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Starting System: Diagnosis Ford Explorer V

Starter 5 illustrations ~970 words

Related Module DTC Chart(s)

This table contains references to module DTC charts which are related to this system.

ModuleReference
PCMREFER to DTC CHART: POWERTRAIN CONTROL MODULE (PCM) .
BCMREFER to DTC CHART: BODY CONTROL MODULE (BCM) .

RELATED MODULE DTC CHART(S)

Diagnostics in this information assume a certain skill level and knowledge of Ford-specific diagnostic practices. REFER to DIAGNOSTIC METHODS for information regarding Ford-specific diagnostic practices.

ConditionPossible SourcesActions
The engine does not crank (without IA)Battery Battery cables Fuse Wiring, terminals or connectors Ignition switch Starter motor Starter relay PCM TR sensor PATS BCMREFER to Diagnostic Routine A: Engine Does Not Crank (Without Intelligent Access) .
The engine does not crank (with IA)Battery Battery cables Fuse Wiring, terminals or connectors Start/stop switch Brake switch Starter motor Starter relay PCM TR sensor PATS BCM RFA moduleREFER to Diagnostic Routine B: Engine Does Not Crank (With Intelligent Access) .
The engine cranks slowlyBattery Battery cables Wiring, terminals or connectors Starter motorCARRY OUT the starter system component test. REFER to Starter Motor - Positive Circuit Test or REFER to Starter Motor - Ground Circuit Test .
Unusual starter noiseStarter motor mounting Starter motor engagement Starter motor Flexplate ring gearREFER to Diagnostic Routine D: Unusual Starter Noise .
The starter spins but the engine does not crankStarter motorINSPECT the starter motor mounting and engagement. REPAIR as necessary.
Damaged flexplateINSPECT the flexplate for damaged, missing or worn teeth. REPAIR as necessary.
The starter does not disengage from the flexplateStarter relay Wiring, terminals or connectorsREMOVE the starter relay. If the engine stops cranking, INSTALL a new relay. If the engine continues to crank, REPAIR circuit CDC25 (BN/GN) for a short to voltage.
The remote start system operates with reduced range (without IA)IKT IKT battery Aftermarket systems High power devices TV/radio transmission towers TPM moduleREFER to DIAGNOSTIC ROUTINE K : The Remote Keyless Entry (RKE) Transmitter Has Poor Range Performance.
The remote start system operates with reduced range (with IA)IA key IA battery Aftermarket systems High power devices TV/radio transmission towers TPM moduleREFER to DIAGNOSTIC ROUTINE L : The Remote Keyless Entry (RKE) Transmitter Has Poor Range Performance.
The remote start is inoperativeWiring, terminals or connectors Hood switch Remote start feature not enabled PCM IKT (without IA) IA key (with IA)REFER to Diagnostic Routine F: The Remote Start Is Inoperative .

SYMPTOM CHART

Pinpoint Test

  1. CHECK THE STARTER MOUNTING Inspect the starter mounting bolts for looseness. Is the starter motor mounted correctly? Yes: GO to 2 . No: INSTALL the starter motor correctly. REFER to «Starter Motor - 2.0L GTDI»(ref-517562-S37217293632012121200000) or «Starter Motor - 3.5L Ti-VCT»(ref-517562-S25416014322012121200000) .
  2. CHECK FOR STARTER NOISE Ignition OFF. Connect a remote starter switch between the starter solenoid C197A-1 ("B" terminal) and C197B-1 ("S" terminal). Engage the starter and verify the noise is due to starter operation. Is the noise due to the starter engagement? Yes: REFER to «Starter Motor Drive Gear and Flywheel Ring Gear Inspection»(ref-517562-S17828832612012121200000) . No: REFER to «SYMPTOM CHART: NVH»(ref-517560-S31158036462012121200000) to continue diagnosis.

Component Test

WARNINGAlways disconnect the battery ground cable at the battery before disconnecting the starter motor battery terminal lead. If a tool is shorted at the starter motor battery terminal, the tool can quickly heat enough to cause a skin burn. Failure to follow this instruction may result in serious personal injury.

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

Scheme 6

Scheme 6
Scheme 6
  1. Make sure the battery is fully charged; carry out a battery drain test. REFER to «BATTERY DRAIN TEST»(ref-517589-S06318841992012121200000) .
  2. Connect a remote starter switch between starter solenoid "S" terminal C197B and the battery positive terminal.
  3. Connect the Digital Multimeter positive lead to the battery positive post. Connect the negative lead to the starter solenoid "M" terminal.
  4. Engage the remote starter switch. Read and record the voltage. The voltage reading should be 0.5 volt or less.
  5. If the voltage reading is 0.5 volt or less, go to the starter motor-ground circuit component test.
  6. 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 Digital Multimeter negative lead to the starter solenoid "B" terminal C197A and repeat the test. If the voltage reading at C197A is lower than 0.5 volt, the concern is either in the connections at the starter solenoid or in the solenoid contacts.
  7. Remove the cables from solenoid C197A, C197B and "M" terminal. 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 or less than 0.5 volt when checked at C197A, the concern is in the solenoid contacts. Install a new starter motor. REFER to «Starter Motor - 3.5L Ti-VCT»(ref-517562-S25416014322012121200000) .
  8. If the voltage reading taken at the solenoid C197A 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.
  9. Clean the positive battery cable connection. If this does not solve the problem, install new battery cables. REFER to «BATTERY CABLES - 3.5L TI-VCT»(ref-517589-S40921320382012121200000) .

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

Scheme 7

Scheme 7: Component Test
Scheme 7: Component Test
  1. Connect a remote starter switch between starter solenoid C197B and the battery positive terminal.
  2. Connect the 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.
  3. Engage the remote starter switch and crank the engine. Read and record the voltage reading. The reading should be 0.5 volt or less.
  4. If the voltage drop is greater than 0.5 volt, clean the negative cable connections at the battery, the body ground connections and the starter ground connection. Retest.
  5. If the voltage drop is greater than 0.5 volt, install new battery cables. REFER to «BATTERY CABLES - 3.5L TI-VCT»(ref-517589-S40921320382012121200000) . If the voltage reading is less than 0.5 volt and the engine still cranks slowly, install a new starter motor. REFER to «Starter Motor - 3.5L Ti-VCT»(ref-517562-S25416014322012121200000) .

Scheme 8

Scheme 8: General Procedure
Scheme 8: General Procedure
  1. Remove the starter motor. REFER to «Starter Motor - 2.0L GTDI»(ref-517562-S37217293632012121200000) or «Starter Motor - 3.5L Ti-VCT»(ref-517562-S25416014322012121200000) .
  2. Inspect the wear patterns on the starter drive and the flywheel or flexplate ring gear. If the wear pattern is normal, install the starter motor. REFER to «Starter Motor - 2.0L GTDI»(ref-517562-S37217293632012121200000) or «Starter Motor - 3.5L Ti-VCT»(ref-517562-S25416014322012121200000) .
  3. If the starter drive gear and the flywheel or flexplate ring gear are not fully meshing or the gears are milled or damaged, install a new flywheel or flexplate and a new starter motor: For 2.0L GTDI, refer to «FLEXPLATE»(ref-517530-S09333771152012121200000) . For 3.5L Ti-VCT, refer to «FLEXPLATE»(ref-517529-S00732731172012121200000) . For starter, refer to «Starter Motor - 2.0L GTDI»(ref-517562-S37217293632012121200000) or «Starter Motor - 3.5L Ti-VCT»(ref-517562-S25416014322012121200000) .

Scheme 9

Scheme 9: Removal
Scheme 9: Removal

Scheme 10

Scheme 10
Scheme 10
  1. WARNING: Always disconnect the battery ground cable at the battery before disconnecting the starter motor battery terminal lead. If a tool is shorted at the starter motor battery terminal, the tool can quickly heat enough to cause a skin burn. Failure to follow this instruction may result in serious personal injury. Disconnect the battery ground cable. REFER to «BATTERY DISCONNECT»(ref-517589-S39248827582012121200000) .
  2. NOTE: It will be necessary to position the coolant hoses as needed to remove the starter motor. Remove the nut and position aside the ground wire. To install, tighten to 18 Nm (159 lb-in).
  3. Remove the starter motor terminal cover.
  4. Remove the starter motor solenoid battery cable nut. To install, tighten to 12 Nm (106 lb-in).
  5. Remove the starter motor solenoid wire nut. To install, tighten to 5 Nm (44 lb-in).
  6. Remove the 2 stud bolts and the starter motor. To install, tighten to 48 Nm (35 lb-ft).

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