Starting System - Diesel Engine -- e350 &e450 Ford Cutaway E350

GENERAL SPECIFICATIONS (6.0L DIESEL)

GENERAL SPECIFICATIONS (6.0L DIESEL)

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

The starting system consists of the following components

1. Starter motor
2. Starter switch, part of the ignition switch
3. Digital transmission range (DTR) sensor
4. Starter motor relay
5. Starter solenoid
6. Starter drive

Scheme 1

Starter Motor

The starter motor

1. is a wound field, gear reduction, 12 VDC motor.
2. has an integral starter solenoid.
3. has an overrunning clutch in the starter drive.

The starter motor functions as follows

1. When the key cylinder turns to the START position, current flows through the solenoid pull-in and hold-in coils until the solenoid plunger is at the end of its travel. The plunger pulls the lever, which pushes the pinion to engage the flywheel.
2. The contact bridges the solenoid terminals that bypass the pull-in coil. This allows the hold-in coil to keep the starter drive engaged and to pass battery current to the starter motor. The starter motor cranks the engine fast enough to start it.
3. As the key returns to the RUN position, the relay cuts off current to the solenoid, and the solenoid disengages the pinion from the flywheel.

Starter Relay

The starter interrupt relay consists of

1. the pull-in coil and contacts.

When the key cylinder is in the START position

1. the pull-in coil is activated and pulls the contacts together.
2. current passes through the starter relay to the starter solenoid.

When the key cylinder is returned to the RUN position

1. the relay turns off the starter solenoid, which disengages the pinion from the flywheel.

Transmission Range Sensor (Automatic Transmission)

The transmission range sensor

1. prevents starter motor engagement unless the transmission is in the NEUTRAL or PARK position. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - TORQSHIFT»(/ford/cutaway-e350/2004-2007/remont/automatic-trans/#automatic-transmission-5r110w-torqshiftr) .

Starter Drive

The starter drive

1. is operated by the starter solenoid.
2. engages the flywheel to turn the engine.
3. has an internal overrunning clutch to disengage the starter motor when the engine starts.

Starter Solenoid

The starter solenoid

1. is an electromagnet.
2. engages the starter drive to the flywheel.
3. when energized, contacts close, connecting the battery to the starter motor to turn the starter drive.
4. is kept in the energized condition by a hold-in winding until the starter switch is released.

Scheme 2

Special Tool(s)

SPECIAL TOOLS 73 III Automotive Meter 105-R0057 or equivalent ARBST Battery and Electrical System Tester 010-00735 or equivalent

Scheme 3

Scheme 4

Inspection and Verification

1. Verify the vehicle owner's original concern by operating the system to duplicate the condition.
2. Inspect the system to determine if any of the following mechanical or electrical concerns apply. VISUAL INSPECTION CHART Mechanical Electrical Starter motor mounting Starter relay mounting Battery condition Electrical connections at the switches, relay and solenoid Fuse
3. If the concern(s) remains after the inspection and verification, determine the symptoms. GO to «SYMPTOM CHART»(/ford/cutaway-e350/2004-2007/remont/starter/#starting-system-diesel-engine-e350-e450__symptom-chart) .

Symptom Chart

STARTING SYSTEM - DIESEL ENGINE SYMPTOM CHART

Scheme 5

Scheme 6

Scheme 7

1. A1 CHECK THE VOLTAGE TO THE STARTER RELAY Measure the voltage between the starter relay pin 30, circuit 1523 (DG) and ground. Is the voltage greater than 12.5 volts? Yes : GO to A2. No : REPAIR circuit 1523 (DG) for an open. TEST the system for normal operation.
2. A2 CHECK THE VOLTAGE TO THE STARTER MOTOR SOLENOID Measure the voltage between the starter motor solenoid positive terminal and ground. Is the voltage 12.5 volts or greater? Yes : GO to A3. No : REPAIR circuit 2037 (RD) for an open. TEST the system for normal operation.
3. A3 MANUALLY JUMP THE STARTER MOTOR Connect one end of a fused (15A) jumper wire to the positive terminal of the battery and touch the other end to the starter solenoid S-terminal. Does the starter solenoid engage? Yes : GO to A4. No : INSTALL a new starter. TEST the system for normal operation.
4. A4 TEST THE STARTER MOTOR RELAY Carry out the relay component test on the starter motor relay. Refer to «RELAY COMPONENT TEST»(/ford/cutaway-e350/2004-2007/remont/starter/#starting-system-diesel-engine-e350-e450) . Does the starter motor relay test good? Yes : REPAIR circuit 113 (YE/LB) for an open. TEST the system for normal operation. No : INSTALL a new starter motor relay. TEST the system for normal operation.

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

1. B1 CHECK THE STARTER MOTOR RELAY COIL FOR VOLTAGE Disconnect: Starter Motor Relay. Key in START position. Measure the voltage between the starter motor relay pin 86, circuit 1093 (TN/RD) and ground while holding the key in the START position. Is the voltage greater than 10 volts? Yes : GO to B5 . No : GO to B2.
2. B2 CHECK FOR VOLTAGE AT FUSE 33 Key in OFF position. Disconnect: Fuse #33. Key in START position. Measure the voltage between the central junction box (CJB) fuse 33, circuit 33 (WH/PK) and ground while holding the key in the START position. Is the voltage greater than 10 volts? Yes : REPAIR circuit 1093 (TN/RD). TEST the system for normal operation. No : GO to B3.
3. B3 CHECK CIRCUIT 1050 (LG/VT) FOR VOLTAGE Key in OFF position. Disconnect: Ignition Switch C250. Key in ON position. Measure the voltage between the ignition switch connector C250, circuit 1050 (LG/VT) and ground. Is the voltage greater than 10 volts? Yes : GO to B4. No : REPAIR circuit 1050 (LG/VT). TEST the system for normal operation.
4. B4 CHECK THE IGNITION SWITCH Carry out the ignition switch component test. Does the ignition switch test good? Yes : REPAIR circuit 33 (WH/PK). TEST the system for normal operation. No : INSTALL a new ignition switch. TEST the system for normal operation.
5. B5 CHECK THE RELAY GROUND CIRCUIT FOR AN OPEN Key in OFF position. Measure the voltage between the starter motor relay pin 85, circuit 1419 (LG/YE) and pin 86, circuit 1093 (TN/RD). Is the voltage greater than 10 volts? Yes : INSTALL a new starter motor relay. TEST the system for normal operation. No : GO to B6.
6. B6 CHECK CIRCUIT 1419 (LG/YE) Key in OFF position. Disconnect: PCM C176A. Measure the resistance between the starter motor relay socket pin 85, circuit 1419 (LG/YE) and the PCM C176A pin 4, circuit 1419 (LG/YE). Is the resistance less than 5 ohms? Yes : INSTALL a new PCM. TEST the system for normal operation. No : REPAIR circuit 1419 (LG/YE). CLEAR the DTCs. TEST the system for normal operation.

PINPOINT TEST C: THE ENGINE CRANKS SLOWLY

Note. Before beginning this test, be sure that the battery is tested and fully charged.

1. C1 CHECK THE VOLTAGE TO THE STARTER Key in OFF position. Measure the voltage between the starter motor solenoid positive terminal and ground. Is the voltage 12.5 volts or greater? Yes : GO to C2. No : REPAIR the circuit between the battery and the starter solenoid. CLEAN and TIGHTEN the connections at the battery terminals. TEST the system for normal operation.
2. C2 CHECK THE MOTOR GROUND CIRCUIT Carry out the motor ground circuit test. Refer to the «COMPONENT TESTS»(/ford/cutaway-e350/2004-2007/remont/starter/#starting-system-diesel-engine-e350-e450) . Is the ground OK? Yes : INSTALL a new starter motor. TEST the system for normal operation. No : REPAIR the ground circuit as necessary. TEST the system for normal operation.

PINPOINT TEST D: UNUSUAL STARTER NOISE

1. D1 CHECK THE STARTER MOTOR MOUNTING Inspect the starter motor mounting brackets for cracks. Check the starter motor mounting bolts for looseness. Is the starter motor mounted correctly? Yes : GO to D2. No : REINSTALL the starter motor correctly.
2. D2 INSPECT THE STARTER MOTOR Remove the starter motor. Inspect the starter motor for damage. Is the starter motor damaged? Yes : INSTALL a new starter motor. TEST the system for normal operation. No : CHECK the starter drive. REFER to component tests, «STARTER DRIVE TEST»(/ford/cutaway-e350/2004-2007/remont/starter/#starting-system-diesel-engine-e350-e450__starter-drive) . INSTALL a new starter motor. TEST the system for normal operation.

PINPOINT TEST E: THE STARTER SPINS BUT THE ENGINE DOES NOT CRANK

1. E1 CHECK THE FLYWHEEL Remove the starter motor. Inspect the flywheel and the drive pinion for damage or excessive wear. Is the flywheel or the drive pinion worn or damaged? Yes : INSTALL a new starter motor and flywheel. TEST the system for normal operation. No : INSTALL a new starter.

Starter Motor - Load Test

Note. The batteries must be fully charged before carrying out a starter load test.

1. Set the parking brake and shift the transmission into the NEUTRAL position.
2. Remove fuse 17 from the engine compartment fuse box.
3. Connect the alternator, regulator, battery and starter tester (ARBST). Follow the manufacturer's supplied instructions.
4. Connect a remote starter switch across the starter relay S-terminal and the battery positive terminal post.
5. Turn the ignition switch to the RUN position.
6. Crank the engine and record the voltmeter reading.
7. Turn the carbon pile control knob until the voltmeter indicates the same reading recorded during cranking the engine. Record the ammeter reading.
8. Compare the ammeter reading with specifications.

Starter Motor - Drive Pinion Test

1. Rotate the pinion drive clockwise and counterclockwise.
2. The pinion drive should free-wheel in one direction and lock to the armature shaft in the other.
3. If the pinion drive free-wheels in both directions, install a new starter motor.

Starter Motor - No-Load Test

1. Connect a fully charged battery to the starter.
2. Connect the alternator, regulator, battery and starter tester (ARBST).
3. Connect a remote starter switch between the starter solenoid Terminal S and the positive battery terminal post.
4. Press the remote starter switch. The pinion should shift to the crank position and the motor should run smoothly.
5. While the starter motor is running, record the voltmeter and ammeter readings.
6. The voltage reading should be greater than 11.0 volts and the amperage should be no more than 170 amps.
7. If the voltage is lower than specified or amperage is higher than specified, refer to the «RESULTS CHART»(/ford/cutaway-e350/2004-2007/remont/starter/#starting-system-diesel-engine-e350-e450__starter-motor-no-load-test-results) below to determine possible cause and corrective action.

Starter Motor No-Load Test Results

STARTER MOTOR NO-LOAD TEST CHART

Starter Motor - Motor Feed Circuit Voltage Drop Test

1. This test is carried out to determine if slow cranking is caused by high resistance in the starter motor circuit wiring.
2. The voltage drop test can only be carried out with the starter motor on the vehicle.
3. Disconnect the fuel pump electrical connector.
4. Connect the positive lead of the 73 Digital Multimeter to the battery positive (+) post, and the negative lead to the starter solenoid M-terminal.
5. Connect a remote starter switch between the starter solenoid S-terminal and the positive battery terminal post.
6. Press the remote starter switch and record the voltage reading.
7. The voltage reading should be 0.5 volt or less. A reading higher than 0.5 volt indicates high resistance.
8. Repeat the test on the starter solenoid B-terminal.
9. If the readings are higher than 0.5 volt, remove the wiring from the starter solenoid.
10. Clean and inspect each wire connector and the starter solenoid terminal.
11. Install the wires onto the starter solenoid and retest.
12. If the reading at the starter solenoid M-terminal is still higher than 0.5 volt or the reading at the B-terminal is lower, carry out the Starter Solenoid Component Test. If no change is noted, install a new positive battery cable lead.

Starter Motor - Motor Ground Circuit Voltage Drop Test

Note. A slow cranking condition can also be caused by high resistance in the ground circuit.

1. Disconnect the wiring from the fuel pump electrical connector.
2. Connect the Digital Volt-Ohmmeter positive lead to the starter motor housing.
3. Connect the Digital Volt-Ohmmeter negative lead to the battery negative (-) terminal.
4. Connect a remote starter switch between the starter solenoid S-terminal and the positive battery terminal post.
5. Press the remote starter switch and record the voltage reading.
6. The voltage reading should be 0.2 volt or less. If the voltage reading is higher, remove and clean the negative cable connections at the battery, starter motor and the body.
7. Retest the system. If readings are still higher than 0.2 volt, test each individual negative cable.

1. Disconnect the battery negative cable.
2. Using the Digital Multimeter, check the windings of the solenoid as follows: Measure the resistance between the starter motor ground terminal and the solenoid case. The resistance reading should be approximately 0.95 ohms. An extremely high resistance reading indicates a break or fault in winding continuity. A very low resistance reading indicates a short or ground in the winding circuit. Either condition is cause for installation of a new solenoid assembly.

Removal and Installation

Scheme 13

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Scheme 16

1. With the vehicle in NEUTRAL position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
3. Remove the retaining nut and position the cable bracket aside.
4. Remove the starter solenoid protective cap.
5. Disconnect the starter motor electrical connections.
6. Remove the bolts and the starter.
7. To install, reverse the removal procedure. Install the starter bolts finger tight. Tighten the upper bolt. Tighten the lower bolts.

See also:
• AUTOMATIC TRANSAXLE/TRANSMISSION - TORQSHIFT
• JACKING & LIFTING
• BATTERY, MOUNTING AND CABLES
• SYMPTOM CHART
• PINPOINT TEST A
• PINPOINT TEST C
• PINPOINT TEST D
• PINPOINT TEST E
• STARTER DRIVE TEST
• RESULTS CHART