Starting System - Diesel: Diagnosis Ford Econoline E150

TROUBLE SHOOTING

Verify customer compliant by operating starting system. Check battery for state of charge. Check cable connections at battery and starter motor. Ensure transmission is fully engaged in Park or Neutral. Check maxi-fuse No. 18 (60-amp) and fuse No. 7 (60-amp) in Battery Junction Box (BJB). (Scheme 4) Check fuse No. 33 (10-amp) in Central Junction Box (CJB). (Scheme 5) If problem is found, repair as necessary. If problem is not found, repair by symptom. See SYMPTOM INDEX table under SYSTEM TESTS.

Scheme 4

Scheme 5

TEST A: ENGINE DOES NOT CRANK & RELAY CLICKS

1. Check The Voltage To The Starter Relay Measure the voltage between the starter relay connector terminal No. 30 (Dark Green wire) and ground. see scheme 6 Is the voltage greater than 12.5 volts? If yes, go to next step. If no, repair Dark Green wire between starter relay and fuse No. 18 (60-amp) in battery junction box for an open. See «WIRING DIAGRAMS»(ref-168260-S03419177992004110300000). Test the system for normal operation.
2. Check The Voltage To The Starter Motor Solenoid Measure the voltage between the starter motor solenoid positive terminal "B" and ground. (Scheme 6) Is the voltage 12.5 volts or greater? If yes, go to next step. If no, repair Red wire between battery and starter for an open. See «WIRING DIAGRAMS»(ref-168260-S03419177992004110300000). Test the system for normal operation.
3. Manually Jump The Starter Motor Connect one end of a fused jumper wire (15A) to the positive terminal of the battery and touch the other end to the starter solenoid "S" terminal. Does the starter solenoid engage? If yes, go to next step. If no, install a new starter. See «STARTER MOTOR»(ref-168260-S22072350662004110300000) under REMOVAL & INSTALLATION. Test the system for normal operation.
4. Test The Starter Motor Relay Carry out the relay component test on the starter motor relay. See «STARTER RELAY»(ref-168260-S02995114272004110300000) under COMPONENT TESTS. Does the starter motor relay test good? If yes, repair Yellow/Light Blue wire between starter relay and starter solenoid for an open. See «WIRING DIAGRAMS»(ref-168260-S03419177992004110300000). Test the system for normal operation. If no, install a new starter motor relay. Test the system for normal operation.

Scheme 6

TEST B: ENGINE DOES NOT CRANK & ENGINE DOES NOT CLICK

Note. Before beginning this test, ensure transmission is in Park or Neutral.

1. Check The Starter Motor Relay Coil For Voltage Disconnect starter motor relay. Turn ignition switch to START position. Measure the voltage between the starter motor relay connector terminal No. 86 (Tan/Red wire) and ground while holding the ignition switch in the START position. see scheme 6 Is the voltage greater than 10 volts? If yes, go to step 5. If no, go to next step.
2. Check For Voltage At Fuse No. 33 Turn ignition off. Disconnect fuse No. 33 (10-amp). Turn ignition switch to START position. Measure the voltage between the Central Junction Box (CJB) fuse 33 (White/Pink wire) and ground while holding the ignition switch in the START position. Is the voltage greater than 10 volts? If yes, repair Tan/Red wire between fuse No. 33 and starter relay. See «WIRING DIAGRAMS»(ref-168260-S03419177992004110300000). Test the system for normal operation. If no, go to next step.
3. Check Light Green/Violet Wire For Voltage Turn the ignition off. Disconnect ignition switch connector. Turn ignition on. Measure the voltage between the ignition switch connector terminal B+ (Light Green/Violet wire) and ground. (Scheme 7) Is the voltage greater than 10 volts? If yes, go to next step. If no, repair Light Green/Violet wire between fuse No. 7 in BJB and ignition switch. See «WIRING DIAGRAMS»(ref-168260-S03419177992004110300000). Test the system for normal operation.
4. Check The Ignition Switch Carry out the ignition switch component test. See appropriate STEERING COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT. Does the ignition switch test good? If yes, repair White/Pink wire between ignition switch and fuse No. 7. See «WIRING DIAGRAMS»(ref-168260-S03419177992004110300000). Test the system for normal operation. If no, install a new ignition switch. See appropriate STEERING COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT. Test the system for normal operation.
5. Check The Relay Ground Circuit For An Open Turn ignition off. Measure the voltage between the starter motor relay connector terminal No. 85 (Light Green/Yellow wire) and terminal No. 86 (Tan/Red wire). see scheme 6 Is the voltage greater than 10 volts? If yes, install a new starter motor relay. Test the system for normal operation. If no, go to next step.
6. Check Light Green/Yellow Wire Turn ignition off. Disconnect PCM connector C176a. Measure the resistance between the starter motor relay connector terminal No. 85 (Light Green/Yellow wire) and PCM connector C176a terminal No. 4. see scheme 6and (Scheme 8). Is the resistance less than 5 ohms? If yes, install a new PCM. Test the system for normal operation. If no, repair Light Green/Yellow wire between starter relay and PCM. See «WIRING DIAGRAMS»(ref-168260-S03419177992004110300000). Clear the DTCs. Test the system for normal operation.

Scheme 7

Scheme 8

TEST C: ENGINE CRANKS SLOWLY

1. Check The Voltage To The Starter Turn ignition off. Measure the voltage between the starter motor solenoid positive terminal and ground. Is the voltage 12.5 volts or greater? If yes, go to next step. If no, repair the Red wire between the battery and the starter solenoid. Clean and tighten the connections at the battery terminals. Test the system for normal operation.
2. Check The Motor Ground Circuit Perform the motor ground circuit test. See «STARTER GROUND CIRCUIT TEST»(ref-168260-S28542364732004110300000) under ON-VEHICLE TESTS. Is the ground okay? If yes, install a new starter motor. Test the system for normal operation. If no, repair the ground circuit as necessary. Test the system for normal operation.

TEST D: UNUSUAL STARTER NOISE

1. Check The Starter Motor Mounting Verify starter is installed properly. Check brackets for cracks. Ensure bolts are tight. Repair or replace as necessary. Check system for normal operation. If noise is still present, go to next step.
2. Check For Proper Engagement Of The Starter Drive Remove starter motor. See «STARTER MOTOR»(ref-168260-S22072350662004110300000) under REMOVAL & INSTALLATION. Inspect starter drive and flywheel for wear or damage. If starter drive and flywheel are okay, replace starter motor. See «STARTER MOTOR»(ref-168260-S22072350662004110300000) under REMOVAL & INSTALLATION. If starter drive and flywheel are damaged, replace starter motor and flywheel. Check system operation.

DRIVE PINION TEST

Remove starter from vehicle. See STARTER MOTOR under REMOVAL & INSTALLATION. Rotate drive pinion in both directions. Pinion should free wheel in one direction and lock to armature shaft in the other direction. If pinion free wheels in both directions, replace starter motor. See STARTER MOTOR under REMOVAL & INSTALLATION.

STARTER LOAD TEST

Note. Batteries must be fully charged before performing a starter load test.

Set parking brake and shift transmission into Neutral. Remove fuse No. 17 (30-amp) from battery junction box. Connect the Alternator, Regulator, Battery and Starter Tester (ARBST). Connect a remote starter switch across starter relay terminal "S" and battery positive terminal post. Turn ignition switch to START position. Crank engine and record DVOM reading. Turn carbon pile control knob until DVOM indicates same reading recorded during cranking engine. Record ammeter reading. Compare ammeter reading with specifications.

STARTER NO-LOAD TEST

Remove starter from vehicle. See STARTER MOTOR under REMOVAL & INSTALLATION. Connect a fully charged battery to starter. Connect Alternator, Regulator, Battery and Starter Tester (ARBST). Connect a remote starter switch between starter solenoid terminal "S" and positive battery terminal post. Press remote starter switch. Pinion should shift to crank position and motor should run smoothly. While starter motor is running, record DVOM and ammeter readings. DVOM should indicate 11 volts or more, and ammeter should indicate no more than 170 amps. If voltage is lower or current is higher than specification, replace or overhaul starter.

VOLTAGE DROP TEST

Note. Make all DVOM connections at component terminal rather than at cable or wire end.

1. Connect positive lead of DVOM to positive battery post on passenger side battery, and negative lead to starter solenoid terminal "M". Connect a remote starter switch between starter solenoid terminal "S" and positive battery terminal post. Press remote starter switch and record voltage reading. (Scheme 9)
2. Voltage reading should be 0.5 volt or less. Repeat test on starter solenoid terminal "B". If readings are greater than 0.5 volt, remove wiring from starter solenoid. Clean and inspect each wire connector and starter solenoid terminals. Install wires onto starter solenoid, and retest.
3. If reading at starter solenoid terminal "M" is still greater than 0.5 volt or reading at terminal "B" is lower, perform «STARTER SOLENOID»(ref-168260-S40178677362004110300000) test under COMPONENT TESTS. If no change is noted, install new positive battery cable assembly.

Scheme 9

STARTER GROUND CIRCUIT TEST

Note. Make all DVOM connections at component terminal rather than at cable or wire end.

Scheme 10

1. Disconnect the wiring from the fuel pump electrical connector. Connect remote starter switch between starter solenoid terminal "S" and positive battery post on passenger side. (Scheme 10)
2. Connect positive DVOM lead to starter housing, and negative lead to negative battery post. Engage remote starter switch while observing DVOM. DVOM should indicate.2 volt or less. If DVOM indicates more than.2 volt, clean negative cable connections at battery and engine. Retest system.
3. If voltage drop is still excessive, repair or replace appropriate negative battery cable and/or engine ground cable as necessary. Repeat starter ground circuit test after repair to ensure problem has been corrected.