1. Diagnosis the engine starting system

2. Diagnosis failures engine starting system Body ground Starter ground Engine ground Body ground BATTERY M CBA Ground Plate Ground pigtail

3. Tests to be performed according to the detected failure 1.Turning the key in start position the starter doesn’t run and the solenoid doesn’t switch on. The following tests should be performed: Test 0 Test 0 Test 4 Test 4 Test 5 Test 5 Test 7 Test 7 Test 8 Test 8 Test 9 Test 9 Test 10 Test 10 Test 11 Test 11 2.Turning the key in start position the starter doesn’t run, but the solenoid switches on. The following tests should be performed: Test 0 Test 0 Test 1 Test 1 Test 2 Test 2 Test 3 Test 3 Test 4 Test 4 Test 5 Test 5 Test 6 Test 6 Test 7 Test 7 Test 9 Test 9

4. Tests to be performed according to the detected failure 3.Turning the key in start position the starter runs slowly. The following tests should be performed: Test 0 Test 0 Test 1 Test 1 Test 3 Test 3 Test 4 Test 4 Test 5 Test 5 Test 6 Test 6 Test 7 Test 7 Test 12 Test 12 4.Turning the key in start position the starter sometimes doesn’t run. The following tests should be performed: Test 0 Test 0 Test 1 Test 1 Test 3 Test 3 Test 4 Test 4 Test 5 Test 5 Test 6 Test 6 Test 7 Test 7 Test 9 Test 9 Test 10 Test 10 Test 12 Test 12

5. Test 0: Check battery voltage Check the battery voltage level. The battery voltage level must not be under 12,3 volt. Failure 1: Go to Test 4 Test 4Test 4 Failure 2: Go to Test 1 Test 1Test 1 Failure 3: Go to Test 1 Test 1Test 1 Failure 4: Go to Test 1 Test 1Test 1

6. Test 1: Check CBA nuts tightening Check the tightening torque of the two nuts of the 500 A fuse in the CBA as shown in the picture. The correct tightening torque must be equal to 11 ± 2,2 Nm Failure 2: Go to Test 2 Test 2Test 2 Failure 3: Go to Test 3 Test 3Test 3 Failure 4: Go to Test 3 Test 3Test 3

7. Test 2: Check efficiency 500 A fuse Check with a tester the current conduction of the 500 A fuse between the two points as shown in the picture Attention: please note that the 500 A fuse with PN 42556405 was substituted by the new PN 42560737 from Chassis 5775801 (Suzzara) and D405152 (Valladolid) in date October 2008 Go to Test 3 Test 3Test 3

8. Test 3: Check the tightening torque of supply cable nuts on the battery and on the derivation junction Check the tightening torque of the three nuts shown in the pictures The tightening torque of the battery power supply cable must be equal to 5,5 Nm Go to Test 4 Test 4Test 4  The tightening torque of the wires fixing nuts on the derivation junction must be equal to 11 ± 2,2 Nm

9. Test 4: Check tightening torque and electrical function of the ground wiring loom  Check by disconnecting the engine ground wiring loom that the area of electrical contact is not rusty, dirty or grease contaminated.  Check the tightening torque of the nut on the engine side  The correct tightening torque must be equal to:  F1A engine 33,5 ± 6,6 Nm, F1C engine 40,5 ± 8 Nm Go to Test 5 Test 5Test 5

10. Test 5: Check starter motor nuts tightening Check the starter motor nuts tightening of the (+30) red wire and (+50) wiring loom. The correct tightening torque must be equal to 15 ± 3 Nm. Failure 1: Go to Test 7 Test 7Test 7 Failure 2: Go to Test 6 Test 6Test 6 Failure 3: Go to Test 6 Test 6Test 6 Failure 4: Go to Test 6 Test 6Test 6

11. Test 6: Check overheating on (+30) starter wire Check the (+30) red wire on starter for any signs of overheating. Go to Test 7 Test 7Test 7

12. Test 7: Check starter motor case Check that the case of the starter motor does not show evident signs of rust or corrosion. Failure 1: Go to Test 8 Test 8Test 8 Failure 2: Go to Test 9 Test 9Test 9 Failure 3: Go to Test 12 Test 12Test 12 Failure 4: Go to Test 9 Test 9Test 9

13. Test 8: Check water infiltration in the OPT fuse box T18 1.Only for vehicles fitted with starter protection relay (T18):  Remove the cover of OPT box and verify the area shown in the figure, together with the relay T18, for signs of water or deposits due to infiltration. Go to Test 9 Test 9Test 9

14. Test 9: Check the ignition lock for jamming Start the engine and verify that returning the ignition key to the “key on” position (execute the operation very slowly) the ignition lock is not jamming at any time. Repeat the operation for at least ten times. Failure 1: Go to Test 10 Test 10Test 10 Failure 2: End of check Failure 4: Go to Test 10 Test 10Test 10

15. Test 10: Check the terminals of the 4-way ignition lock connector Check that the terminals of the 4-way ignition lock connector are not loose or oxidized 1 2 3 4 Failure 1: Go to Test 11 Test 11Test 11 Failure 4: Go to Test 12 Test 12Test 12

16. Test 11: Check current conduction of the connector between ignition lock and starter motor Verify with a tester the current conduction between pin 2 of the 4-way ignition lock connector and the (+50) starter motor wire 2 End of check

17. Test 12: Check starter motor voltage between +50 and ground By ignition key in engine start position check with a tester the starter motor voltage between (+50) and ground. End of check

18. VoltsOKKO Test 0  Check battery voltageMeasured voltage YESNO Test 1  Check CBA nuts tighteningFixing correct? YESNO Test 2  Check efficiency 500 A FuseFuse blown? YESNO Test 3  Check tightening torque of the power supply cable nuts Fixing correct? YESNO Test 4  Check tightening torque and electrical function of the ground wiring loom Fixing correct? Electrical function? YESNO Test 5  Check starter motor nuts tighteningFixing correct? YESNO Test 6  Check overheating on (+30) starter wireOverheating? Report diagnosis engine starting system

19. YESNO Test 7  Check starter motor caseSigns of oxidation / rust? YESNO Test 8  Check water infiltration in the OPT fuse box Signs of infiltration? YESNO Test 9  Check the ignition lock for jammingIgnition lock jams ? If so what?YESNO Test 10  Check the terminals of the 4-way ignition lock connector Failures found? YESNO Test 11  Check current conduction of the connector between ignition lock and starter motor Electrical function? Volts Test 12  Check starter motor voltage between +50 and ground Measured voltage