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Starting System: Diagnosis Ford Focus I

Starter 5 illustrations ~1441 words

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). Check fuses No. 8 (30-amp) and No. 10 (10-amp) in battery junction box. On models equipped with anti-theft system, ensure anti-theft system is operating properly. See PASSIVE ANTI-THEFT SYSTEMS - FOCUS article. If problem is found, repair as necessary. If problem is not found, repair by symptom. See SYMPTOM INDEX table under SYSTEM TESTS.

VOLTAGE DROP TEST

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

Scheme 3

Scheme 3: VOLTAGE DROP TEST
Scheme 3: VOLTAGE DROP TEST
  1. Disconnect inertia fuel shutoff switch to prevent vehicle from starting. Connect remote starter switch between starter solenoid terminal "S" and positive battery post.
  2. Connect positive voltmeter lead to positive battery post, and negative lead to solenoid terminal "M". (Scheme 3)
  3. Engage remote starter switch. Voltmeter should indicate.5 volt or less. If voltmeter indicates.5 volt or less, system is okay. If voltmeter indicates greater than.5 volt, go to next step.
  4. 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, then go to next step.
  5. If voltmeter still indicates greater than.5 volt at terminal "M" and less than.5 volt at terminal "B", solenoid contacts are bad. Replace solenoid. If voltmeter indicates greater than.5 volt at terminal "B", clean cables and connections at solenoid and go to next step.
  6. If voltmeter still indicates greater than.5 volt at terminal "B", check for poor positive battery cable connection or bad cable. Repair as necessary.

STARTER NO-LOAD TEST

Connect Starter, Alternator, Battery, and Regulator (SABRE) tester, or equivalent. Follow tester manufacturer's instructions. Engage remote starter switch. Starter should turn smoothly. Voltmeter should indicate 11 volts or greater, and ammeter should indicate 60-80 amps. If voltage is lower or current is higher than specification, replace or repair starter.

TEST A: STARTER DOES NOT CRANK BUT RELAY CLICKS

  1. Check battery condition. If battery is okay, go to next step. If battery is not okay, replace battery and/or repair charging system as necessary.
  2. Turn ignition switch to OFF position. Remove starter relay from Central Junction Box (CJB). Test starter relay. See «STARTER RELAY»(ref-99000-S13680419812001061200000) 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 CJB starter relay cavity No. 3. (Scheme 4) Turn ignition switch to RUN position. If voltage is greater than 10 volts, go to next step. If voltage is 10 volts or less, repair power distribution circuit as necessary. See «WIRING DIAGRAMS»(ref-99000-S31018608952001061200000).
  4. Turn ignition switch to OFF position. Install starter relay. Disconnect starter motor harness connector. Measure voltage between ground and starter motor harness connector Gray wire terminal. Turn ignition switch to START position. If battery voltage does not exist, go to next step. If battery voltage exists, perform «TEST C: STARTER CRANKS SLOWLY»(ref-99000-S15040518522001061200000).
  5. Turn ignition switch to LOCK position. On vehicles with A/T, go to next step. On vehicle with M/T, repair open in Gray wire between starter motor and starter relay.
  6. Disconnect Transmission Range (TR) sensor harness connector C438. Measure voltage between ground and TR sensor harness connector C438 terminal No. 6 (Gray/Red wire). (Scheme 5) Turn ignition switch to START position. If battery voltage exists, go to next step. If battery voltage does not exist, repair open in wiring between TR sensor and starter relay. See «WIRING DIAGRAMS»(ref-99000-S31018608952001061200000).
  7. Turn ignition switch to LOCK position. Measure resistance in Gray wire between starter motor harness connector and terminal No. 9 at TR sensor harness connector C438. If resistance is 5 ohms or less, go to next step. If resistance is greater than 5 ohms, repair open in Gray wire between TR sensor and starter motor.
  8. Check TR sensor adjustment. See «TRANSMISSION RANGE SENSOR»(ref-99000-S17182316482001080900000) under ADJUSTMENTS. If TR sensor is not properly adjusted, adjust as necessary. If TR sensor is properly adjusted, replace TR sensor.

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5

TEST B: STARTER DOES NOT CRANK & RELAY DOES NOT CLICK

  1. Turn ignition switch to RUN position and observe Passive Anti-Theft System (PATS) warning indicator. If warning indicator does not flash when attempting to start vehicle, go to next step. If warning indicator flashes when attempting to start vehicle, repair anti-theft system as necessary. See PASSIVE ANTI-THEFT SYSTEMS - FOCUS article.
  2. Remove starter relay from central junction box. Test starter relay. See «STARTER RELAY»(ref-99000-S13680419812001061200000) under COMPONENT TESTS. If starter relay tests okay, go to next step. If starter relay does not test okay, replace relay.
  3. Check battery condition. If battery is okay, go to next step. If battery is not okay, replace battery and/or repair charging system as necessary.
  4. Turn ignition switch to LOCK position. Measure voltage between ground and starter relay cavity No. 1. (Scheme 4) Turn ignition switch to START position. If voltage is less than 10 volts, go to next step. If voltage is greater than 10 volts, go to step 6 (A/T) or go to step 7 (M/T).
  5. Turn ignition switch to OFF position. Remove and inspect battery junction box fuse No. 8 (30-amp). If fuse is okay, go to step 9. If fuse is not okay, replace fuse. If fuse blows again, inspect circuits for short to ground in power distribution circuit. See POWER DISTRIBUTION article in WIRING DIAGRAMS.
  6. Turn ignition switch to LOCK position. Disconnect Powertrain Control Module (PCM) harness connector C415. Measure resistance between starter relay cavity No. 2 and PCM harness connector C415 terminal No. 12 (Black/Red wire). (Scheme 4)and (Scheme 6). If resistance is 5 ohms or less, repair anti-theft system as necessary. See PASSIVE ANTI-THEFT SYSTEMS - FOCUS article. If resistance is greater than 5 ohms, repair open in circuit between PCM and starter relay. See «WIRING DIAGRAMS»(ref-99000-S31018608952001061200000).
  7. Turn ignition switch to LOCK position. Disconnect Powertrain Control Module (PCM) harness connector C415. Measure resistance between starter relay cavity No. 2 and PCM harness connector C415 terminal No. 12 (Black/Red wire). (Scheme 4)and (Scheme 6). Depress clutch pedal. If resistance is greater than 5 ohms, go to next step. If resistance is 5 ohms or less, repair anti-theft system as necessary. See PASSIVE ANTI-THEFT SYSTEMS - FOCUS article.
  8. Disconnect start inhibit switch harness connector C936. Measure resistance between start inhibit switch terminals No. 1 and 2 (component side). Depress and release clutch pedal. Resistance should be 5 ohms or less with clutch pedal depressed and greater than 10 k/ohms with clutch pedal released. If resistance is as specified, repair wiring between start inhibit switch and starter relay, and/or between start inhibit switch and PCM. If resistance is not as specified, replace start inhibit switch.
  9. Turn ignition switch to OFF position. Disconnect ignition switch harness connector C456. Measure voltage between ground and ignition switch harness connector C456 terminal No. 4 (Red wire). (Scheme 7) If voltage is greater than 10 volts, go to next step. If voltage is less than 10 volts, repair power distribution circuit as necessary. See POWER DISTRIBUTION article in WIRING DIAGRAMS. If fault is still present, repair or replace battery junction box as necessary.
  10. Measure resistance of Green/Yellow wire between ignition switch harness connector C456 terminal No. 7 and starter relay cavity No. 1. (Scheme 4)and (Scheme 7). If resistance is 5 ohms or less, replace ignition switch. If resistance is greater than 5 ohms, repair open in Green/Yellow wire.

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7

TEST C: STARTER CRANKS SLOWLY

  1. Ensure battery is fully charged. Engage parking brake and place transmission selector in Neutral. Connect Starter, Alternator, Battery, and Regulator (SABRE) tester, or equivalent, and perform starter load test to manufacturer's instructions. If starter tests okay, go to next step. If starter does not test okay, replace starter. See «STARTER MOTOR»(ref-99000-S23868546122001061200000) under REMOVAL & INSTALLATION.
  2. Measure voltage drop between starter motor terminal "B" (component side) and positive battery terminal, with ignition switch in RUN position. If voltage drop is less than .5 volt, go to next step. If voltage drop is greater than .5 volt, clean and tighten all positive battery terminal connections. If fault is still present, replace positive battery cable.
  3. Measure voltage drop between starter housing and negative battery cable, with ignition switch in RUN position. If voltage drop is less than .5 volt, repair charging system. See GENERATORS & REGULATORS - FOCUS article. If voltage drop is greater than .5 volt, clean and tighten all negative battery cable connections, starter motor mounting and body to engine grounds. If fault is still present, replace negative battery cable. Restore electrical connections and retest system operation.

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