| Diagnosis and Testing Refer to Wiring Diagrams Section 303-06, for schematic and connector information. Inspection and Verification - Verify the customer concern.
- Visually inspect for obvious signs of electrical damage.
Visual Inspection Chart | Electrical | - Fuse(s)
- Wiring harness
- Electrical connector(s)
- Relay
- Battery junction box (BJB)
- Switch(es)
- Battery
- Starter motor
| - If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
- If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart Symptom Chart | Symptom | Possible Sources | Action | | The engine does not crank/the relay does click | * Battery. | * REFER to: Battery (414-01 Battery, Mounting and Cables, Diagnosis and Testing). | | * Starter motor relay. | * CARRY OUT the relay Component Test. REFER to the wiring diagrams. | | * Transmission range sensor - Vehicles with automatic transaxle. | * REFER to WDS. | | * Starter motor. | * | | The engine does not crank/the relay does not click | * Battery. | * REFER to: Battery (414-01 Battery, Mounting and Cables, Diagnosis and Testing). | | * Fuse. | * INSTALL a new fuse as required. If the fuse fails again, check for short to ground. | | * Passive anti-theft system (PATS). | * REFER to: Anti-Theft - Passive (419-01B Anti-Theft - Passive, Diagnosis and Testing). | | * Ignition switch. * Circuit(s). | * | | The engine cranks slowly | * Battery. | * REFER to: Battery (414-01 Battery, Mounting and Cables, Diagnosis and Testing). | | * Circuit(s). | * | | Unusual starter noise | * Starter motor. | * REMOVE the starter motor.
REFER to: Starter Motor - 1.8L Duratec-HE (MI4)/1.8L Duratec-SCi (MI4)/2.0L Duratec-HE (MI4)/2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Vehicles With: 5-Speed Manual Transmission (MTX-75)/6-Speed Manual Transmission (MMT6)/4-Speed Automatic Transmission (CD4E) (303-06 Starting System, Removal and Installation) /
Starter Motor - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel, Vehicles With: 6-Speed Manual Transmission (MMT6)/5-Speed Automatic Transmission (5F31J) (303-06 Starting System, Removal and Installation) /
Starter Motor - 2.5L Duratec-VE (VE6), Vehicles With: 5-Speed Manual Transmission (MTX-75) (303-06 Starting System, Removal and Installation) /
Starter Motor - 2.5L Duratec-VE (VE6), Vehicles With: CD4E/4-Speed Automatic Transaxle (CD4E) (303-06 Starting System, Removal and Installation) /
Starter Motor - 3.0L Duratec-ST (VE6), Vehicles With: MTX-75/5-Speed Manual Transmission (MTX-75) (303-06 Starting System, Removal and Installation) /
Starter Motor - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Vehicles With: MMT6/6-Speed Manual Transmission (MMT6) (303-06 Starting System, Removal and Installation).
INSPECT the starter motor gear for damage. INSTALL a new starter motor as necessary. | | * Flywheel ring gear. | * INSPECT the flywheel for damage.
REFER to: Flywheel Inspection - 1.8L Duratec-HE (MI4)/1.8L Duratec-SCi (MI4)/2.0L Duratec-HE (MI4), Vehicles With: Dual Mass Flywheel (303-00 Engine System - General Information, General Procedures) /
Flywheel Inspection - 2.5L Duratec-VE (VE6)/3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6)/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Vehicles With: Dual Mass Flywheel (303-00 Engine System - General Information, General Procedures).
| | The starter spins but the engine does not crank | * Starter motor. | * REMOVE the starter motor.
REFER to: Starter Motor - 1.8L Duratec-HE (MI4)/1.8L Duratec-SCi (MI4)/2.0L Duratec-HE (MI4)/2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Vehicles With: 5-Speed Manual Transmission (MTX-75)/6-Speed Manual Transmission (MMT6)/4-Speed Automatic Transmission (CD4E) (303-06 Starting System, Removal and Installation) /
Starter Motor - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel, Vehicles With: 6-Speed Manual Transmission (MMT6)/5-Speed Automatic Transmission (5F31J) (303-06 Starting System, Removal and Installation) /
Starter Motor - 2.5L Duratec-VE (VE6), Vehicles With: 5-Speed Manual Transmission (MTX-75) (303-06 Starting System, Removal and Installation) /
Starter Motor - 2.5L Duratec-VE (VE6), Vehicles With: CD4E/4-Speed Automatic Transaxle (CD4E) (303-06 Starting System, Removal and Installation) /
Starter Motor - 3.0L Duratec-ST (VE6), Vehicles With: MTX-75/5-Speed Manual Transmission (MTX-75) (303-06 Starting System, Removal and Installation) /
Starter Motor - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Vehicles With: MMT6/6-Speed Manual Transmission (MMT6) (303-06 Starting System, Removal and Installation).
INSPECT the starter motor gear for damage. INSTALL a new starter motor as necessary. | | * Flywheel ring gear. | * INSPECT the flywheel for damage.
REFER to: Flywheel Inspection - 1.8L Duratec-HE (MI4)/1.8L Duratec-SCi (MI4)/2.0L Duratec-HE (MI4), Vehicles With: Dual Mass Flywheel (303-00 Engine System - General Information, General Procedures) /
Flywheel Inspection - 2.5L Duratec-VE (VE6)/3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6)/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Vehicles With: Dual Mass Flywheel (303-00 Engine System - General Information, General Procedures).
| Pinpoint Tests | PINPOINT TEST A : THE ENGINE DOES NOT CRANK/THE RELAY DOES CLICK | | TEST CONDITIONS | DETAILS/RESULTS/ACTIONS | | A1: CHECK VOLTAGE TO STARTER SOLENOID | | | 1 Ignition switch in position III. | | | 2 Measure the voltage between starter motor terminal 50, harness side and ground. | | | Is the voltage greater than 10 volts? Yes No | | A2: CHECK STARTER MOTOR FEED | | | 1 Measure the voltage between starter motor terminal 30, component side and the battery positive terminal. | | | Is the voltage less than 0.5 volts? Yes No CLEAN and TIGHTEN all battery positive cable connections. TEST the system for normal operation. If the concern persists, INSTALL a new starter motor to battery cable.
REFER to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
TEST the system for normal operation. | | A3: CHECK CIRCUIT 30-DB1 (RD) FOR OPEN | | | 1 Ignition switch in position 0. | | | 2 Disconnect Starter Relay C910. | | | 3 Measure the voltage between starter relay C910 pin 5, circuit 30-DB1 (RD), harness side and ground. | | | Is the voltage greater than 10 volts? Yes CARRY out starter motor relay component test. INSTALL a new starter motor relay as necessary. If the concern persists, REPAIR circuit 50-BB10 (GY/BK). TEST the system for normal operation. No REPAIR the circuit. CHECK fuse F29 (30A). INSTALL a new fuse as necessary. If the fuse fails again for check for a short to ground. TEST the system for normal operation. | | A4: CHECK THE STARTER MOTOR GROUND CIRCUIT FOR OPEN | | | 1 Measure the resistance between the starter motor casing and battery ground terminal. | | | Is the resistance less than 0.5 ohms? Yes INSTALL a new starter motor.
REFER to: Starter Motor - 1.8L Duratec-HE (MI4)/1.8L Duratec-SCi (MI4)/2.0L Duratec-HE (MI4)/2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Vehicles With: 5-Speed Manual Transmission (MTX-75)/6-Speed Manual Transmission (MMT6)/4-Speed Automatic Transmission (CD4E) (303-06 Starting System, Removal and Installation) /
Starter Motor - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel, Vehicles With: 6-Speed Manual Transmission (MMT6)/5-Speed Automatic Transmission (5F31J) (303-06 Starting System, Removal and Installation) /
Starter Motor - 2.5L Duratec-VE (VE6), Vehicles With: 5-Speed Manual Transmission (MTX-75) (303-06 Starting System, Removal and Installation) /
Starter Motor - 2.5L Duratec-VE (VE6), Vehicles With: CD4E/4-Speed Automatic Transaxle (CD4E) (303-06 Starting System, Removal and Installation) /
Starter Motor - 3.0L Duratec-ST (VE6), Vehicles With: MTX-75/5-Speed Manual Transmission (MTX-75) (303-06 Starting System, Removal and Installation) /
Starter Motor - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Vehicles With: MMT6/6-Speed Manual Transmission (MMT6) (303-06 Starting System, Removal and Installation).
TEST the system for normal operation. No CLEAN and TIGHTEN all battery and engine ground cable connections. TEST the system for normal operation. | | PINPOINT TEST B : THE ENGINE DOES NOT CRANK/RELAY DOES NOT CLICK | | TEST CONDITIONS | DETAILS/RESULTS/ACTIONS | | B1: CHECK SWITCHED POWER TO THE STARTER RELAY | | | 1 Disconnect Starter Relay C910. | | | 2 Ignition switch in position III. | | | 3 Measure the voltage between starter motor relay C910 pin 1, harness side and ground. | | | Is the voltage greater than 10 volts? Yes No | | B2: CHECK VOLTAGE AT IGNITION SWITCH CIRCUIT 50-BB12 (GY) | | | 1 Disconnect Ignition Switch C400. | | | 2 Ignition switch in position III. | | | 3 Measure the voltage between ignition switch C400 pin 7, circuit 50-BB12 (GY), component side and ground. | | | Is the voltage greater than 10 volts? Yes No CARRY OUT the Ignition Switch Component Test, REFER to the wiring diagrams. If the concern persists, GO to B7. TEST the system for normal operation. | | B3: CHECK CIRCUIT 50-BB12 (GY) FOR OPEN | | | 1 Ignition switch in position 0. | | | 2 Measure the resistance between ignition switch C400 pin 7, circuit 50-BB12 (GY), harness side and starter relay C910 pin 1, circuit 30-BB12 (GY), harness side. | | | Is the resistance less than 5 ohms? Yes No REPAIR the circuit. TEST the system for normal operation. | | B4: CHECK CIRCUIT 31S-BB12 (BK/YE) FOR OPEN | NOTE:Make sure that the transaxle is in the PARK position before carrying out this test - (vehicles with automatic transaxle). | | | 1 Ignition switch in position 0. | | | 2 Measure the resistance between starter relay C910 pin 2, harness side and ground. | | | Is the resistance less than 5 ohms? Yes INSTALL a new starter relay. TEST the system for normal operation. No For vehicles with manual transaxle, REPAIR the circuit. TEST the system for normal operation. For vehicles with automatic transaxle, GO to B5. | | B5: CHECK CIRCUIT 31S-BB12 (BK/YE) FOR OPEN | | | 1 Disconnect Transmission Range (TR) Sensor C187. | | | 2 Measure the resistance between transmission range (TR) sensor C187 pin 9, circuit 31S-BB12 (BK/YE), and the starter relay C910 pin 2, circuit 30-BB12 (GY/YE), harness side. | | | Is the resistance less than 5 ohms? Yes No REPAIR the circuit. TEST the system for normal operation. | | B6: CHECK CIRCUIT 31S-BB12A (BK/YE) FOR OPEN | | | 1 Measure the resistance between TR sensor C187 pin 4, circuit 31S-BB12A (BK/YE), harness side and ground. | | | Is the resistance less than 5 ohms? Yes INSTALL a new TR sensor. For vehicles with 4-speed automatic transaxle,
REFER to: Transmission Range (TR) Sensor (307-01A Automatic Transmission/Transaxle - Vehicles With: 4-Speed Automatic Transmission (CD4E), In-vehicle Repair).
Or for vehicles with 5-speed automatic transaxle,
REFER to: Transmission Range (TR) Sensor (307-01B Automatic Transmission/Transaxle - Vehicles With: 5-Speed Automatic Transmission (5F31J), In-vehicle Repair).
TEST the system for normal operation. No REPAIR the circuit. TEST the system for normal operation. | | B7: CHECK FOR POWER TO IGNITION SWITCH | | | 1 Ignition switch in position 0. | | | 2 Measure the voltage between ignition switch C400 pin 4, circuit 30-BB9 (RD), harness side and ground. | | | Is the voltage greater than 10 volts? Yes REPAIR circuit 50-BB12 (GY). TEST the system for normal operation. No CHECK Fuse F28 (20A). INSTALL a new fuse as necessary. If the fuse fails again for check for a short to ground. REPAIR circuit 30-BB9 (RD). TEST the system for normal operation. | | PINPOINT TEST C : THE ENGINE CRANKS SLOWLY | | TEST CONDITIONS | DETAILS/RESULTS/ACTIONS | | C1: CHECK THE VOLTAGE DROP | | | 1 Ignition switch in position III. | | | 2 Measure the voltage between starter motor terminal 30, component side and the battery positive terminal. | | | Is the voltage less than 0.5 volts? Yes No CLEAN and TIGHTEN all battery positive cables connections. TEST the system for normal operation. If the concern persists, INSTALL a new battery to starter motor solenoid cable.
REFER to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
TEST the system for normal operation. | | C2: CHECK FOR GROUND CONNECTION | | | 1 Ignition switch in position III. | | | 2 Measure the voltage between starter motor case and the battery ground cable. | | | Is the voltage less than 0.5 volts? Yes CHECK the battery charging system.
REFER to: Charging System (414-00 Charging System - General Information, Diagnosis and Testing).
TEST the system for normal operation. No CLEAN and TIGHTEN all battery negative cable connections, starter motor mounting and body to ground straps. TEST the system for normal operation. If the concern persists, INSTALL a new battery negative cable. TEST the system for normal operation. | |
