Starting System: Overview — Ford Transit VII (2006-2013)

Principles of Operation

When the ignition switch is turned to the START position and the vehicle is in the NEUTRAL or PARK position, the starter relay switches power to the starter solenoid, causing the starter motor to engage.

The starting system is electronically controlled by the Passive Anti-Theft System (PATS). PATS is controlled by the Instrument Cluster (IC). PATS recognizes the correct electronically coded ignition key and the IC will send a message to 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.

Normal Operation

Under normal operation, the Battery Junction Box (BJB) supplies constant power to the starter motor relay on circuit 30-BB12 (RD) through fuse 11 (30A). When the key is placed in the START position with the vehicle in PARK or NEUTRAL, the Transmission Range (TR) sensor provides power on circuit 31S-BB16 (BK/RD) and the PCM provides ground on circuit 31-BB16 (BK). The coil of the relay is energized and sends power to the starter motor on circuit 50-BB12 (GY). 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 30-BB10 (RD) to the starter motor to start the engine.

This pinpoint test is intended to diagnose the following

Battery
Starter motor
Starter motor relay
Start diode
Circuit
PCM
TR sensor

Scheme 1

Scheme 1: PINPOINT TEST A: THE ENGINE DOES NOT CRANK

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

A1 CHECK THE BATTERY Check the battery condition and state of charge. Refer to Diagnosis and Testing in «BATTERY, MOUNTING AND CABLES»(ref-356758) . Is the battery OK? Yes : GO to A2 . No : CHARGE or INSTALL a new battery as necessary. REFER to «BATTERY, MOUNTING AND CABLES»(ref-356758) . TEST the system for normal operation.
A2 CHECK FOR PCM DTCs Using the DTCs retrieved in Inspection and Verification, check for PCM DTCs. Were any PCM DTCs retrieved? Yes : If PCM DTC P1260:00 is retrieved, REFER to «ANTI-THEFT - PASSIVE ANTI-THEFT SYSTEM (PATS)»(ref-356783) . All other PCM DTCs, REFER to the «INTRODUCTION - GASOLINE MODELS»(ref-355661) . No : GO to A3 .
A3 CHECK THE PCM AUTOMATIC TR SENSOR PID Connect the scan tool. Ignition ON. Enter the following diagnostic mode on the scan tool: DataLogger - PCM. While observing the TR sensor PID, place the vehicle in PARK and NEUTRAL. Does the PID match the gear selection? Yes : GO to A4 . No : REFER to «AUTOMATIC TRANSAXLE/TRANSMISSION - 4F27E»(ref-356736) to diagnose the TR sensor alignment.
A4 CHECK THE STARTER MOTOR CONTROL OUTPUT DETECTED (SMC_MON) PID Enter the following diagnostic mode on the scan tool: DataLogger - PCM. Monitor the SMC_MON PID with the ignition switch in the START position. Does the PID change from OFF to ON? Yes : GO to A5 . No : GO to A12 .
A5 CHECK THE STARTER MOTOR RELAY ENABLE (STRT_RLY) PID Enter the following diagnostic mode on the scan tool: DataLogger - PCM. Monitor the STRT_RLY PID with the ignition switch in the START position. Does the PID change from DISABLED to ENABLED? Yes : GO to A6 . No : GO to A24 .
A6 CHECK FOR VOLTAGE TO THE STARTER MOTOR RELAY 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 Relay. Measure the voltage between BJB starter motor relay pin 3, circuit 30-BB12 (RD), harness side and ground. Is the voltage greater than 10 volts? Yes : GO to A7 . No : VERIFY BJB fuse 11 (30 A) is OK. If OK, REPAIR the circuit 30-BB12 (RD). TEST the system for normal operation. If not OK, REFER to the «SYSTEM WIRING DIAGRAMS»(ref-360992) to identify the possible causes of the circuit short.
A7 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 A8 . No : INSTALL a new battery ground cable. REFER to «BATTERY, MOUNTING AND CABLES»(ref-356758) . TEST the system for normal operation.
A8 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 A9 . No : CLEAN the starter motor mounting flange and MAKE SURE the starter motor is correctly mounted. TEST the system for normal operation.
A9 CHECK THE POWER SUPPLY TO THE STARTER MOTOR Measure the voltage between starter motor C197A-1, circuit 30-BB10 (RD) and ground. Is the voltage greater than 10 volts? Yes : GO to A10 . No : INSTALL a new positive battery cable. REFER to «BATTERY, MOUNTING AND CABLES»(ref-356758) . TEST the system for normal operation.
A10 CHECK THE STARTER MOTOR B-PIN Connect one end of a fused jumper wire to starter motor solenoid C197A-1, circuit 30-BB10 (RD). Momentarily connect the other end of the jumper to starter motor C197B-1, circuit 50-BB12 (GY). Did the starter motor engage and the engine crank? Yes : GO to A11 . No : INSTALL a new starter motor. REFER to «STARTER MOTOR»(ref-356774-S32553860042010022700000) . TEST the system for normal operation.
A11 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. Disconnect: Starter Motor Relay. Measure the resistance between starter motor solenoid C197B-1, circuit 50-BB12 (GY), harness side and BJB starter relay pin 5, circuit 50-BB12 (GY), harness side. Is the resistance less than 5 ohms? Yes : INSTALL a new starter motor relay. TEST the system for normal operation. No : REPAIR the circuit 50-BB12 (GY). TEST the system for normal operation.
A12 CHECK FOR VOLTAGE TO THE STARTER MOTOR RELAY 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 Relay. Measure the voltage between BJB starter motor relay pin 3, circuit 30-BB12 (RD), harness side and ground. Is the voltage greater than 10 volts? Yes : GO to A13 . No : VERIFY BJB fuse 11 (30 A) is OK. If OK, REPAIR the circuit 30-BB12 (RD). TEST the system for normal operation. If not OK, REFER to the «SYSTEM WIRING DIAGRAMS»(ref-360992) to identify the possible causes of the circuit short.
A13 CHECK THE STARTER MOTOR RELAY Carry out the Starter Motor Relay Component Test. Refer to «SYSTEM WIRING DIAGRAMS»(ref-360992) for component testing. Did the starter motor relay pass the component test? Yes : GO to A14 . No : INSTALL a new starter motor relay. TEST the system for normal operation.
A14 CHECK CIRCUIT 31S-BB16 (BK/RD) FOR VOLTAGE Measure the voltage between BJB starter motor relay pin 1, circuit 31S-BB16 (BK/RD), harness side and ground with the ignition switch in the START position. Is the voltage greater than 10 volts? Yes : GO to A21 . No : GO to A15 .
A15 CHECK THE START DIODE Disconnect: Start Diode. Check the start diode for an open or shorted condition. Is the start diode OK? Yes : GO to A16 . No : INSTALL a new start diode. TEST the system for normal operation.
A16 CHECK FOR VOLTAGE AT THE START DIODE Measure the voltage between start diode cell, circuit 50-BB16 (GY/BK), harness side and ground with the ignition switch in the START position. Is the voltage greater than 10 volts? Yes : GO to A19 . No : GO to A17 .
A17 CHECK CIRCUIT 30-BB9 (RD) FOR VOLTAGE Disconnect: Ignition Switch C250. Measure the voltage between ignition switch C250-4, circuit 30-BB9 (RD), harness side and ground. Is the voltage greater than 10 volts? Yes : GO to A18 . No : VERIFY BJB fuse 3 (20 A) is OK. If OK, REPAIR circuit 30-BB9 (RD). TEST the system for normal operation. If not OK, REFER to the «SYSTEM WIRING DIAGRAMS»(ref-360992) to identify the possible causes of the circuit short.
A18 CHECK THE IGNITION SWITCH Carry out the Ignition Switch Component Test. Refer to «SYSTEM WIRING DIAGRAMS»(ref-360992) for component testing. Did the ignition switch pass the component test? Yes : REPAIR circuit 50-BB16 (GY/BK). TEST the system for normal operation. No : INSTALL a new ignition switch. REFER to «STEERING COLUMN SWITCHES»(ref-356759) . TEST the system for normal operation.
A19 CHECK CIRCUIT 50-BB15A (GY/OG) TO THE TR SENSOR FOR AN OPEN Ignition OFF. Disconnect: TR Sensor C167. Disconnect: PCM C175B. Measure the resistance between BJB start diode cell, circuit 50-BB1 (GY/RD), harness side and TR sensor C167-6, circuit 50-BB15 (GY/OG), harness side. Is the resistance less than 5 ohms? Yes : GO to A20 . No : REPAIR the circuit 50-BB1 (GY/RD) or 50-BB15 (GY/OG). TEST the system for normal operation.
A20 CHECK CIRCUIT 31S-BB16 (BK/RD) FROM THE TR SENSOR TO THE STARTER MOTOR RELAY FOR AN OPEN Measure the resistance between BJB starter motor relay pin 1, circuit 31S-BB16 (BK/RD), harness side and TR sensor C167-9, circuit 31S-BB16 (BK/RD), harness side. Is the resistance less than 5 ohms? Yes : INSTALL a new TR sensor. REFER to «AUTOMATIC TRANSAXLE/TRANSMISSION - 4F27E»(ref-356736) . No : REPAIR the circuit 31S-BB16 (BK/RD). TEST the system for normal operation.
A21 CHECK CIRCUIT 50-BB15 (GY/OG) FOR AN OPEN Disconnect: Start Diode. Disconnect: PCM C175B. Disconnect: TR Sensor C167. Measure the resistance between BJB start diode cell, circuit 50-BB1 (GY/RD), harness side and PCM C175B-37, circuit 50-BB15A (GY/OG), harness side. Is the resistance less than 5 ohms? Yes : GO to A22 . No : REPAIR the circuit 50-BB1 (GY/RD) or 50-BB15A (GY/OG). TEST the system for normal operation.
A22 CHECK CIRCUIT 50-BB14 (GY/RD) FOR AN OPEN Connect: TR Sensor C167. Disconnect: Ignition Switch C250. Measure the resistance between BJB start diode cell, circuit 50-BB16 (GY/BK), harness side and PCM C175B-16, circuit 50-BB14 (GY/RD), harness side. Is the resistance less than 5 ohms? Yes : GO to A23 . No : REPAIR the circuit 50-BB14 (GY/RD). TEST the system for normal operation.
A23 CHECK THE CIRCUIT 31-BB16 (BK) FOR AN OPEN Connect: Start Diode. Disconnect: Starter Motor Relay. Measure the resistance between the BJB starter motor relay pin 2, circuit 31-BB16 (BK), harness side and C175B-7, circuit 31-BB16 (BK), harness side. Is the resistance less than 5 ohms? Yes : INSTALL a new PCM. REFER to «ELECTRONIC ENGINE CONTROLS»(ref-356781) . TEST the system for normal operation. No : REPAIR circuit 31-BB16 (BK). TEST the system for normal operation.
A24 CHECK FOR VOLTAGE TO THE STARTER MOTOR RELAY 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 Relay. Measure the voltage between BJB starter motor relay pin 3, circuit 30-BB12 (RD), harness side and ground. Is the voltage greater than 10 volts? Yes : GO to A25 . No : VERIFY BJB fuse 11 (30 A) is OK. If OK, REPAIR the circuit 30-BB12 (RD). TEST the system for normal operation. If not OK, REFER to the «SYSTEM WIRING DIAGRAMS»(ref-360992) to identify the possible causes of the circuit short.
A25 CHECK THE STARTER MOTOR RELAY Carry out the Starter Motor Relay Component Test. Refer to «SYSTEM WIRING DIAGRAMS»(ref-360992) for component testing. Did the starter motor relay pass the component test? Yes : GO to A26 . No : INSTALL a new starter motor relay. TEST the system for normal operation.
A26 CHECK CIRCUIT 31-BB16 (BK) FOR AN OPEN Ignition OFF. Disconnect: PCM C175B. Disconnect: Starter Motor Relay. Measure the resistance between the BJB starter motor relay pin 2, circuit 31-BB16 (BK), harness side and PCM C175B-7, circuit 31-BB16 (BK), harness side. Is the resistance less than 5 ohms? Yes : INSTALL a new PCM. REFER to «ELECTRONIC ENGINE CONTROLS»(ref-356781) . TEST the system for normal operation. No : REPAIR circuit 31-BB16 (BK). TEST the system for normal operation.

When the ignition switch is turned in the START position and released, the PCM receives a starter motor request signal. With the vehicle in PARK or NEUTRAL, power flows from the PCM to the starter motor relay through circuits 31S-BB16 (BK/RD) and 50-BB15 (GY/OG). A ground is supplied through circuit 31-BB16 (BK) from the PCM causing the starter motor relay coil to energize and the relay contacts close. This allows power from starter motor relay through circuit 50-BB12 (GY) to the starter solenoid. The solenoid is grounded at the starter motor. Energizing the starter solenoid will engage the starter drive into the ring gear and closes the solenoid contacts, allowing power directly from the battery through circuit 30-BB10 (RD) to the starter motor to start the engine. The customer is no longer in the loop after the initial crank request, the customer may release the key to the RUN/START position. The PCM will disengage the starter motor based on engine running (RPM threshold), a set crank time has been exceeded or the ignition switch has been turned to the OFF position.