Starters: Diagnosis Ford Escape I

TROUBLE SHOOTING

Check battery for state of charge. Check cable connections at battery and starter motor. Ensure transmission is fully engaged in Park or Neutral (A/T) or clutch pedal is fully depressed (M/T). On models equipped anti-theft system, ensure anti-theft system is operating properly. See appropriate ANTI-THEFT SYSTEMS article in ACCESSORIES & EQUIPMENT for additional information. If problem is found, repair as necessary. If problem is not found, repair by symptom. See SYMPTOM INDEX table under SYSTEM TESTS.

TEST A: ENGINE DOES NOT CRANK OR RELAY CLICKS

1. Ensure battery is fully charged and has sufficient capacity. Ensure battery terminals are clean and tight. If battery is okay, go to next step. If problem is found, replace battery as necessary.
2. Turn ignition switch to LOCK position. Remove starter relay from battery junction box. Test starter relay. See «STARTER RELAY»(ref-139338-S35672519532002043000000) under COMPONENT TESTS. If starter relay is okay, go to next step. If starter relay is defective, replace starter relay.
3. Measure voltage between ground and starter relay connector terminal No. 30 (Yellow wire). (Scheme 1) If voltage is greater than 10 volts, go to next step. If voltage is not greater than 10 volts, replace battery junction box. Check system operation.
4. Install starter relay. Disconnect PCM connector 175. Connect a jumper wire between ground and PCM connector terminal No. 44 (Dark Blue/Orange wire). Turn ignition switch to START position. If engine cranks, see appropriate ANTI-THEFT SYSTEMS article in ACCESSORIES & EQUIPMENT. If engine does not crank, go to next step.
5. Turn ignition switch to LOCK position. Disconnect the starter relay. Measure the resistance in Dark Blue/Orange wire between central junction box and PCM connector 175. Connect positive voltmeter lead to starter relay connector terminal No. 85 and negative voltmeter lead to PCM connector terminal No. 44. If resistance is less than 5 ohms, go to next step. If resistance is more than 5 ohms, ensure starter relay diode is not at fault, repair circuit between starter relay and PCM as necessary.
6. Install starter relay. Connect PCM connector 175. Turn ignition switch to RUN position. On M/T vehicles, ensure clutch pedal is depressed completely. On A/T vehicles, ensure transmission is in Park. On all models, turn ignition switch to START position. Measure voltage between ground and starter relay connector terminal No. 86 (Tan/Red wire). If voltage is greater than 10 volts, go to next step. If voltage is not greater than 10 volts, go to step 9 (A/T) or step 13 (M/T).
7. Turn ignition switch to LOCK position. Disconnect starter motor solenoid "S"connector. (Scheme 2) Measure the resistance of the White/Pink wire between starter motor solenoid terminal "S" connector and starter relay connector terminal No. 87. If resistance is less than 5 ohms, go to next step. If resistance is greater than 5 ohms, repair circuit in White/Pink wire between starter relay and starter motor. Check system operation.
8. Install starter relay. Connect starter motor solenoid "S" connector. Perform «STARTER GROUND CIRCUIT TEST»(ref-139338-S29138582852002043000000) under ON-VEHICLE TESTING. If starter motor ground circuit is okay, perform «VOLTAGE DROP TEST»(ref-139338-S08986665712002043000000) under ON-VEHICLE TESTING. If starter motor ground is not okay, repair or replace battery ground cable and/or engine ground cable as needed. Check system operation.
9. Ensure the transaxle linkage is adjusted properly. If linkage adjustment is okay, go to next step. If linkage adjustment is not okay, adjust linkage. Check system operation.
10. Check Digital Transmission Range (DTR) sensor adjustment. See «DIGITAL TRANSMISSION RANGE SENSOR»(ref-139338-S26475162142002043000000) under ADJUSTMENTS. If adjustment is okay, go to next step. If out of adjustment, adjust DTR sensor as necessary. Check system operation.
11. Disconnect DTR sensor harness connector. Turn ignition switch to START position. Measure voltage between ground and DTR sensor harness connector terminal No. 9 (Tan/Light Blue wire). (Scheme 3) If voltage is greater than 10 volts, go to next step. If voltage is not greater than 10 volts, repair power distribution circuit as necessary (Tan/Light Blue wire). See «POWER DISTRIBUTION»(ref-143428-S40783610392002082600000) in SYSTEM WIRING DIAGRAMS article ELECTRICAL. Check system operation.
12. Turn ignition switch to LOCK position. Remove starter relay from Battery Junction Box (BJB). Measure resistance between DTR sensor harness connector terminal No. 4 (Tan/Red wire) and starter relay connector terminal No. 86. (Scheme 1)and (Scheme 3). If resistance is less than 5 ohms, replace DTR sensor. If resistance is greater than 5 ohms, repair Tan/Red wire between DTR sensor and BJB. Check system operation.
13. Disconnect Clutch Pedal Position (CPP) switch harness connector. Turn ignition switch to START position. Measure voltage between ground and CPP switch harness connector terminal No. 1 (Tan/Light Blue wire). (Scheme 4) If voltage is greater than 10 volts, go to next step. If battery voltage is not greater than 10 volts, repair power distribution circuit as necessary (Tan/Light Blue wire). See «POWER DISTRIBUTION»(ref-143428-S40783610392002082600000) in SYSTEM WIRING DIAGRAMS article in ELECTRICAL. Check system operation.
14. Turn ignition switch to LOCK position. Measure resistance in Tan/Red wire between CPP switch harness connector terminal No. 2 and starter relay connector terminal No. 86. (Scheme 1)and (Scheme 4). If resistance is less than 5 ohms, replace CPP switch. Check system operation. If resistance is greater than 5 ohms, repair Tan/Red wire between CPP switch and starter relay. Check system operation.

Scheme 1

Scheme 2

Scheme 3

Scheme 4

TEST B: UNUSUAL STARTER NOISE

1. Verify starter is installed properly. Ensure bolts are tight. See «TORQUE SPECIFICATIONS»(ref-139338-S13688772852002043000000) . If starter is mounted properly, go to next step. If starter is not mounted properly, repair as necessary and check system for normal operation.
2. Remove starter motor. See «STARTER MOTOR»(ref-139338-S29196489922002043000000) under REMOVAL & INSTALLATION. Inspect flywheel ring gear for wear or damage. If ring gear is okay, replace starter motor. If ring gear is worn or damaged, replace ring gear and inspect starter drive gear. If drive gear is also damaged, replace starter motor. If noise is not coming from starter motor, diagnose engine mechanical concern. See appropriate article in ENGINES.

ON VEHICLE TESTING

VOLTAGE DROP TEST

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

Scheme 5

1. Ensure battery is fully charged. Disconnect ignition coil connector. Connect remote starter switch between starter solenoid terminal "S" and positive battery post. (Scheme 5)Connect positive voltmeter lead to positive battery post, and negative lead to solenoid terminal "M".
2. Engage remote starter switch. If voltmeter indicates.5 volt or less, go to «STARTER GROUND CIRCUIT TEST»(ref-139338-S29138582852002043000000). If voltmeter indicates greater than.5 volt, go to next step.
3. Move negative voltmeter lead to solenoid terminal "B". Engage remote starter switch. If voltmeter indicates less than.5 volt, solenoid connections or contacts are bad. Clean solenoid terminals "B", "S" and "M". Repeat steps 1 - 3.
4. If voltmeter still indicates more than.5 volt at terminal "M" and less than.5 volt at terminal "B", solenoid contacts are bad. Replace starter motor. See «STARTER MOTOR»(ref-139338-S29196489922002043000000) under REMOVAL & INSTALLATION. If voltmeter indicates greater than.5 volt at terminal "B", clean cables and connections at solenoid.
5. If voltmeter still indicates greater than.5 volt at terminal "B", check for poor positive battery cable connection or bad cable. Repair connection or replace battery cable as necessary.

STARTER GROUND CIRCUIT TEST

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

1. Disconnect ignition coil connector. Connect remote starter switch between starter solenoid terminal "S" and positive battery post. (Scheme 6) Connect positive voltmeter lead to starter housing, and negative lead to negative battery post.
2. Engage remote starter switch while observing voltmeter. Voltmeter should indicate.2 volt or less. If voltmeter indicates greater than.2 volt, clean negative cable connections at battery, body ground connections and starter ground connections. Then retest.
3. If voltage drop is still excessive, repair or replace negative battery cable and/or engine ground cable as necessary. Repeat starter circuit test after repair to ensure problem has been corrected.
4. If the reading is less than.2 volt and the engine still cranks slowly, install a new starter motor. See «STARTER MOTOR»(ref-139338-S29196489922002043000000) under REMOVAL & INSTALLATION.

Scheme 6