Troubleshooting Guide

[sr19]

TROUBLESHOOTING GUIDE: CHECK THE BASICS FIRST!!


Check BATTERY for SECURITY.

Check BATTERY GROUND CABLE & NEG TERMINAL for Quality, Cleanliness & Security @ Battery.

Check BATTERY GROUND CABLE for Quality, Cleanliness & Security @ Engine Mount/Transmission.

Check BATTERY GROUND CABLE for Quality, Cleanliness & Security @ Fender.

Check U/H FUSE BOX GROUND CABLE for Quality, Cleanliness & Security @ RH Side of Engine Compartment.

Check BATTERY POSITIVE CABLE & POS TERMINAL for Quality, Cleanliness & Security @ Battery.

Check BATTERY POSITIVE CABLE for Quality, Cleanliness & Security @ Starter Motor Solenoid.

Check Starter Solenoid Wire for Quality, Cleanliness & Security @ STARTER MOTOR.


Check These FUSES in U/H FUSE BOX:

Fuse #15 - 80 Amp - Batt+ 12V.
Fuse #24 - 7.5 Amp - ECU/Radio/Clock Back Up
Fuse #28 - 10 Amp - EFI Main Relay Switching
Fuse #19 - 50 Amp - Ignition Source

Check These FUSES in UNDER DASH FUSE BOX:

Fuse#2 - 15 Amp - EFI Main Relay/TCU/EMCU/Fan Timer/Charge Light
Fuse #9 - 7.5 Amp - Starting Circuit

BATTERY VOLTAGE TEST.

Ignition OFF
Remove NEG Battery Cable, then Remove POS Battery Cable.
Select VOLTS
Connect RED MM Lead to BATTERY POSITIVE
Connect BLACK MM Lead to BATTERY NEGATIVE.
VOLTAGE => 12.7 Volts - OK
VOLTAGE 3.0 Volts. Check Wiring Connections, Check Battery, Check Ignition Switch, Check Starter Motor, Check Starter Circuitry.

ALTERNATOR OUTPUT CHECK.

Extremely Important: DO NOT DISCONNECT BATTERY CABLES WHILE ENGINE IS RUNNING.

Check ALL ALTERNATOR Connections @ ALTERNATOR and BATTERY for Quality, Cleanliness & Security.
Check ALTERNATOR Drive Belt Quality & Tension.
Connect RED MM Lead to Battery POS.
Connect BLACK MM Lead to Battery GROUND.
Make Sure Battery is Fully Charged.
Start engine.
Operate engine at 1500-2000 RPM

Check Alternator Output Voltage.

If voltage is > 15.1 Volts, Voltage Regulator is overcharging and may be faulty or Battery may have Low Voltage and Volt Reg is Overcompensating. If Battery Voltage Is Low refer back to BATTERY TESTING. If Battery Voltage is OK. Replace the Alternator.
If voltage is less than 13.9 Volts, Voltage regulator is not charging.
Apply Load (Lights, Acc, Radio Etc) until voltage is between 12.0 and 13.5 volts. Check amperage - should be => 30 Amps. If amperage is less than 30 Amps, Replace alternator.

TESTING ALTERNATOR WIRING.

With engine at N.O.T, stop engine, unplug alternator harness, turn key to ON position WITHOUT engine running.

1. Check for BATTERY VOLTAGE between the BLACK/YELLOW wire and GROUND.

If no voltage is present check dash fuse No. 2 or inspect for an open in the BLACK/YELLOW wire.
Charge Warning Light should not be on. If "Charge Warning Light" is ON, check for SHORT to GROUND in WHITE/BLUE wire, check for Shorted Integrated Control Unit (ICU) or Shorted ABS Control Unit (if the vehicle is equipped with these items.)

2. Connect jumper wire between the WHITE/BLUE wire and GROUND.

If "Charge Light" comes on, circuit is GOOD.
If "Charge Light" does not come on, then check for a BLOWN BULB, OPEN circuit in the WHITE/BLUE wire, open circuit in the BLACK/YELLOW wire between the warning light and the dash fuse box or between dash fuse box and ignition switch.

3. Check for battery voltage between WHITE/GREEN wire and GROUND.

If VOLTAGE is present, circuit is GOOD.
If VOLTAGE is NOT present, check for OPEN in WHITE/GREEN wire, faulty ECU or faulty Electric Load Detector (ELD).

4. Turn ignition switch OFF and Reconnect Alternator Harness and check Green Plug For Security in Alternator.

Check ECU Ground @ Thermo Housing for Quality, Cleanliness & Security.

Check Ground @ Valve Cover & PS/ALT Bracket for Quality, Cleanliness & Security.

Check All Other Grounds in Engine Bay and Dash Fuse Box for Quality, Cleanliness & Security.

Check for Stray Current due to Poor Grounds.