DIAGNOSIS AND REPAIR WORKFLOW
Work Flow (With EXP-800 NI or GR8-1200 NI)
CHARGING SYSTEM DIAGNOSIS WITH EXP-800 NI OR GR8-1200 NI
To test the charging system, use the following special service tools:
NOTE: Refer to the applicable Instruction Manual for proper charging system diagnosis procedures.
OVERALL SEQUENCE

DETAILED FLOW
NOTE: To ensure a complete and thorough diagnosis, the battery, starter and generator test segments must be done as a set from start to finish.
1.PRELIMINARY INSPECTION
Perform the preliminary inspection
2.STOP POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM
Stop the operation of the power generation voltage variable control in either of the following procedures.
3.DIAGNOSIS WITH EXP-800 NI OR GR8-1200 NI
Perform the charging system test using Multitasking battery and electrical diagnostic station GR8-1200 NI or Battery and electrical diagnostic analyzer EXP-800 NI. Refer to the applicable Instruction Manual for proper testing procedures.
4.INSPECTION WITH CHARGE WARNING LAMP (IGNITION SWITCH IS ON)
Turn the ignition switch ON.
5."L" TERMINAL CIRCUIT (OPEN) INSPECTION
Check "L" terminal circuit (open).
6.INSPECTION WITH CHARGE WARNING LAMP (IDLING)
Start the engine and run it at idle.
7."L" TERMINAL CIRCUIT (SHORT) INSPECTION
Check "L" terminal circuit (short).
8."S" TERMINAL CIRCUIT INSPECTION
Check "S" terminal circuit
9.INSPECTION WITH CHARGE WARNING LAMP (ENGINE AT 3,000 RPM)
Increase and maintain the engine speed at 3,000 rpm.
10.INSPECTION OF GENERATOR PULLEY
Check generator pulley.
11."B" TERMINAL CIRCUIT INSPECTION
Check "B" terminal circuit
12."B" TERMINAL CIRCUIT INSPECTION
Check "B" terminal circuit
13.INSPECTION OF GENERATOR PULLEY
Check generator pulley
14."S" TERMINAL CIRCUIT INSPECTION
Check "S" terminal circuit.
Work Flow (Without EXP-800 NI or GR8-1200 NI)
OVERALL SEQUENCE
Before performing a generator test, make sure that the battery is fully charged. A 30-volt voltmeter and suitable test probes are necessary for the test.

DETAILED FLOW
1.PRELIMINARY INSPECTION
Perform the preliminary inspection
2.STOP POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM
Stop the operation of the power generation voltage variable control in either of the following procedures:
3.INSPECTION WITH CHARGE WARNING LAMP (IGNITION SWITCH IS TURNED ON)
When ignition switch is turned ON.
4.INSPECTION WITH CHARGE WARNING LAMP (IDLING)
Start the engine and run it at idle
5.INSPECTION WITH CHARGE WARNING LAMP (ENGINE AT 2,500 RPM)
Increase and maintain the engine speed at 2,500 rpm.
6."L" TERMINAL CIRCUIT (SHORT) INSPECTION
Check terminal "L" circuit for (short).
7. "S" TERMINAL CIRCUIT INSPECTION
Check terminal "S" circuit.
8.MEASURE "B" TERMINAL VOLTAGE
Start engine. With engine running at 2,500 rpm, measure "B" terminal voltage.
9."B" TERMINAL CIRCUIT INSPECTION
Check "B" terminal circuit
10.INSPECTION WITH CHARGE WARNING LAMP (IGNITION SWITCH IS ON)
11.CHECK "L" TERMINAL CIRCUIT (OPEN)
Check "L" terminal circuit (OPEN).
Charging systemParking, license plate and tail lamps are not turned on
Description
The parking, license plate and tail lamps do not turn ON in with any lighting
switch setting.
Diagnosis Procedure
1.COMBINATION SWITCH (LIGHTING AND TURN SIGNAL SWITCH) INSPECTION
Check the combination switch (lighting and turn signal switch).
2.CHECK TAIL LAMP RELAY REQUEST SIGNA ...
Evaporative emission system
System Diagram
System Description
*1: ECM determines the start signal status by the signals of engine speed and
battery voltage.
*2: This signal is sent to the ECM via the CAN communication line.
SYSTEM DESCRIPTION
The evaporative emission system is used to reduce hydrocarbons emitte ...
Basic inspection
DIAGNOSIS AND REPAIR WORKFLOW
Work Flow
OVERALL SEQUENCE
DETAILED FLOW
1.OBTAIN INFORMATION ABOUT SYMPTOM
Interview the customer to obtain as much information as possible about the
conditions and environment under
which the malfunction occurred.
>> GO TO 2
2.CHECK SYMPTOM
Chec ...