Starting System: Diagnosis Ford Windstar I

TROUBLE SHOOTING

Check the following items before proceeding with testing

1. Check battery for state of charge.
2. Check cable connections at battery and starter motor.
3. Ensure transmission is fully engaged in Park or Neutral position.
4. Check Maxi-fuse "C" (60-amp) in engine compartment fuse/relay box.
5. On models equipped anti-theft system, ensure anti-theft system is operating properly (horn honks, lights flash ect.) Check fuse No. 2 instrument panel fuse panel. See «ANTI-THEFT SYSTEM - ACTIVE»(ref-58768) article in ACCESSORIES & EQUIPMENT for additional information.

SYSTEM TESTING

VOLTAGE DROP TEST

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

Scheme 2

1. Disconnect both connectors from distributor. Connect remote starter switch between starter solenoid terminal "S" and positive battery post.
2. Using a digital voltmeter set at lowest voltage scale, connect positive voltmeter lead to positive battery post, and negative lead to solenoid terminal "M". (Scheme 2)
3. Engage remote starter switch. Voltmeter should indicate.5 volt or less. If voltmeter indicates more than.5 volt, move negative voltmeter lead to solenoid terminal "B". If voltmeter indicates.5 volt or less, go to STARTER GROUND CIRCUIT TEST.
4. 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) through 4). If voltmeter still indicates more than.5 volt at terminal "M" and less than.5 volt at terminal "B", solenoid contacts are bad. Remove and repair or replace solenoid.
5. If voltmeter indicates more than.5 volt at terminal "B", clean cables and connections at solenoid. If voltmeter still indicates more than.5 volt at terminal "B", check for poor positive battery cable connection or bad cable. Repair as necessary.
6. To locate excessive voltage drop, move voltmeter negative lead toward battery, and check each connection point. When high voltmeter reading disappears, last connection point checked is cause of problem.

STARTER GROUND CIRCUIT TEST

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

1. Disconnect both connectors from distributor. Connect remote starter switch between starter solenoid terminal "S" and positive battery post. (Scheme 2)
2. Using a digital voltmeter set at lowest voltage scale, connect positive voltmeter lead to starter housing, and negative lead to negative battery post.
3. Engage remote starter switch while observing voltmeter. Voltmeter should indicate.3 volt or less. If voltmeter indicates more than.3 volt, clean negative cable connections at battery and chassis. Also clean engine ground cable connections at front cover and engine mount bracket.
4. 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.
5. If battery and cables test okay and starter motor still cranks slowly or not at all, remove and repair starter.

STARTER NO-LOAD TEST

Connect battery, voltmeter, ammeter, and remote starter switch to starter. (Scheme 3) Engage remote starter switch. Starter should turn smoothly. Voltmeter should indicate 11 volts or more, and ammeter should indicate no more than 80 amps. If voltage is lower or current is higher than specification, replace or overhaul starter.

Scheme 3

STARTER CURRENT DRAW TEST

Ensure battery is fully charged. Ensure battery connections are clean and tight. Disconnect inertia fuel shutoff switch to prevent engine from starting. Clamp inductive ammeter lead around all positive (or negative) battery cables. (Scheme 3) Crank engine for about 5 seconds and check amperage reading while cranking. Normal amperage draw is 130-220 amps. If amperage draw exceeds specification, replace starter.