Starters: Diagnosis Lincoln Aviator I

TROUBLE SHOOTING

Verify customer compliant by operating starting system. Check battery for state of charge. Check cable connections at battery and starter motor. Ensure transmission is fully engaged in Park or Neutral position. Check maxi-fuse No. 12 (50-amp) and fuse No. 23 (30-amp) in battery junction box. (Scheme 1) Check fuse No. 29 (10-amp) in central junction box. (Scheme 2) On models equipped anti-theft system, ensure anti-theft system is operating properly. See appropriate ANTI-THEFT SYSTEMS article for additional information. If problem is found, repair as necessary. If problem is not found, repair by symptom. See SYMPTOM INDEX table under SYSTEM TESTS.

Scheme 1

Scheme 2

TEST A: ENGINE DOES NOT CRANK & RELAY CLICKS

1. Check For Voltage Drop Check starter motor feed and ground circuits for voltage drop. See «ON-VEHICLE TESTING»(ref-168133-S35122007502004110100000). Is the voltage drop within specification? If yes go to next step. If no, repair as necessary.
2. Check The Starter Motor Connect one end of a fused jumper wire to the "B" terminal of the starter motor and momentarily connect the other end to the starter solenoid "S" terminal. (Scheme 3) Recheck system operation. Does the starter motor engage and the engine crank? If yes, go to next step. If no, install a new starter motor. See «STARTER MOTOR»(ref-168133-S02784538662004110100000) under REMOVAL & INSTALLATION. Test the system for normal operation.
3. Check The Start Input To The Starter Motor Disconnect starter "S" connector. (Scheme 3) Hold the ignition switch in the START position. Measure the voltage at the starter motor solenoid "S" connector. Is the voltage reading greater than 10 volts? If yes, clean the starter solenoid "S" terminal and connector. Check the wiring and the starter motor for a loose or intermittent connection. Test the system for normal operation. If no, go to next step.
4. Check The Start Input To The Starter Relay Turn ignition off. Disconnect starter relay. Hold the ignition switch in the START position. Measure the voltage between starter relay connector terminal No. 85 (White/Pink wire) and ground. (Scheme 4) Is the voltage reading greater than 10 volts? If yes, go to next step. If no, go to step 10.
5. Check The Battery Supply Power To The Starter Relay Measure the voltage between starter relay connector terminal No. 30 (Light Green/Violet wire) and ground. (Scheme 4) Is the voltage reading greater than 10 volts? If yes, go to next step. If no, repair open in Light Green/Violet wire between starter motor relay and BJB. See «WIRING DIAGRAMS»(ref-168133-S07832782632004110100000). Test then system for normal operation.
6. Check Yellow/Light Blue Wire For Short To Ground Disconnect starter relay. Measure the resistance between starter relay connector terminal No. 87 (Yellow/Light Blue wire) and ground. Is the resistance reading less than 10,000 ohms? (Scheme 4) If yes, repair Yellow/Light Blue wire between starter relay and starter for a short to ground. See «WIRING DIAGRAMS»(ref-168133-S07832782632004110100000). Test the system for normal operation. If no, go to next step.
7. Check Yellow/Light Blue Wire For An Open Disconnect Starter Relay. Measure the resistance of Yellow/Light Blue wire between starter relay connector terminal No. 87 and the starter "S" connector. (Scheme 3)and (Scheme 4). Is the resistance reading less than 5 ohms? If yes, go to next step. If no, repair Yellow/Light Blue wire between stater relay and starter for an open. See «WIRING DIAGRAMS»(ref-168133-S07832782632004110100000). Test the system for normal operation.
8. Check Orange Wire For A Short To Ground Disconnect starter relay. Measure the resistance of Orange wire between starter relay connector terminal No. 86 and ground. (Scheme 4) Is the resistance reading less than 10,000 ohms? If yes, repair Orange wire between starter relay and PCM for a short to ground. See «WIRING DIAGRAMS»(ref-168133-S07832782632004110100000). Test the system for normal operation. If no, go to next step.
9. Check Orange Wire For An Open Disconnect starter relay. Measure the resistance of Orange wire between starter relay connector terminal No. 86 and the PCM connector C175b terminal No. 39. (Scheme 4)and (Scheme 5). Is the resistance less than 5 ohms? If yes, install a new starter relay. Test the system for normal operation. If no, repair Orange wire between starter relay and PCM for an open. See «WIRING DIAGRAMS»(ref-168133-S07832782632004110100000). Test the system for normal operation.
10. Check White/Pink Wire For Voltage Turn ignition switch to START position. Disconnect starter relay. Measure the voltage between DTR sensor connector terminal No. 10 (White/Pink wire) harness side and ground, while holding the ignition switch in the START position. (Scheme 6) Is the voltage reading greater than 10 volts? If yes, go to next step. If no, repair White/Pink wire. See «WIRING DIAGRAMS»(ref-168133-S07832782632004110100000). Test the system for normal operation.
11. Check For Voltage At The DTR Sensor Turn ignition to START position. Measure the voltage between DTR sensor connector terminal No. 12 (Red/Light Blue wire) and ground in the START position. (Scheme 6) Is the voltage greater than 10 volts? If yes, install a new DTR sensor switch. If no, go to next step.
12. Check Dark Green Wire For An Open Disconnect starter relay. Measure the resistance of the Dark Green wire between ignition switch connector terminal No. 7 and the input cavity of fuse No. 29 (10A). (Scheme 7) Is the resistance less than 5 ohms? If yes, go to next step. If no, repair Dark Green wire between ignition switch and fuse No. 29. See «WIRING DIAGRAMS»(ref-168133-S07832782632004110100000). Test the system for normal operation.
13. Check The Power Supply To The Ignition Switch Disconnect ignition switch connector. Measure the voltage at ignition switch connector terminal No. 4 (Yellow wire). (Scheme 7) Is the voltage reading greater than 10 volts? If yes, install a new ignition switch. See appropriate STEERING COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT. If no, repair Yellow wire between ignition switch and fuse No. 23 in BJB for an open. See «WIRING DIAGRAMS»(ref-168133-S07832782632004110100000). TEST the system for normal operation.

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

TEST B: UNUSUAL STARTER NOISE

1. Check The Starter Mounting Verify starter is installed properly. Ensure bolts are tight. Repair as necessary and check system for normal operation. If starter is mounted properly, go to next step.
2. Check For Engine Noise Connect remote starter switch between positive battery terminal and starter motor relay terminal "S" (Yellow/Light Blue wire). (Scheme 3) Engage starter motor and verify noise is coming from starter motor. If noise is coming from starter motor, go to next step. If noise is not coming from starter motor, diagnose engine mechanical concern. See appropriate engine article in ENGINES.
3. Check For Unusual Wear Remove starter motor. See «STARTER MOTOR»(ref-168133-S02784538662004110100000) under REMOVAL & INSTALLATION. Inspect flywheel ring gear for wear or damage. If ring gear is okay, replace starter motor. If ring gear is worn or damaged, replace ring gear and inspect starter drive gear. If drive gear is also damaged, replace starter motor.

ON-VEHICLE TESTING

VOLTAGE DROP TEST

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

Scheme 8

1. Ensure battery is fully charged. Disconnect inertia fuel shutoff switch to prevent vehicle from starting. Connect remote starter switch between starter solenoid terminal "S" and positive battery post. Connect positive DVOM lead to positive battery post, and negative lead to solenoid terminal "M". (Scheme 8)
2. Engage remote starter switch. If DVOM indicates.5 volt or less, go to «STARTER GROUND CIRCUIT TEST»(ref-168133-S28586354832004110100000). If DVOM indicates greater than.5 volt, go to next step.
3. Move negative DVOM lead to solenoid terminal "B". Engage remote starter switch. If DVOM indicates less than.5 volt, solenoid connections or contacts are bad. Clean solenoid terminals "B", "S" and "M". Repeat steps 1 - 3.
4. If DVOM still indicates more than.5 volt at terminal "M" and less than.5 volt at terminal "B", solenoid contacts are bad. Replace starter motor. See «STARTER MOTOR»(ref-168133-S02784538662004110100000) under REMOVAL & INSTALLATION. If DVOM indicates greater than.5 volt at terminal "B", clean cables and connections at solenoid.
5. If DVOM still indicates greater than.5 volt at terminal "B", check for poor positive battery cable connection or bad cable. Repair connection or replace battery cable as necessary.

STARTER GROUND CIRCUIT TEST

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

1. Disconnect inertia fuel shutoff switch to prevent vehicle from starting. Connect remote starter switch between starter solenoid terminal "S" and positive battery post. (Scheme 9) Connect positive DVOM lead to starter housing, and negative lead to negative battery post.
2. Engage remote starter switch while observing DVOM. DVOM should indicate.2 volt or less. If DVOM indicates greater than.2 volt, clean negative cable connections at battery and engine.
3. 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.
4. If battery and cables test okay and starter motor still cranks slowly or not at all, replace starter motor. See «STARTER MOTOR»(ref-168133-S02784538662004110100000) under REMOVAL & INSTALLATION.

Scheme 9