Starting System Ford Five Hundred I

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Starter Motor

The starter motor

1. is a permanent-magnet, gear reduction, 12V dc motor.
2. has an integral starter solenoid.

Starter Relay

The starter relay

1. is a mini ISO relay that switches power to the starter solenoid to engage the starter motor.
2. receives a START signal from the ignition switch.
3. is controlled by the powertrain control module (PCM).

Starter System - Operation

When the ignition switch is turned to the START position, the starter relay switches power to the starter solenoid causing the starter motor to engage as long as

1. the digital transmission range (TR) sensor is in PARK or NEUTRAL.
2. the anti-theft system is operational.

Refer to STARTING/CHARGING (Montego), STARTING/CHARGING (Five Hundred), or STARTING/CHARGING (Freestyle) for schematic and connector information.

Special Tool(s)

SPECIAL TOOL CHART 73III Automotive Meter 105-R0057 or equivalent Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool SABRE Electrical System Tester 010-00736 or equivalent

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Inspection and Verification

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

1. Verify the customer concern by operating the starting system to duplicate the conditions.
2. Inspect to determine if any of the following mechanical or electrical concerns apply. VISUAL INSPECTION CHART Mechanical Electrical Starter motor Brackets Battery Open fuse Damaged wiring harness Starter relay Anti-theft system Loose or corroded connections
3. If the inspection reveals an obvious concern that can be readily identified, repair as necessary.
4. If the concern remains after the inspection, determine the symptom. GO to «SYMPTOM CHART»(/ford/five-hundred/i-2004-2007/remont/starter/#starting-system__symptom-chart) .

Symptom Chart

SYMPTOM CHART

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Normal Operation

Under normal operation, voltage is supplied to the ignition switch through circuit 1715 (RD). When the ignition switch is turned to the START position, voltage is sent to the smart junction box (SJB) fuse through circuit 1522 (DG). From the fuse, voltage is sent to the starter relay coil through circuit 1785 (LG/VT). Ground for the starter relay coil is provided from the PCM through circuit 329 (PK). Voltage is supplied to the starter relay switch through circuit 1786 (BN/PK). When the relay is energized, voltage is sent to the starter motor through circuit 33 (WH/PK).

Possible Causes

1. An open in circuit 1715 (RD), 1522 (DG), 1785 (LG/VT), 329 (PK), 1786 (BN/PK) or 33 (WH/PK).
2. Starter motor
3. Starter relay
4. Battery

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Scheme 17

1. A1 CHECK FOR POWERTRAIN CONTROL MODULE (PCM) DTCs NOTE: The PATS system DTCs are the only DTCs of concern in this step. Only repair retrieved non-PATS DTCs if a customer concern is reported. Carry out the powertrain control module (PCM) self-test. Refer to «INTRODUCTION - GASOLINE»(/ford/five-hundred/i-2004-2007/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) article . Were any PATS DTCs retrieved? Yes : GO to «ANTI-THEFT - PATS»(/ford/five-hundred/i-2004-2007/remont/door-locks-anti-theft-systems/#anti-theft-system-pats) to repair the PATS system DTCs before proceeding with this test. No : GO to A2.
2. A2 CHECK TRANSMISSION RANGE SENSOR OPERATION Enter the following diagnostic mode on the diagnostic tool: PCM Transmission Range Sensor PID. While observing the PCM Transmission Range Sensor PID, place the vehicle in PARK and NEUTRAL. Does the PID match the gear selection? Yes : GO to A3. No : GO to «AUTOMATIC TRANSAXLE/TRANSMISSION - CVT»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) or «AUTOMATIC TRANSAXLE - 6 SPEED»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transaxle-6-speed) to diagnose the transmission range sensor.
3. A3 CHECK THE BATTERY Check the battery condition and charge. Refer to «CHARGING SYSTEM - GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/charging-system/#charging-system-general-information) . Is the battery OK? Yes : GO to A4. No : CHARGE or INSTALL a new battery. REFER to «CHARGING SYSTEM - GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/charging-system/#charging-system-general-information) . TEST the system for normal operation.
4. A4 CHECK THE BATTERY GROUND CABLE Measure the resistance between the negative battery post and the battery ground cable connection on the engine. Is the resistance greater than 5 ohms? No : GO to A5. Yes : INSTALL a new battery ground cable. TEST the system for normal operation.
5. A5 CHECK THE STARTER MOTOR GROUND Measure the resistance between the starter motor case and ground. Is the resistance greater than 5 ohms? No : GO to A6. Yes : CLEAN the starter motor mounting flange and make sure the starter motor is correctly mounted. TEST the system for normal operation.
6. A6 CHECK THE POWER SUPPLY TO THE STARTER MOTOR Measure the voltage between starter motor B-terminal and ground. Is the voltage greater than 10 volts? Yes : GO to A7. No : INSTALL a new positive battery cable. TEST the system for normal operation.
7. A7 CHECK THE STARTER MOTOR SOLENOID OPERATION Connect a fused jumper wire to the B-terminal of the starter motor. Momentarily connect the other lead of the fused jumper wire to the starter motor S-terminal. Did the starter motor engage and the engine crank? Yes : GO to A8. No : INSTALL a new starter motor. TEST the system for normal operation.
8. A8 CHECK THE START INPUT TO THE STARTER MOTOR Disconnect: Starter Motor S-Terminal. Measure the voltage between starter motor S-terminal connector, circuit 33 (WH/PK), and ground, while holding the ignition switch in the START position. Is the voltage greater than 10 volts in START? Yes : CLEAN the starter motor S-terminal and connector. CHECK the wiring and the starter motor for a loose connection. TEST the system for normal operation. No : GO to A9.
9. A9 CHECK THE START INPUT TO THE STARTER RELAY Disconnect: Starter Relay. Measure the voltage between starter relay pin 85, circuit 1785 (LG/VT) and ground, while holding the ignition switch in the START position. Is the voltage greater than 10 volts? Yes : GO to A10. No : GO to A14 .
10. A10 CHECK THE BATTERY SUPPLY TO THE STARTER RELAY Measure the voltage between starter relay pin 87, circuit 1786 (BN/PK) and ground. Is the voltage greater than 10 volts? Yes : GO to A11. No : REPAIR circuit 1786 (BN/PK) for an open. TEST the system for normal operation.
11. A11 CHECK THE GROUND SIGNAL TO THE STARTER RELAY Measure the voltage between starter relay pin 85, circuit 1785 (LG/VT), and starter relay pin 86, circuit 329 (PK), while holding the ignition switch in the START position. Is the voltage greater than 10 volts? Yes : GO to A13 . No : GO to A12.
12. A12 CHECK CIRCUIT 329 (PK) FOR AN OPEN Disconnect: PCM C175. Measure the resistance between starter relay pin 86, circuit 329 (PK) and PCM C175-2, circuit 329 (PK). Is the resistance less than 5 ohms? Yes : INSTALL a new PCM. REFER to «ELECTRONIC ENGINE CONTROLS»(/ford/five-hundred/i-2004-2007/remont/removal-installation/#electronic-engine-control-system) . TEST the system for normal operation. No : REPAIR circuit 329 (PK) for an open. TEST the system for normal operation.
13. A13 CHECK CIRCUIT 33 (WH/PK) FOR AN OPEN Disconnect: Starter Motor C197a. Measure the resistance between starter relay pin 87, circuit 33 (WH/PK), harness side and starter motor S-terminal, circuit 33 (WH/PK). Is the resistance less than 5 ohms? Yes : INSTALL a new starter relay. TEST the system for normal operation. No : REPAIR circuit 33 (WH/PK) for an open. TEST the system for normal operation.
14. A14 CHECK START INPUT TO SMART JUNCTION BOX (SJB) FUSE 14 (7.5A) Disconnect: SJB Fuse 14 (7.5A). Measure the voltage between SJB fuse 14 (7.5A), circuit 1522 (DG) input cavity and ground, while holding the ignition switch in the START position. Is the voltage greater than 10 volts? Yes : REPAIR circuit 1785 (LG/VT) for an open. TEST the system for normal operation. No : GO to A15.
15. A15 CHECK THE POWER SUPPLY TO THE IGNITION SWITCH Disconnect: Ignition Switch C250. Measure the voltage between ignition switch C250-4, circuit 1715 (RD) and ground. Is the voltage greater than 10 volts? Yes : GO to A16. No : REPAIR circuit 1715 (RD) for an open. TEST the system for normal operation.
16. A16 CHECK THE IGNITION SWITCH Carry out the ignition switch component test. Refer to «SYSTEM WIRING DIAGRAMS»(ref-177503) (Montego), «SYSTEM WIRING DIAGRAMS»(ref-177518) (Five Hundred) or «SYSTEM WIRING DIAGRAMS»(ref-177519) (Freestlye). Did the ignition switch pass the component test? Yes : REPAIR circuit 1522 (DG). TEST the system for normal operation. No : INSTALL a new ignition switch. REFER to «STEERING COLUMN SWITCHES»(/ford/five-hundred/i-2004-2007/remont/ignition-switchsteering-lock/#steering-column-switches) . TEST the system for normal operation.

Under normal operation, voltage is supplied to the ignition switch through circuit 1715 (RD). When the ignition switch is turned to the START position, voltage is sent to the smart junction box fuse through circuit 1522 (DG). From the fuse, voltage is sent to the starter relay coil through circuit 1785 (LG/VT). Ground for the starter relay coil is provided from the PCM through circuit 329 (PK). Voltage is supplied to the starter relay switch through circuit 1786 (BN/PK). When the relay is energized, voltage is sent to the starter motor through circuit 33 (WH/PK).

1. Starter motor
2. Ring gear

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1. B1 CHECK THE STARTER MOUNTING Inspect the starter mounting bolts and brackets for looseness. Is the starter motor mounted correctly? Yes : GO to B2. No : INSTALL the starter motor correctly. REFER to «STARTER MOTOR - CVT»(/ford/five-hundred/i-2004-2007/remont/starter/#starting-system) or «STARTER MOTOR - 6 SPEED»(/ford/five-hundred/i-2004-2007/remont/starter/#starting-system) . TEST the system for normal operation.
2. B2 CHECK FOR ENGINE NOISE Key in OFF position. Connect a remote starter switch between the starter solenoid B and S terminals. Engage the starter motor and verify the noise is due to the starter operation. Is the noise due to the starter motor engagement? Yes : GO to B3. No : REFER to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/mechanical/#engine-system-general-information) to continue diagnosis.
3. B3 CHECK FOR UNUSUAL WEAR Remove the starter motor. Inspect the ring gear for damaged or worn teeth. Refer to «ENGINE»(/ford/five-hundred/i-2004-2007/remont/mechanical/#engine) . Is the noise due to ring gear tooth damage? Yes : INSTALL a new ring gear. REFER to «ENGINE»(/ford/five-hundred/i-2004-2007/remont/mechanical/#engine) . EXAMINE the starter pinion teeth. If damaged, INSTALL a new starter motor. REFER to «STARTER MOTOR - CVT»(/ford/five-hundred/i-2004-2007/remont/starter/#starting-system) or «STARTER MOTOR - 6 SPEED»(/ford/five-hundred/i-2004-2007/remont/starter/#starting-system) . TEST the system for normal operation. No : INSTALL a new starter motor. REFER to «STARTER MOTOR - CVT»(/ford/five-hundred/i-2004-2007/remont/starter/#starting-system) or «STARTER MOTOR - 6 SPEED»(/ford/five-hundred/i-2004-2007/remont/starter/#starting-system) . TEST the system for normal operation.

Component Tests

Always make the 73III Automotive Meter 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. For additional information, refer to «CHARGING SYSTEM - GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/charging-system/#charging-system-general-information) .
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 73III Automotive Meter positive lead to the battery positive (+) post. Connect the negative lead to the starter solenoid 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»(/ford/five-hundred/i-2004-2007/remont/starter/#starting-system__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 73III Automotive Meter 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.
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 or 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

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1. Connect the 73III Automotive Meter 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.

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1. Remove the starter motor. For additional information, refer to «STARTER MOTOR - CVT»(/ford/five-hundred/i-2004-2007/remont/starter/#starting-system) or «STARTER MOTOR - 6 SPEED»(/ford/five-hundred/i-2004-2007/remont/starter/#starting-system) .
2. Check the wear patterns on the starter drive gear and the flywheel ring gear. If the wear pattern is normal, install the starter motor. For additional information, refer to «STARTER MOTOR - CVT»(/ford/five-hundred/i-2004-2007/remont/starter/#starting-system) or «STARTER MOTOR - 6 SPEED»(/ford/five-hundred/i-2004-2007/remont/starter/#starting-system) .
3. If the starter drive gear and the flywheel ring gear are not fully meshing and both of the gears are scored or damaged, install a new starter motor. For additional information, refer to «STARTER MOTOR - CVT»(/ford/five-hundred/i-2004-2007/remont/starter/#starting-system) or «STARTER MOTOR - 6 SPEED»(/ford/five-hundred/i-2004-2007/remont/starter/#starting-system) . If necessary, install a new flywheel. For additional information, refer to «ENGINE»(/ford/five-hundred/i-2004-2007/remont/mechanical/#engine) .

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Removal and Installation

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
2. Remove the air cleaner assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/five-hundred/i-2004-2007/remont/removal-installation/#intake-air-distribution-system-filtering-system) .
3. Remove the starter solenoid terminal cover.
4. Remove the nuts and position the starter solenoid cables aside. To install, tighten the large nut to 12 Nm (9 lb-ft). To install, tighten the small nut to 6 Nm (53 lb-in).
5. Remove the bolts and the starter motor. To install, tighten to 25 Nm (18 lb-ft).
6. To install, reverse the removal procedure.

Material

MATERIAL CHART

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
2. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/five-hundred/i-2004-2007/remont/removal-installation/#intake-air-distribution-system-filtering-system) .
3. Remove the transaxle roll restrictor bolt. To install, clean the bolt using a wire brush, apply new threadlocker to the threads and tighten to 48 Nm (35 lb-ft).
4. Remove the 4 bolts and the transaxle roll restrictor cross brace assembly. To install, clean the bolts using a wire brush, apply new threadlocker to the threads and tighten to 55 Nm (41 lb-ft).
5. Remove the starter solenoid terminal cover.
6. Remove the nuts and position the starter solenoid cables aside. To install, tighten the large nut to 12 Nm (9 lb-ft). To install, tighten the small nut to 6 Nm (53 lb-in).
7. Remove the bolts and the starter motor. To install, tighten to 25 Nm (18 lb-ft).
8. To install, reverse the removal procedure.

See also:
• INTRODUCTION - GASOLINE
• ANTI-THEFT - PATS
• AUTOMATIC TRANSAXLE/TRANSMISSION - CVT
• AUTOMATIC TRANSAXLE - 6 SPEED
• CHARGING SYSTEM - GENERAL INFORMATION
• ELECTRONIC ENGINE CONTROLS
• STEERING COLUMN SWITCHES
• ENGINE SYSTEM-GENERAL INFORMATION
• ENGINE
• BATTERY, MOUNTING AND CABLES
• INTAKE AIR DISTRIBUTION & FILTERING
• SYMPTOM CHART
• PINPOINT TEST A
• Component Tests
• STARTER MOTOR - GROUND CIRCUIT