Diagnosis and repair workflow
Work Flow (With GR8-1200 NI)
STARTING SYSTEM DIAGNOSIS WITH GR8-1200 NI
To test the starting system, use the following special service tool:
NOTE:
Refer to the diagnostic station Instruction Manual for proper starting system diagnosis procedures.
OVERALL SEQUENCE

DETAILED FLOW
NOTE:
To ensure a complete and thorough diagnosis, the battery, starter motor and generator test segments must be done as a set from start to finish.
1.DIAGNOSIS WITH MULTITASKING BATTERY AND ELECTRICAL DIAGNOSTIC STATION GR8-1200 NI
Perform the starting system test with Multitasking battery and electrical diagnostic station GR8-1200 NI. For details and operating instructions, refer to diagnostic station Instruction Manual.
Test result
CRANKING NORMAL>>GO TO 2.
LOW VOLTAGE>>GO TO 5.
CHARGE BATTERY>>Perform the slow battery charging procedure. (Initial rate of charge is 10A for 12 hours.) Perform battery test again. Refer to diagnostic station instruction manual.
REPLACE BATTERY>>Before replacing battery, clean the battery cable clamps and battery posts. Perform battery test again. Refer to diagnostic station instruction manual. If second test result is “REPLACE BATTERY”, then do so. Perform battery test again to confirm repair.
2.CRANKING CHECK
Check that the starter motor operates properly.
Does the engine crank normally? YES >> GO TO 3.
NO >> GO TO 4.
3.ENGINE START CHECK
Check that the engine starts.
Does the engine start? YES >> Inspection End.
NO >> Perform further diagnosis of engine mechanical or engine control system. Refer to EM and EC sections. Once resolved, perform battery test again.
4.STARTER MOTOR ACTIVATION
Check that the starter motor operates.
Does the starter motor turn? YES >> Check ring gear and starter motor drive pinion. Once resolved, perform battery test again.
NO >> GO TO 7.
5.COMPARISON BETWEEN ENGINE COOLANT AND CRANKING VOLTAGE
Compare the engine coolant temperature and verify the cranking voltage is within specifications.
Minimum Specification of Cranking Voltage Referencing Coolant Temperature

Is the voltage less than the specified value? YES >> GO TO 7.
NO >> GO TO 6.
6.STARTER OPERATION
Check the starter operation.
Does the starter motor turn smoothly? YES >> Inspection End.
NO >> GO TO 7.
7.“B” TERMINAL CIRCUIT INSPECTION
Check “B” terminal circuit. Refer to STR-26, "Diagnosis Procedure".
Is “B” terminal circuit normal? YES >> GO TO 8.
NO >> Repair as needed.
8.“S” CONNECTOR CIRCUIT INSPECTION
Check “S” connector circuit. Refer to STR-28, "Diagnosis Procedure".
Is “S” connector circuit normal? YES >> GO TO 9.
NO >> Repair as needed.
9.ENGINE ROTATION STATUS
Check that the engine can be rotated by hand.
Does the engine turn freely by hand? YES >> Replace starter motor.
NO >> Perform further diagnosis of engine mechanical or powertrain mechanism. Once resolved, perform battery test again using Multitasking battery and electrical diagnostic station GR8-1200 NI.
Refer to the diagnostic station Instruction Manual for proper testing procedures.
Work Flow (Without GR8-1200 NI)
Starting system (without intelligent key)Removal and installation
ACCELERATOR CONTROL SYSTEM
Exploded View
Accelerator pedal assembly
Brake pedal bracket
Locating hook
Locating pin
Removal and Installation
REMOVAL
Remove instrument lower panel LH. Refer to IP-21, "Removal and
Installation".
Disconnect the harness connector ...
P0863 TCM Communication
DTC Logic
DTC DETECTION LOGIC
DTC
CONSULT screen terms
(Trouble diagnosis content)
DTC detection condition
Possible causes
P0863
TCM COMMUNICATION
(TCM Communication Circuit)
An error is detected at the initial CAN diagnosis of TCM.
TCM
DTC CONFIRMATIO ...
Precautions For Engine Service
DISCONNECTING FUEL PIPING
Before starting work, check no fire or spark producing items are in the
work area.
Release fuel pressure before disconnecting and disassembly.
After disconnecting pipes, plug openings to stop fuel leakage.
DRAINING ENGINE COOLANT
Drain engine coolant and engi ...