Starting System Lincoln Zephyr US

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

The starting system consists of the following components

1. Starter motor
2. Starter motor relay - part of smart junction box (SJB)
3. Transmission range (TR) sensor - automatic transmission
4. Clutch cutoff switch - manual transmission
5. Battery
6. Ignition switch

When the key is placed in the START position, the starter solenoid is energized and a magnetic field is created in the starter solenoid windings. The iron plunger core is drawn into the starter solenoid coil, and a drive lever and pin connected to the starter drive engages the drive pinion gear to the flexplate/flywheel ring gear. When the plunger is pulled all the way in, its contact disc closes the circuit between the battery and the starter motor solenoid feed terminals. This sends current to the motor, and the drive pinion gear cranks the flexplate/flywheel to start the engine. When current flows to the starter motor, the starter solenoid pull-in coil is bypassed, and the hold-in coil keeps the drive pinion gear engaged with the flywheel until the ignition switch is released from the START position.

An overrunning clutch in the starter drive protects the starter motor from excessive speeds during the brief period before the driver releases the ignition switch from the START position as the engine starts.

Vehicles equipped with a manual transaxle have a clutch cutoff switch mounted on the clutch pedal bracket. The clutch cutoff switch prevents operation of the starter motor unless the clutch is fully depressed.

Vehicles equipped with an automatic transmission have a TR sensor mounted on the transaxle. The TR sensor prevents operation of the starter motor unless NEUTRAL or PARK is selected.

Refer to appropriate procedure appropriate SYSTEM WIRING DIAGRAMS for schematic and connector information.

SPECIAL TOOL 73III Automotive Meter 105-R0057 or equivalent SABRE Premium Battery and Electrical System Tester 010-00730 or equivalent Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool

Scheme 1

Anti-Theft Intervention

The starting system is electronically controlled by the passive anti-theft system (PATS). The PATS system recognizes the correct electronically coded ignition key and signals the instrument cluster to provide a ground for the starter relay. The energized relay provides voltage to the starter solenoid, thereby allowing the starter motor to activate.

Inspection and Verification

Note. When working on the starter system, make sure the anti-theft system is operating correctly.

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 Battery junction box (BJB) fuses: 23 (60A) 14 (15A) Smart junction box (SJB) fuses: 10 (30A) 22 (7.5A) 3.0L vehicles only Wiring harness Starter relay (part of SJB) Anti-theft system Loose or corroded connections
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
4. If the cause is not visually evident, connect the diagnostic tool to the data link connector (DLC) and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: Check that the program card is correctly installed. Check the connections to the vehicle. Check the ignition switch position.
5. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool operating manual.
6. Carry out the diagnostic tool data link test. If the diagnostic tool responds with: Appropriate communication networks, such as SCP, ISO, UBP, CAN circuit fault; all electronic control units no response/not equipped, refer to «MODULE COMMUNICATIONS NETWORK»(/lincoln/zephyr/us-2006-2006/remont/communication-devices/#module-communications-network) . No response/not equipped for generic electronic module (GEM), refer to «MULTIFUNCTION ELECTRONIC CONTROL MODULES»(/lincoln/zephyr/us-2006-2006/remont/communication-devices/#multifunction-electronic-control-modules) . System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and carry out the self-test diagnostics for the GEM.
7. If the DTCs retrieved are related to the concern, go to the «PASSIVE ANTI-THEFT SYSTEM (PATS) - DIAGNOSTIC TROUBLE CODE (DTC) INDEX»(/lincoln/zephyr/us-2006-2006/remont/starter/#starting-system) .
8. If no DTCs related to the concern are retrieved, GO to «SYMPTOM CHART»(/lincoln/zephyr/us-2006-2006/remont/starter/#starting-system__symptom-chart) . PASSIVE ANTI-THEFT SYSTEM (PATS) - DIAGNOSTIC TROUBLE CODE (DTC) INDEX DTC Description Source Action B1213 Anti-Theft Number of Programmed Keys is Below Minimum Powertrain control module (PCM) REFER to «ANTI-THEFT - PATS»(/lincoln/zephyr/us-2006-2006/remont/door-locks-anti-theft-systems/#anti-theft-pats) . B1232 Transceiver Module Antenna Failure. Memory Failure in The PCM. PCM REFER to «ANTI-THEFT - PATS»(/lincoln/zephyr/us-2006-2006/remont/door-locks-anti-theft-systems/#anti-theft-pats) . B1342 ECU is Defective PCM CLEAR the DTCs. REPEAT the self-test. If DTC B1342 is retrieved again, INSTALL a powertrain control module (PCM). REFER to «ELECTRONIC ENGINE CONTROLS - 2.3L»(ref-256210) or «ELECTRONIC ENGINE CONTROLS - 3.0L (4V)»(/lincoln/zephyr/us-2006-2006/remont/removal-installation/#electronic-engine-controls-30l-4v) . CLEAR the DTCs. REPEAT the self-test. B1600 Passive Anti-Theft System (PATS) Key Transponder is Not Received PCM REFER to «ANTI-THEFT - PATS»(/lincoln/zephyr/us-2006-2006/remont/door-locks-anti-theft-systems/#anti-theft-pats) . B1601 PATS Received Incorrect Key-Code From Key Transponder PCM REFER to «ANTI-THEFT - PATS»(/lincoln/zephyr/us-2006-2006/remont/door-locks-anti-theft-systems/#anti-theft-pats) . B1602 PATS Received Invalid Format of Key-Code From Key Transponder PCM REFER to «ANTI-THEFT - PATS»(/lincoln/zephyr/us-2006-2006/remont/door-locks-anti-theft-systems/#anti-theft-pats) . B1681 PATS Transceiver Module Signal is Not Received PCM REFER to «ANTI-THEFT - PATS»(/lincoln/zephyr/us-2006-2006/remont/door-locks-anti-theft-systems/#anti-theft-pats) . B2103 Antenna Not Connected PCM REFER to «ANTI-THEFT - PATS»(/lincoln/zephyr/us-2006-2006/remont/door-locks-anti-theft-systems/#anti-theft-pats) . B2431 Key Program Failure (Defective Key or Transceiver) PCM VERIFY if the correct PATS key is being used. If the PATS key is defective, USE a new key for programming.

Symptom Chart

SYMPTOM CHART

Normal Operation

Under normal operation, constant power is supplied to the starter relay on circuit SBB23 (WH/RD), the starter on circuit SDC02 (RD) and to the ignition switch on circuit SBB14 (BN/RD). When the key is placed in the START position, with the vehicle in PARK or NEUTRAL or with the clutch pedal depressed, power is supplied to the smart junction box (SJB) on circuit CDC35 (BU/WH) through the SJB fuse 10 (30A) to the starter relay. Inputs from the transmission range (TR) sensor and clutch cutoff switch to the powertrain control module (PCM) provide a ground to the starter relay on circuit CDC12 (YE). When the coil of the relay is energized, it sends power to the starter motor on circuit CDC25 (BN/GN).

Possible Causes

1. Battery
2. Fuse(s)
3. Ignition switch
4. Starter relay (part of SJB)
5. Powertrain control module (PCM)
6. Anti-theft system
7. Circuitry

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

1. A1 CHECK THE BATTERY Check the battery condition and charge. Refer to «BATTERY, MOUNTING AND CABLES»(/lincoln/zephyr/us-2006-2006/remont/body-electrical/#battery-mounting-and-cables) . Is the battery OK? Yes : GO to A2. No : CHARGE or INSTALL a new battery as necessary. REFER to «BATTERY, MOUNTING AND CABLES»(/lincoln/zephyr/us-2006-2006/remont/body-electrical/#battery-mounting-and-cables) . TEST the system for normal operation.
2. A2 CHECK THE CONDITION OF THE PATS NOTE: The PATS diagnostic trouble codes (DTCs) are the only DTCs of concern in this step. Only repair retrieved non-PATS DTCs if a customer concern is reported. Check for PATS DTCs. Were any PATS DTCs retrieved? Yes : REFER to «ANTI-THEFT - PERIMETER»(/lincoln/zephyr/us-2006-2006/remont/door-locks-anti-theft-systems/#anti-theft-perimeter) to diagnose the PATS DTCs. No : GO to A3.
3. A3 CHECK THE AUTOMATIC TRANSMISSION RANGE (TR) SENSOR Enter the following diagnostic mode on the diagnostic tool: PCM TR sensor PID While observing the PCM TR sensor PID, place the vehicle in PARK and NEUTRAL. Does the PID match the gear selection? Yes : GO to A4. No : GO to the «AUTOMATIC TRANSAXLE/TRANSMISSION - FNR5 -- FUSION, MILAN, ZEPHYR»(ref-256261) to diagnose the TR sensor.
4. A4 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 A5. No : INSTALL a new battery ground cable. REFER to «BATTERY, MOUNTING AND CABLES»(/lincoln/zephyr/us-2006-2006/remont/body-electrical/#battery-mounting-and-cables) . TEST the system for normal operation.
5. A5 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 A6. No : 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 the starter motor B-pin and ground. Is the voltage greater than 10 volts? Yes : GO to A7. No : INSTALL a new positive battery cable. REFER to «BATTERY, MOUNTING AND CABLES»(/lincoln/zephyr/us-2006-2006/remont/body-electrical/#battery-mounting-and-cables) . TEST the system for normal operation.
7. A7 CHECK THE STARTER MOTOR B-PIN Connect one end of a fused (30A) jumper wire to the B-terminal of the starter motor. Momentarily connect the other end of the jumper 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. REFER to «STARTER MOTOR - 2.3L»(/lincoln/zephyr/us-2006-2006/remont/starter/#starting-system) or «STARTER MOTOR - 3.0L»(/lincoln/zephyr/us-2006-2006/remont/starter/#starting-system) . TEST the system for normal operation.
8. A8 CHECK THE STARTER MOTOR RELAY POWER Measure the voltage between smart junction box (SJB) C2280f-1, circuit SBB23 (WH/RD) and ground. Is the voltage greater than 10 volts? Yes : GO to A9. No : REPAIR the circuit. TEST the system for normal operation.
9. A9 CHECK THE START SIGNAL TO THE STARTER MOTOR RELAY Disconnect: SJB C2280b. NOTE: For manual transaxle, fully disengage the clutch. Measure the voltage between SJB C2280b-30, circuit CDC35 (BU/WH), harness side and ground with the ignition switch in the START position. Is the voltage greater than 10 volts? Yes : GO to A12 . No : GO to A10.
10. A10 CHECK CIRCUIT CDC35 (BU/WH) FOR AN OPEN Key in OFF position. Disconnect: Ignition Switch C250. Measure the resistance between SJB C2280b-30, circuit CDC35 (BU/WH), harness side and ignition switch C250-7, circuit CDC35 (BU/WH). Is the resistance less than 5 ohms? Yes : GO to A11. No : REPAIR the circuit. TEST the system for normal operation.
11. A11 CHECK CIRCUIT CDC35 (BU/WH) Measure the voltage between ignition switch C250-4, circuit SBB14 (BN/RD) and ground. Is the voltage greater than 10 volts? Yes : INSTALL a new ignition switch. TEST the system for normal operation. No : REPAIR the circuit. TEST the system for normal operation.
12. A12 CHECK THE GROUND SIGNAL TO THE STARTER RELAY Disconnect: SJB C2280a. NOTE: For manual transaxle, fully disengage the clutch. Measure the voltage between SJB C2280b-30, circuit CDC35 (BU/WH) and SJB C2280a-18, circuit CDC12 (YE), while placing the ignition switch in the START position. Is the voltage greater than 10 volts? Yes : GO to A15 . No : GO to A13.
13. A13 CHECK CIRCUIT CDC12 (YE) FOR AN OPEN Key in OFF position. Disconnect: PCM C175B. Measure the resistance between SJB C2280a-18, circuit CDC12 (YE), harness side and PCM C175B-34, circuit CDC12 (YE), harness side. Is the resistance less than 5 ohms? Yes : For 2.3L vehicles, INSTALL a new PCM. For 3.0L vehicles, GO to A14. No : REPAIR the circuit. TEST the system for normal operation.
14. A14 CHECK CIRCUIT CBP13 (GY/BN) FOR POWER TO THE PCM Measure the voltage between PCM C175b-10, circuit CBP13 (GY/BN) and ground, while placing the ignition switch in the START position. Is the voltage greater than 10 volts? Yes : REPLACE the PCM. Refer to «ELECTRONIC ENGINE CONTROLS - 2.3L»(ref-256210) or «ELECTRONIC ENGINE CONTROLS - 3.0L (4V)»(/lincoln/zephyr/us-2006-2006/remont/removal-installation/#electronic-engine-controls-30l-4v) . TEST the system for normal operation. No : REPAIR the circuit. TEST the system for normal operation.
15. A15 CHECK THE CIRCUIT TO THE STARTER MOTOR Key in OFF position. Disconnect: Starter Solenoid C197b. Measure the resistance between starter solenoid S-terminal C197b, circuit CDC25 (BN/GN) harness side and the SJB C2280a-17, circuit CDC25 (BN/GN) harness side. Is the resistance less than 5 ohms? Yes : INSTALL a new SJB. TEST the system for normal operation. No : REPAIR the circuit. TEST the system for normal operation.

1. Starter motor mounting
2. Starter motor mounting bolts
3. Starter motor drive
4. Flywheel or flexplate ring gear
5. Starter motor

PINPOINT TEST B: UNUSUAL STARTER NOISE

1. B1 CHECK THE STARTER MOUNTING Inspect the starter motor 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 - 2.3L»(/lincoln/zephyr/us-2006-2006/remont/starter/#starting-system) or «STARTER MOTOR - 3.0L»(/lincoln/zephyr/us-2006-2006/remont/starter/#starting-system) . TEST the system for normal operation.
2. B2 CHECK FOR ENGINE NOISE Turn the ignition switch to the OFF position. Connect a fused jumper wire from the B-terminal to the S-terminal of the starter motor. Engage the starter motor and verify that 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»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-system-general-information) to continue the diagnosis.
3. B3 CHECK FOR UNUSUAL WEAR Remove the starter motor. Refer to «STARTER MOTOR - 2.3L»(/lincoln/zephyr/us-2006-2006/remont/starter/#starting-system) or «STARTER MOTOR - 3.0L»(/lincoln/zephyr/us-2006-2006/remont/starter/#starting-system) . Inspect the ring gear for damaged or worn teeth. Is the noise due to flexplate/flywheel ring gear tooth damage? Yes : INSTALL a new flexplate/flywheel ring gear. EXAMINE the starter pinion teeth. If damaged, INSTALL a new starter motor. REFER to «STARTER MOTOR - 2.3L»(/lincoln/zephyr/us-2006-2006/remont/starter/#starting-system) or «STARTER MOTOR - 3.0L»(/lincoln/zephyr/us-2006-2006/remont/starter/#starting-system) . TEST the system for normal operation. No : INSTALL a new starter motor. REFER to «STARTER MOTOR - 2.3L»(/lincoln/zephyr/us-2006-2006/remont/starter/#starting-system) or «STARTER MOTOR - 3.0L»(/lincoln/zephyr/us-2006-2006/remont/starter/#starting-system) . TEST the system for normal operation.

Component Tests

Connect the 73III Automotive Meter 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.

Scheme 14

1. Make sure the battery is fully charged. Carry out a battery load test. Refer to «BATTERY, MOUNTING AND CABLES»(/lincoln/zephyr/us-2006-2006/remont/body-electrical/#battery-mounting-and-cables) .
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 M-terminal.
5. Engage the remote starter switch. Read and record the voltage. The voltage reading should be 0.8 volt or less.
6. If the voltage reading is 0.8 volt or less, go to the «STARTER MOTOR - GROUND CIRCUIT»(/lincoln/zephyr/us-2006-2006/remont/starter/#starting-system__starter-motor-ground-circuit) .
7. If the voltage reading is greater than 0.8 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 0.8 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 0.8 volt when checked at the M-terminal and less than 0.8 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 0.8 volt after cleaning the cables and the connections at the solenoid, the concern is either in the positive (+) battery cable connection or in the positive battery cable itself. Clean the positive (+) battery cable connection. If this does not solve the problem, install a new positive battery cable. Refer to «BATTERY, MOUNTING AND CABLES»(/lincoln/zephyr/us-2006-2006/remont/body-electrical/#battery-mounting-and-cables) .

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

Scheme 15

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 0.5 volt or less.
3. If the voltage is more than 0.5 volt, clean the negative cable connections at the battery, the body ground connections and the starter ground connections. Retest.
4. If the voltage is more than 0.5 volt, install a new cable. If the voltage reading is less than 0.5 volt and the engine still cranks slowly, install a new starter motor.

Scheme 16

Removal and Installation

Scheme 17

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/lincoln/zephyr/us-2006-2006/remont/hoistjack/#jacking-lifting) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/lincoln/zephyr/us-2006-2006/remont/body-electrical/#battery-mounting-and-cables) .
3. If equipped, remove the 7 screws and the underbody cover.
4. Remove the starter motor solenoid wire nut and position the wire aside. To install, tighten to 5 Nm (44 lb-in).
5. Position the starter motor solenoid battery cable terminal cover aside.
6. Remove the starter motor solenoid battery cable nut and position the cable aside. To install, tighten to 12 Nm (9 lb-ft).
7. Disconnect the wiring harness retainer from the top and bottom starter motor stud bolt and position the wiring harness aside.
8. Remove the starter motor stud bolt, bolt and the starter motor. To install, tighten to 25 Nm (18 lb-ft).
9. To install, reverse the removal procedure.

Scheme 18

1. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/lincoln/zephyr/us-2006-2006/remont/body-electrical/#battery-mounting-and-cables) .
2. Remove the starter motor solenoid wire nut and position the wire aside. To install, tighten to 5 Nm (44 lb-in).
3. Position the starter motor solenoid terminal battery cable cover aside.
4. Remove the starter motor solenoid battery cable nut and position aside the cable. To install, tighten to 12 Nm (9 lb-ft).
5. Remove the 2 starter motor bolts and the starter motor. To install, tighten to 27 Nm (20 lb-ft).
6. To install, reverse the removal procedure.

See also:
• MODULE COMMUNICATIONS NETWORK
• MULTIFUNCTION ELECTRONIC CONTROL MODULES
• ANTI-THEFT - PATS
• ELECTRONIC ENGINE CONTROLS - 3.0L (4V)
• BATTERY, MOUNTING AND CABLES
• ANTI-THEFT - PERIMETER
• ENGINE SYSTEM-GENERAL INFORMATION
• JACKING & LIFTING
• PASSIVE ANTI-THEFT SYSTEM (PATS) - DIAGNOSTIC TROUBLE CODE (DTC) INDEX
• SYMPTOM CHART
• PINPOINT TEST B
• STARTER MOTOR - GROUND CIRCUIT