped with dual batteries and will need to be tested accordingly.

Does the battery pass the load test?

--

Go to Step 8

Go to Step 9

4

  1. Connect a DMM J 39200 between the outboard battery negative terminal and the engine block.
  2. Place the ignition switch in the START position.
  3. Observe the voltage reading on the J 39200 .

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

0.5 V

Go to Step 10

Go to Step 5

5

  1. Connect a DMM J 39200 between the inboard battery negative terminal and the engine block.
  2. Place the ignition switch in the START position.
  3. Observe the voltage reading on the J 39200 .

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

0.5 V

Go to Step 10

Go to Step 6

6

  1. Connect a DMM J 39200 between the outboard battery positive terminal and starter solenoid terminal B.
  2. Place the ignition switch in the START position.
  3. Observe the voltage reading on the J 39200 .

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

0.5 V

Go to Step 11

Go to Step 7

7

  1. Connect a DMM J 39200 between the outboard battery positive terminal and starter solenoid terminal B.
  2. Place the ignition switch in the START position.
  3. Observe the voltage reading on the J 39200 .

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

0.5 V

Go to Step 11

Go to Step 12

8

Replace the starter motor.

Is the repair complete?

--

System OK

--

9

Replace the failed battery.

Is the repair complete?

--

System OK

--

10

Locate and repair the high resistance in the CKT 50 (BLK) negative cable between the battery and the battery ground.

Is the repair complete?

--

System OK

--

11

Locate and repair the high resistance in the CKT 1 (BLK) positive cable between the battery and the starter.

Is the repair complete?

--

System OK

--

12

Repair or replace the starter motor.

Is the repair complete?

--

System OK

--