Starting System Ford Econoline E250

SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

The starting system consists of the following

1. Starter motor
2. Starter solenoid
3. Starter drive
4. Starter motor relay
5. Battery
6. Digital Transmission Range (TR) sensor (4R75E transmission)
7. Ignition switch
8. PCM
9. Start diode, part of the One-Touch Integrated Start (OTIS) system

The function of the starting system is to crank the engine at a speed fast enough to permit the engine to start. When the starter solenoid is energized, a magnetic field is created in the starter solenoid windings. The iron plunger core is drawn into the starter solenoid coil, and a drive lever and pin connected to the starter drive engages the drive pinion gear to the flexplate ring gear. When the plunger is pulled all the way in, the contact disc closes the circuit between the battery and the motor feed terminals. This sends current to the motor and the drive pinion gear cranks the flexplate to start the engine. When current flows to the starter motor, the starter solenoid pull-in coil is bypassed, and the hold-in coil keeps the drive pinion gear engaged with the flexplate.

The 4R75E automatic transmission has a digital TR sensor mounted on the transmission. The TR sensor prevents operation of the starter motor unless NEUTRAL or PARK is selected.

The TorqShift transmission has a Park/Neutral Position (PNP) switch in the transmission. The PNP switch prevents operation of the starter motor unless PARK or NEUTRAL is selected.

One-Touch Integrated Start (OTIS)

The vehicle is equipped with OTIS, a computer-assisted cranking system. This feature assists in starting the engine. If the ignition key is turned to the START position and released when the engine begins cranking, the engine may continue cranking for up to 10 seconds or until the vehicle starts.

Once the ignition is turned to the START position, the PCM reads starter motor request from the ignition switch and gains control of the starter engagement. The customer is no longer in the loop after the initial crank request, the customer may release the key to the RUN position. The PCM will disengage the starter motor based on the following events

1. The engine is started (RPM threshold)
2. A set time has been exceeded
3. The ignition key has been turned to the OFF position

SPECIAL TOOLS CHART Flex Probe Kit 300-NUD105-R025DE or equivalent Fluke 77-IV Digital Multimeter FLU77-4 or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Scheme 1

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Principles of Operation

All vehicles are equipped with a One-Touch Integrated Start (OTIS) starting system.

The starting system is electronically controlled by the PCM. The PCM receives the following inputs

1. Correctly coded ignition key, from the Passive Anti-Theft System (PATS)
2. Starter motor request, ignition switch in the START position
3. Transmission in PARK or NEUTRAL, from the digital Transmission Range (TR) sensor

When the ignition switch is placed in the START position, voltage is supplied to the coil of the starter relay through the OTIS start diode. A starter motor request signal is also sent to the PCM. If the PCM recognizes the needed input signals, it provides the starter relay coil with both voltage and a ground. The starter relay contacts close providing voltage to the starter solenoid, allowing the starter motor to activate. Once the starter motor begins to crank, the ignition switch may be released. The starter motor will continue to crank until the engine starts, the timing circuit in the PCM times out or the ignition switch is turned to the OFF position.

The starting system is electronically controlled by the Passive Anti-Theft System (PATS). The PATS recognizes the correct electronically coded ignition key and signals the PCM to provide a ground for the starter relay. The energized relay provides voltage to the starter solenoid, thereby allowing the starter motor to activate.

Inspection and Verification

Note. The PATS must be functioning correctly before a logical starting system diagnosis can be carried out. Address PATS concerns before continuing.

1. Verify the customer concern by operating the starting system to duplicate the conditions.
2. Remove the accessory drive belt. Refer to «ACCESSORY DRIVE»(/ford/econoline-e250/2012-2013/remont/accessory-drive-belts/#accessory-drive-system) . Verify the crankshaft and each of the components driven by the accessory drive belt rotate and are not seized or damaged.
3. Inspect to determine if any of the following mechanical or electrical concerns apply. VISUAL INSPECTION CHART Mechanical Electrical Flexplate Starter motor Starter motor bolts Passive Anti-Theft System (PATS) Battery Battery Junction Box (BJB) fuse 13 (30A) BJB fuse 35 (20A) (stripped chassis only) Smart Junction Box (SJB) fuse 27 (20A) (all except stripped chassis) Damaged wiring harness Loose or corroded connections Starter relay Digital Transmission Range (TR) sensor Start diode
4. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
5. If the cause is not visually evident, connect the scan tool to the Data Link Connector (DLC).
6. If the scan tool does not communicate with the VCM: check the VCM connection to the vehicle. check the scan tool connection to the VCM. refer to «MODULE COMMUNICATIONS NETWORK»(/ford/econoline-e250/2012-2013/remont/communication-devices/#module-communications-network) , No Power To The Scan Tool, to diagnose no power to the scan tool.
7. If the scan tool does not communicate with the vehicle: verify the ignition key is in the ON position. verify the scan tool operation with a known good vehicle. refer to «MODULE COMMUNICATIONS NETWORK»(/ford/econoline-e250/2012-2013/remont/communication-devices/#module-communications-network) to diagnose no response from the PCM.
8. Carry out the network test. If the scan tool responds with no communication for one or more modules, refer to «MODULE COMMUNICATIONS NETWORK»(/ford/econoline-e250/2012-2013/remont/communication-devices/#module-communications-network) . If the network test passes, retrieve and record Continuous Memory Diagnostic Trouble Codes (CMDTCs).
9. Clear the continuous DTCs and carry out the self-test diagnostics for the PCM.
10. If the DTCs retrieved are related to the concern, go to the «PCM DTC Chart»(/ford/econoline-e250/2012-2013/remont/starter/#starting-system) . For all other DTCs, refer to «MULTIFUNCTION ELECTRONIC MODULES»(/ford/econoline-e250/2012-2013/remont/cruise-control-systems/#multifunction-electronic-modules) .
11. If no DTCs related to the concern are retrieved, GO to «SYMPTOM CHART»(/ford/econoline-e250/2012-2013/remont/starter/#starting-system__symptom-chart) .

DTC Charts

PCM DTC CHART

Symptom Chart

SYMPTOM CHART

Pinpoint Test A: The Engine Does Not Crank/The Relay Does/Does Not Click

Refer to OEM WIRING DIAGRAMS - STARTING SYSTEM for schematic and connector information.

Normal Operation

Under normal operation, the Battery Junction Box (BJB) supplies constant power to the starter motor relay through fuse 13 (30A). When the key is placed in the START position, power is sent to the start diode through circuit CDC35 (BU/WH). Power continues through circuit CE336 (GN/WH) to the PCM and to the starter relay (TorqShift transmission) or the digital Transmission Range (TR) sensor (4R75 transmission). If the TR is in either the PARK or NEUTRAL position, power flows to the starter relay through circuit CET40 (GN/OG).

On vehicles equipped with a TorqShift transmission, the PCM will receive a signal from the transmission that the vehicle is in PARK or NEUTRAL through circuit VET32 (VT).

The PCM then provides ground on circuit CDC12 (YE) to the starter motor relay. The coil of the relay is energized and sends power to the starter motor on circuit CDC25 (BN/GN). The solenoid is grounded at the starter motor. Energizing the starter solenoid will engage the starter drive into the flexplate ring gear and closes the solenoid contacts allowing power directly from the battery through circuit SDC02 (RD) to the starter motor to start the engine.

The PCM will disengage the starter motor based on RPM threshold, a set time has been exceeded or the ignition key has been turned to the OFF position.

This pinpoint test is intended to diagnose the following

1. Battery
2. Circuitry
3. Fuse(s)
4. Ignition switch
5. PCM
6. Start diode
7. Starter motor
8. Starter motor relay
9. TR sensor

Scheme 4

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Scheme 13

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Scheme 17

1. A1 CHECK THE BATTERY Check the battery condition and charge. Refer to «BATTERY, MOUNTING AND CABLES»(/ford/econoline-e250/2012-2013/remont/charging-system/#battery-battery-mounting-battery-cables) . Is the battery OK? Yes : GO to A2. No : CHARGE or INSTALL a new battery as necessary. REFER to «BATTERY, MOUNTING AND CABLES»(/ford/econoline-e250/2012-2013/remont/charging-system/#battery-battery-mounting-battery-cables) . TEST the system for normal operation.
2. A2 CHECK THE PCM FOR DTCs Check for PCM DTCs. Were any PCM DTCs retrieved? Yes : If PCM DTC P1260 is retrieved, REFER to «ANTI-THEFT - PASSIVE ANTI-THEFT SYSTEM (PATS)»(/ford/econoline-e250/2012-2013/remont/door-locks-anti-theft-systems/#anti-theft-system-passive-anti-theft-system) . All other PCM DTCs, REFER to «INTRODUCTION - GASOLINE MODELS»(/ford/econoline-e250/2012-2013/remont/oem-general-information/#service-information-introduction) . No : GO to A3.
3. A3 CHECK THE TR SENSOR PID Enter the following diagnostic mode on the scan tool: PCM DataLogger/PID. While observing the PCM TR sensor PID, place the vehicle in PARK and NEUTRAL. Does the PID match the gear selection? Yes : GO to A4. No : For vehicles equipped with a 4R75 transmission, GO to «AUTOMATIC TRANSAXLE/TRANSMISSION - 4R70E/4R75E»(/ford/econoline-e250/2012-2013/remont/automatic-trans/#automatic-transmission-4r70ew-4r75ew) . For vehicles equipped with a TorqShift transmission, GO to «AUTOMATIC TRANSAXLE/TRANSMISSION - TORQSHIFT»(/ford/econoline-e250/2012-2013/remont/automatic-trans/#automatic-transmission-5r110w-torqshiftr) .
4. A4 CHECK THE STARTER MOTOR CONTROL OUTPUT DETECTED (SMC_MON) PID Enter the following diagnostic mode on the scan tool: PCM DataLogger/PID. Monitor the PCM PID SMC_MON with the ignition switch in the START position. Does the PID change from OFF to ON? Yes : GO to A5. No : GO to A20 .
5. A5 CHECK THE BATTERY GROUND CABLE Measure the voltage between the positive battery post and the battery ground cable connection at the engine. Is the voltage greater than 10 volts? Yes : GO to A6. No : INSTALL a new battery ground cable. REFER to «BATTERY, MOUNTING AND CABLES»(/ford/econoline-e250/2012-2013/remont/charging-system/#battery-battery-mounting-battery-cables) . TEST the system for normal operation.
6. A6 CHECK THE STARTER MOTOR GROUND Measure the voltage between the positive battery post and the starter motor case. Is the voltage greater than 10 volts? Yes : GO to A7. No : CLEAN the starter motor mounting flange and make sure the starter motor is correctly mounted. TEST the system for normal operation.
7. A7 CHECK THE POWER SUPPLY TO THE STARTER MOTOR Measure the voltage between starter motor solenoid terminal C197A-1, circuit 2037 (RD) and ground. Is the voltage greater than 10 volts? Yes : GO to A8. No : INSTALL a new positive battery cable. REFER to «BATTERY, MOUNTING AND CABLES»(/ford/econoline-e250/2012-2013/remont/charging-system/#battery-battery-mounting-battery-cables) . TEST the system for normal operation.
8. A8 CHECK THE STARTER MOTOR Connect one end of a fused jumper wire to starter motor solenoid terminal C197A-1, circuit SDC02 (RD). Momentarily connect the other end of the jumper to starter motor solenoid terminal C197B-1, circuit CDC25 (BN/GN). Did the starter motor engage and the engine crank? Yes : GO to A9. No : INSTALL a new starter motor. REFER to «STARTER MOTOR»(/ford/econoline-e250/2012-2013/remont/starter/#starting-system) . TEST the system for normal operation.
9. A9 CHECK THE CIRCUIT TO THE STARTER MOTOR NOTE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. Ignition OFF. Disconnect: Starter Motor Solenoid C197B-1. Disconnect: Starter Motor Relay. Measure the resistance between starter motor solenoid terminal C197B-1, circuit CDC25 (BN/GN) and the starter motor relay cavity 5, circuit CDC25 (BN/GN). Is the resistance less than 5 ohms? Yes : GO to A10. No : REPAIR circuit CDC25 (BN/GN). TEST the system for normal operation.
10. A10 CHECK THE BATTERY SUPPLY TO THE STARTER RELAY NOTE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. Measure the voltage at starter motor relay cavity 3 circuit SBB13 (GY/RD). Is the voltage reading greater than 10 volts? Yes : GO to A11. No : VERIFY the PDB fuse 13 (30A) is OK. If OK, REPAIR circuit SDC02 (RD). If not OK, REFER to the appropriate System Wiring Diagrams information to identify the possible causes of the circuit short.
11. A11 CHECK THE STARTER MOTOR RELAY Carry out the Starter Motor Relay Component Test. Refer to «OEM COMPONENT TESTING»(/ford/econoline-e250/2012-2013/remont/body-electrical/#oem-component-testing) for component testing. Did the starter motor relay pass the component test? Yes : Vehicles equipped with a 4R75 transmission, GO to A12. Vehicles equipped with a TorqShift transmission, GO to A16 . No : INSTALL a new starter motor relay. TEST the system for normal operation.
12. A12 CHECK CIRCUIT CET40 (GN/OG) FOR VOLTAGE NOTE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. Key in START position. Measure the voltage between starter motor relay cavity 1, circuit CET40 (GN/OG) and ground with the ignition switch in the START position. Is the voltage greater than 10 volts? Yes : GO to A20 . No : GO to A13.
13. A13 CHECK CIRCUIT CET40 (GN/OG) FOR AN OPEN NOTE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. Disconnect: TR Sensor. Measure the resistance between TR sensor C167-10 circuit CET40 (GN/OG) and starter motor relay cavity 1 circuit CET40 (GN/OG). Is the resistance less than 5 ohms? Yes : GO to A14. No : REPAIR circuit CET 40 (GN/OG). TEST the system for normal operation.
14. A14 CHECK CIRCUIT CE336 (GN/WT) FOR VOLTAGE NOTE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. Key in START position. Measure the voltage between TR sensor C167-10 circuit CE336 (GN/WH), harness side and ground. Is the voltage greater than 10 volts? Yes : INSTALL a new TR sensor. REFER to «AUTOMATIC TRANSAXLE/TRANSMISSION - 4R70E/4R75E»(/ford/econoline-e250/2012-2013/remont/automatic-trans/#automatic-transmission-4r70ew-4r75ew) . TEST the system for normal operation. No : GO to A15.
15. A15 CHECK CIRCUIT CE336 (GN/WH) FOR AN OPEN NOTE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. Disconnect: Start Diode. Measure the resistance between TR sensor C167-12 circuit CE336 (GN/WH) harness side and start diode cavity 1 circuit CE336 (GN/WH). Is the resistance less than 5 ohms? Yes : GO to A18 . No : REPAIR circuit CE336 (GN/WH). TEST the system for normal operation.
16. A16 CHECK CIRCUIT CE336 (GN/WH) FOR VOLTAGE NOTE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. Key in START position. Measure the voltage between starter motor relay cavity 1 circuit CE336 (GN/WH) and ground with the key in the START position. Is the voltage greater than 10 volts? Yes : GO to A20 . No : GO to A17.
17. A17 CHECK CIRCUIT CE336 (GN/WH) FOR AN OPEN NOTE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. Disconnect: Start Diode. Measure the resistance between start motor relay cavity 1 circuit CE336 (GN/WH) and start diode cavity 1 circuit CE336 (GN/WH). Is the resistance less than 5 ohms? Yes : GO to A18. No : REPAIR circuit CE336 (GN/WH). TEST the system for normal operation.
18. A18 CHECK CIRCUIT CDC35 (BU/WH) FOR VOLTAGE NOTE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. Key in START position. Measure the voltage between the start diode cavity 2 circuit CDC35 (BU/WH) and ground with the key in the START position. Is the reading greater than 10 volts? Yes : INSTALL a new start diode. CHECK the system for normal operation. No : GO to A19.
19. A19 CHECK THE IGNITION SWITCH Carry out the ignition switch component test. Refer to «OEM COMPONENT TESTING»(/ford/econoline-e250/2012-2013/remont/body-electrical/#oem-component-testing) for component testing. Did the ignition switch pass the component test? Yes : REPAIR circuit CDC35 (BU/WH). TEST the system for normal operation. No : INSTALL a new ignition switch. TEST the system for normal operation.
20. A20 CHECK CIRCUIT CDC12 (YE) FOR AN OPEN NOTE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. Disconnect: PCM C175B (4.6L or 5.4L engines) or PCM C1551B (6.8L engines). For vehicles equipped with a 4.6L or 5.4L engine, measure the resistance between the starter motor relay cavity 2 circuit CDC12 (YE) and PCM C175B-7, circuit CDC12 (YE). For vehicles equipped with a 6.8L engine, measure the resistance between the starter motor relay cavity 2 circuit CDC12 (YE) and PCM C1551B-2, circuit CDC12 (YE). Is the resistance reading 5 ohms or less? Yes : DIAGNOSE the PCM. REFER to the «INTRODUCTION - GASOLINE MODELS»(/ford/econoline-e250/2012-2013/remont/oem-general-information/#service-information-introduction) . No : REPAIR circuit CDC12 (YE) for an open. TEST the system for normal operation.

Pinpoint Test B: One-Touch Integrated Start (OTIS) Does Not Operate Correctly

Refer to OEM WIRING DIAGRAMS - STARTING SYSTEM for schematic and connector information.

Under normal operation, the Battery Junction Box (BJB) supplies constant power to the starter motor relay through fuse 13 (30A). When the key is placed in the START position, power is sent to the start diode through circuit CDC35 (BU/WH). Power continues through circuit CE336 (GN/WH) to the PCM and to the starter relay (TorqShift transmission) or the digital Transmission Range (TR) sensor (4R75 transmission). If the TR is in either the PARK or NEUTRAL position, power flows to the starter relay through circuit CET40 (GN/OG).

On vehicles equipped with a TorqShift transmission, the PCM will receive a signal from the transmission that the vehicle is in PARK or NEUTRAL through circuit VET32 (VT).

The PCM then provides ground on circuit CDC12 (YE) to the starter motor relay. The coil of the relay is energized and sends power to the starter motor on circuit CDC25 (BN/GN). The solenoid is grounded at the starter motor. Energizing the starter solenoid will engage the starter drive into the flexplate ring gear and closes the solenoid contacts allowing power directly from the battery through circuit SDC02 (RD) to the starter motor to start the engine.

The PCM will disengage the starter motor based on RPM threshold, a set time has been exceeded or the ignition key has been turned to the OFF position.

This pinpoint test is intended to diagnose the following

1. Circuitry
2. PCM

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1. B1 CHECK THE STATUS OF OTIS (OTS_STAT) PID Enter the following diagnostic mode on the scan tool: PCM DataLogger/PID. Monitor the PCM PID OTS_STAT with the ignition switch in the RUN position. Is the OTIS PID enabled? Yes : GO to B2. No : ENABLE One-Touch Integrated Start (OTIS). TEST the system for normal operation. If OTIS will not enable, INSTALL a new PCM. REFER to «ELECTRONIC ENGINE CONTROLS»(/ford/econoline-e250/2012-2013/remont/removal-installation/#engine-controls-electronic-engine-controls) . TEST the system for normal operation.
2. B2 CHECK THE KEY POSITION FOR START INDICATED (START_KEY) PID Enter the following diagnostic mode on the scan tool: PCM DataLogger/PID. Monitor the PCM PID START_KEY with the ignition switch in the START position. Does the PID change from OFF to ON? Yes : GO to B4 . No : GO to B3.
3. B3 CHECK CIRCUIT CDC35 (BU/WH) FOR AN OPEN NOTE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. Disconnect: Start Diode. Disconnect: PCM C175B (4.6L or 5.4L engines) or PCM C1551B (6.8L engines). For vehicles equipped with a 4.6L or 5.4L engine, measure the resistance between start diode cavity 2, circuit CDC35 (BU/WH) and PCM C175B-16, circuit CDC35 (BU/WH), harness side. For vehicles equipped with a 6.8L engine, measure the resistance between start diode cavity 2 circuit CDC35 (BU/WH) and PCM C1551B-20, circuit CDC35 (BU/WH). Is the resistance less than 5 ohms? Yes : DIAGNOSE the PCM. REFER to «INTRODUCTION - GASOLINE MODELS»(/ford/econoline-e250/2012-2013/remont/oem-general-information/#service-information-introduction) . No : REPAIR circuit CDC35 (BU/WH). TEST the system for normal operation.
4. B4 CHECK THE STARTER MOTOR RELAY ENABLE (STRT_RLY) PID Enter the following diagnostic mode on the scan tool: PCM DataLogger/PID. Monitor the PCM PID STRT_RLY with the ignition switch in the START position. Does the PID change from DISABLED to ENABLED? Yes : GO to B6 . No : GO to B5.
5. B5 CHECK THE STARTER MOTOR CONTROL OUTPUT DETECTED (SMC_MON) PID Enter the following diagnostic mode on the scan tool: PCM DataLogger/PID. Monitor the PCM PID SMC_MON with the ignition switch in the START position. Does the PID change from OFF to ON? Yes : GO to B6. No : DIAGNOSE the PCM. REFER to «INTRODUCTION - GASOLINE MODELS»(/ford/econoline-e250/2012-2013/remont/oem-general-information/#service-information-introduction) .
6. B6 CHECK CIRCUIT CE336 (GN/WH) BETWEEN THE START DIODE AND THE PCM FOR AN OPEN NOTE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. Disconnect: Start Diode. Disconnect: PCM C175B (4.6L or 5.4L engines) or PCM C1551B (6.8L engines). For vehicles equipped with a 4.6L or 5.4L engine, measure the resistance between start diode cavity 1, circuit CE336 (GN/WH) and PCM C175B-37, circuit CE336 (GN/WH), harness side. For vehicles equipped with a 6.8L engine, measure the resistance between start diode cavity 1 circuit CE336 (GN/WH) and PCM C1551B-38, circuit CE336 (GN/WH). Is the resistance less than 5 ohms? Yes : DIAGNOSE the PCM. REFER to «INTRODUCTION - GASOLINE MODELS»(/ford/econoline-e250/2012-2013/remont/oem-general-information/#service-information-introduction) . No : REPAIR circuit CE336 (GN/WH). TEST the system for normal operation.

Pinpoint Test C: The Engine Cranks Slowly

Refer to OEM COMPONENT TESTING for schematic and connector information.

Under normal operation, the Battery Junction Box (BJB) supplies constant power to the starter motor relay through fuse 13 (30A). When the key is placed in the START position, power is sent to the start diode through circuit CDC35 (BU/WH). Power continues through circuit CE336 (GN/WH) to the PCM and to the starter relay (TorqShift transmission) or the digital Transmission Range (TR) sensor (4R75 transmission). If the TR is in either the PARK or NEUTRAL position, power flows to the starter relay through circuit CET40 (GN/OG).

On vehicles equipped with a TorqShift transmission, the PCM will receive a signal from the transmission that the vehicle is in PARK or NEUTRAL through circuit VET32 (VT).

The PCM then provides ground on circuit CDC12 (YE) to the starter motor relay. The coil of the relay is energized and sends power to the starter motor on circuit CDC25 (BN/GN). The solenoid is grounded at the starter motor. Energizing the starter solenoid will engage the starter drive into the flexplate ring gear and closes the solenoid contacts allowing power directly from the battery through circuit SDC02 (RD) to the starter motor to start the engine.

The PCM will disengage the starter motor based on RPM threshold, a set time has been exceeded or the ignition key has been turned to the OFF position.

This pinpoint test is intended to diagnose the following

1. Battery
2. Circuitry
3. Ground circuit
4. Starter motor

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1. C1 CHECK THE BATTERY Check the battery condition and charge Refer to «BATTERY, MOUNTING AND CABLES»(/ford/econoline-e250/2012-2013/remont/charging-system/#battery-battery-mounting-battery-cables) . Is the battery OK? Yes : GO to C2. No : CHARGE or INSTALL a new battery as required. TEST the system for normal operation.
2. C2 CHECK THE VOLTAGE TO THE STARTER Ignition OFF. Measure the voltage between starter motor solenoid C197A-1, circuit 2037 (RD) and ground. Is the voltage 10 volts or greater? Yes : GO to C3. No : REPAIR circuit 2037 (RD). CLEAN and TIGHTEN the connections at the battery terminals. TEST the system for normal operation.
3. C3 CHECK MOTOR GROUND CIRCUIT Carry out the «STARTER MOTOR - GROUND CIRCUIT TEST»(/ford/econoline-e250/2012-2013/remont/starter/#starting-system__starter-motor-ground-circuit) . Refer to the «COMPONENT TESTS»(/ford/econoline-e250/2012-2013/remont/starter/#starting-system__component-tests) . 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.

Under normal operation, the Power Distribution Box (PDB) supplies constant power to the starter motor relay through fuse 13 (30A). When the key is placed in the START position, power is sent to the start diode through circuit CDC35 (BU/WH). Power continues through circuit CE336 (GN/WH) to the PCM and to the starter relay (TorqShift transmission) or the digital Transmission Range (TR) sensor (4R75 transmission). If the TR is in either the PARK or NEUTRAL position, power flows to the starter relay through circuit CET40 (GN/OG).

On vehicles equipped with a TorqShift transmission, the PCM will receive a signal from the transmission that the vehicle is in PARK or NEUTRAL through circuit VET32 (VT).

The PCM then provides ground on circuit CDC12 (YE) to the starter motor relay. The coil of the relay is energized and sends power to the starter motor on circuit CDC25 (BN/GN). The solenoid is grounded at the starter motor. Energizing the starter solenoid will engage the starter drive into the flexplate ring gear and closes the solenoid contacts allowing power directly from the battery through circuit SDC02 (RD) to the starter motor to start the engine.

The PCM will disengage the starter motor based on RPM threshold, a set time has been exceeded or the ignition key has been turned to the OFF position.

This pinpoint test is intended to diagnose the following

1. Starter motor mounting
2. Starter motor mounting bolts
3. Starter motor drive
4. Flywheel or flexplate ring gear
5. Starter motor

Scheme 23

1. D1 CHECK THE STARTER MOTOR MOUNTING Inspect the starter motor mounting bolts for looseness. Is the starter motor mounted correctly? Yes : GO to D2. No : REINSTALL the starter motor correctly. REFER to «STARTER MOTOR»(/ford/econoline-e250/2012-2013/remont/starter/#starting-system) .
2. D2 CHECK FOR ENGINE NOISE Ignition OFF. Connect a remote starter switch between the starter motor solenoid terminals C197A-1, circuit 2037 (RD), and C197B-1, circuit 113 (YE/LB). Engage the starter motor and verify that the noise is due to the starter operation. Is the noise due to the starter motor engagement? Yes : GO to D3. No : REFER to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/econoline-e250/2012-2013/remont/mechanical/#engine-system-general-information-e-series) to continue the diagnosis.
3. D3 CHECK FOR UNUSUAL WEAR Remove the starter motor. Refer to «STARTER MOTOR»(/ford/econoline-e250/2012-2013/remont/starter/#starting-system) . Inspect the ring gear for damaged or worn teeth. Is the noise due to ring gear tooth damage? Yes : INSTALL a new flexplate. REFER to «ENGINE - 4.6L (2V)»(/ford/econoline-e250/2012-2013/remont/mechanical/#engine-mechanical-46l-2v) for 4.6L and 5.4L engines. REFER to «ENGINE - 6.8L»(/ford/econoline-e250/2012-2013/remont/mechanical/#engine-mechanical-68l-e-series) for 6.8L engines. EXAMINE the starter pinion teeth. If damaged, INSTALL a new starter motor. REFER to «STARTER MOTOR»(/ford/econoline-e250/2012-2013/remont/starter/#starting-system) . TEST the system for normal operation. No : INSTALL a new starter motor. REFER to «STARTER MOTOR»(/ford/econoline-e250/2012-2013/remont/starter/#starting-system) . TEST the system for normal operation.

Component Tests

Always make the Fluke 77-IV Digital Multimeter connections at the component terminal rather than at the wiring end connector. Making a connection at the wiring end connector could result in false readings because the meter will not pick up a high resistance between the wiring connector and the component.

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1. Make sure the battery is fully charged; carry out a battery load test. Refer to «BATTERY, MOUNTING AND CABLES»(/ford/econoline-e250/2012-2013/remont/charging-system/#battery-battery-mounting-battery-cables) .
2. Disconnect the Inertia Fuel Shutoff (IFS) switch.
3. Connect a remote starter switch between the starter solenoid S-terminal and the battery positive (+) terminal.
4. Connect the Fluke 77-IV Digital Multimeter positive lead to the battery positive (+) post. Connect the negative lead to the starter solenoid M-terminal. Item Part Number Description 1 - S-terminal 2 - Remote starter switch 3 10653 Battery 4 - Fluke 77-IV Digital Multimeter 5 - B-terminal 6 - M-terminal
5. Engage the remote starter switch. Read and record the voltage. The voltage reading should be 0.5 volt or less.
6. If the voltage reading is 0.5 volt or less, go to the starter motor-ground circuit component test.
7. If the voltage reading is greater than 0.5 volt, this is an indication of excessive resistance in the connections, the positive battery cable or in the starter solenoid. Move the Fluke 77-IV Digital Multimeter negative lead to the starter solenoid B-terminal and repeat the test. If the voltage reading at the B-terminal is lower than 0.5 volt, the concern is either in the connections at the starter solenoid or in the solenoid contacts. Item Part Number Description 1 - S-terminal 2 - Remote starter switch 3 10653 Battery 4 - Fluke 77-IV Digital Multimeter 5 - B-terminal 6 - M-terminal
8. Remove the cables from solenoid B-, S- and M-terminals. Clean the cables and connections and reinstall the cables to the correct terminals. Repeat Steps 3 through 6 . If the voltage drop reading is still greater than 0.5 volt when checked at the M-terminal and less than 0.5 volt when checked at the B-terminal, the concern is in the solenoid contacts. Install a new starter motor.
9. If the voltage reading taken at the solenoid B-terminal is still greater than 0.5 volt after cleaning the cables and connections at the solenoid, the concern is either in the positive (+) battery cable connection or in the positive battery cable itself.
10. Clean the positive (+) battery cable connection. If this does not solve the problem, install a new positive battery cable.

Starter Motor - Ground Circuit

A slow cranking condition can be caused by resistance in the ground or return portion of the cranking circuit. Check the voltage drop in the ground circuit as follows

1. Connect the Fluke 77-IV Digital Multimeter positive lead to the starter motor housing (the connection must be clean and free of rust or grease). Connect the negative lead to the negative (-) battery terminal.
2. Engage the remote starter switch and crank the engine. Read and record the voltage reading. The reading should be 0.2 volt or less.
3. If the voltage drop is more than 0.2 volt, clean the negative cable connections at the battery, the body ground connections and the starter ground connection. Retest.
4. If the voltage drop is greater than 0.2 volt, install a new cable. If the voltage reading is less than 0.2 volt and the engine still cranks slowly, install a new starter motor.

Scheme 26

Scheme 27

1. Check the wear patterns on the starter drive and the flexplate ring gear. If the wear pattern is not normal, install a new starter motor. For additional information, refer to «STARTER MOTOR»(/ford/econoline-e250/2012-2013/remont/starter/#starting-system) .
2. If the starter drive gear and the flywheel ring gear are not fully meshing or the gears are milled or damaged, install a new starter motor. For additional information, refer to «STARTER MOTOR»(/ford/econoline-e250/2012-2013/remont/starter/#starting-system) . Install a new flexplate. For additional information, refer to «ENGINE - 4.6L (2V)»(/ford/econoline-e250/2012-2013/remont/mechanical/#engine-mechanical-46l-2v) or «ENGINE - 6.8L»(/ford/econoline-e250/2012-2013/remont/mechanical/#engine-mechanical-68l-e-series) .

Scheme 28

Removal and Installation

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/econoline-e250/2012-2013/remont/hoistjack/#jacking-lifting) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/econoline-e250/2012-2013/remont/charging-system/#battery-battery-mounting-battery-cables) .
3. Detach the starter motor solenoid terminal cover.
4. Remove the starter solenoid S-terminal nut and disconnect the S-terminal eyelet. To install, tighten to 6 Nm (53 lb-in).
5. Remove the starter solenoid B-terminal nut and disconnect the B-terminal eyelet. To install, tighten to 12 Nm (106 lb-in).
6. Remove the starter motor ground cable nut and disconnect the ground cable eyelet. To install, tighten to 25 Nm (18 lb-ft).
7. Remove the bolts, the stud bolt and the starter motor. To install, tighten the upper bolt before tightening the lower fasteners. To install, tighten to 25 Nm (18 lb-ft).
8. To install, reverse the removal procedure.

See also:
• ACCESSORY DRIVE
• MODULE COMMUNICATIONS NETWORK
• MULTIFUNCTION ELECTRONIC MODULES
• OEM COMPONENT TESTING
• BATTERY, MOUNTING AND CABLES
• ANTI-THEFT - PASSIVE ANTI-THEFT SYSTEM (PATS)
• INTRODUCTION - GASOLINE MODELS
• AUTOMATIC TRANSAXLE/TRANSMISSION - 4R70E/4R75E
• AUTOMATIC TRANSAXLE/TRANSMISSION - TORQSHIFT
• ELECTRONIC ENGINE CONTROLS
• ENGINE SYSTEM - GENERAL INFORMATION
• ENGINE - 4.6L (2V)
• ENGINE - 6.8L
• JACKING & LIFTING
• PCM DTC Chart
• SYMPTOM CHART
• PINPOINT TEST A
• PINPOINT TEST B
• PINPOINT TEST C
• STARTER MOTOR - GROUND CIRCUIT TEST
• COMPONENT TESTS