1.1 Starter Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

 

 

2.2 Initial Diagnostic Check: Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.3 Speedometer Self Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.4 Speedometer/Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.5 Breakout Box: Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

2.6 Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2.7 Oil, Air and Voltmeter Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.8 Indicator Lamps: FLTR, FLHT/C/U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

2.9 Indicator Lamps: FLHR/C/S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

2.10 DTC B1004, B1005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

2.11 DTC B1006, B1007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

2.12 DTC B1008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

2.13 DTC U1016 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

2.14 DTC U1064, U1255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

2.15 DTC U1300, U1301 or "BUS Er" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

GENERAL

 

 

 

 

The troubleshooting tables beginning on page 1-1 contain

detailed procedures to solve and correct problems. Follow the

1.2 STARTING SYSTEM DIAGNOSIS diagram to diagnose

starting system problems. The VOLTAGE DROPS procedure

below will help you to locate poor connections or components

with excessive voltage drops.

 

 

 

VOLTAGE DROPS

 

 

Check the integrity of all wiring, switches, circuit breakers and

connectors between the source and destination.

The voltage drop test measures the difference in potential or the

actual voltage dropped between the source and destination.

1. See ITEM A in Figure 1-1. Attach your red meter lead to

the most positive part of the circuit, which in this case

would be the positive post of the battery.

2. See ITEM B in Figure 1-1. Attach the black meter lead to

the final destination or component in the circuit (solenoid

terminal from relay).

3. Activate the starter and observe the meter reading. The

meter will read the voltage dropped or the difference in

potential between the source and destination.

4. An ideal circuit’s voltage drop would be 0 volts or no voltage

dropped, meaning no difference in potential.

5. See ITEM C in Figure 1-1. An open circuit should read

12 volts, displaying all the voltage dropped, and the

entire difference in potential displayed on the meter.

 

NOTE

Open circuits on the ground side will read zero.

 

 

 

 

 

CHECK ENGINE LAMP

To diagnose electronic control module (ECM) or ignition control

module (ICM) system problems, start by observing the

behavior of the check engine lamp.

 

 

 

NOTES

 

 

●

 

See Figure 2-2. “Key ON” means that the ignition key is

turned to ON and the engine stop switch is set to RUN

(although the engine is

not

running).

●

When the ignition switch is turned ON, the check engine

lamp will illuminate for approximately four seconds and

then turn off.

●

If the check engine lamp is not illuminated at Key ON.

See 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER.

●

If the check engine lamp comes on late (after 20 seconds).

See 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER.

●

If the check engine lamp fails to turn OFF after the initial

four second period. See 2.2 INITIAL DIAGNOSTIC

CHECK: SPEEDOMETER.

1. See Figure 2-3. After lamp turns off after being illuminated

for the first four second period, one of three situations

may occur.

a. The lamp remains off. This indicates there are no

current fault conditions or stored diagnostic trouble

codes (DTC) currently detected by the ignition control

module (ICM) or electronic control module

(ECM).

b. The lamp stays off for only four seconds and then

comes back on for an eight second period. This indicates

an diagnostic trouble code is stored, but no

current diagnostic trouble code exists.

c. If the lamp remains on beyond the eight second

period, then a current diagnostic trouble code exists.

2. See CODE TYPES which follows for a complete description

of diagnostic trouble code formats.

 

 

 

 

 

 

 

 

 

 

SYSTEM PROBLEMS

All system problems fall into at least one of three general categories.

No Start

The engine cranks over freely, but will not start. This does not

include situations where the engine will not crank, such as a

bad starter, dead battery, etc. This condition assumes that all

obvious checks (fuel in tank, etc.) have been made.

 

Poor Performance

The engine starts but there are performance problems. These

problems may include poor fuel economy, rough idle, engine

misfire, engine hesitation, severe spark knock, etc.

Check Engine Lamp

See Figure 4-2. The check engine lamp indicates the ignition

control module (ICM) has determined a fault condition exists.

There may also be starting or performance problems.

RESOLVING PROBLEMS

To resolve system problems, five basic steps are involved. In

order of occurrence, they are:

1. Check for diagnostic trouble codes (DTCs) by observing

check engine lamp. See 4.3 CHECKING FOR TROUBLE

CODES.

2. Retrieve DTCs using speedometer self diagnostics. See

4.5 SPEEDOMETER SELF DIAGNOSTICS.

3. Diagnose system problems. This involves using special

tools and the diagnostic flow charts in this section.

4. Correct problems through the replacement and/or repair

of the affected components.

5. After repairs are performed, the work must be validated.

This involves clearing the DTCs and confirming proper

vehicle operation as indicated by the behavior of the

check engine lamp.

 

 

1.1 Starter Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

 

1.2 Starting System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.3 Starter Activation Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1.4 Diagnostics/Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.5 Starter System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1.6 Testing Assembled Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

1.7 Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

1.8 Battery Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

2.1 Checking For Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1