Starters: Other Mercury Cougar VIII

SYSTEM TESTS

STARTER CRANKS SLOWLY OR SOLENOID CLICKS

1. Check starter motor for excessive current draw during operation using ammeter or starting/charging system tester. Refer to tool manufacturer's instructions. If starter current draw is excessive, repair or replace starter motor. If starter current draw is okay, go to next step.
2. To check voltage drop, measure voltage between starter motor battery cable terminal and positive battery terminal with ignition switch in START position. If voltage drop is .5 volt or less, go to next step. If voltage drop is greater than .5 volt, clean or repair cable connections, or replace cable as necessary. Restore electrical connections and check system operation.
3. To check ground circuit voltage drop, measure voltage between starter motor case and negative battery terminal with ignition switch in START position. If ground circuit voltage drop is .5 volt or less, diagnose charging system. See appropriate GENERATORS & REGULATORS article. If ground circuit voltage drop is greater than .5 volt, clean and tighten starter and engine ground connections. If okay, replace negative battery cable.

Scheme 3

Scheme 4

1. Verify battery condition. Battery voltage should be 12 volts or more. Load test battery at approximately one-half cold cranking amperage rating. See load tester manufacturer's instructions. If battery is okay, go to next step. If battery voltage is less than 12 volts or loaded battery voltage is less than 9.6 volts, service battery or charging system as necessary.
2. Remove starter relay from power distribution box in engine compartment. Check relay resistance and continuity between relay terminals as specified. See «STARTER RELAY SPECIFICATIONS»(ref-4452-S12160273482000062800000) table. (Scheme 3) If relay resistance or continuity is not as specified, replace relay. If relay resistance is as specified, go to next step. STARTER RELAY SPECIFICATIONS Relay Terminals Continuity 85 & 86 (1) 30 & 87a Yes 30 & 87 No 30 & 86 No 86 & 87a No 86 & 87 No (1) Resistance should be 50-100 ohms.
3. Connect 2 jumper wires from battery positive post to relay terminals No. 30 and No. 85. Connect jumper from relay terminal No. 86 to ground. (Scheme 3) Measure voltage between relay terminals No. 86 and No. 87. Battery voltage should be present. Disconnect jumper from relay terminal No. 85. Measure voltage between relay terminals No. 86 and No. 87A. Battery voltage should be present. If voltage is as specified, go to next step. If battery voltage is not as specified, replace relay.
4. Measure voltage between starter relay harness connector terminal No. 30 and ground. (Scheme 4) If battery voltage is present, go to next step. If battery voltage is not present, verify headlight operation. If headlights operate, replace battery junction box and check system operation. If headlights do not operate, repair Red wire between battery and starter relay harness connector terminal No. 30.
5. Perform «STARTER NO-LOAD TEST»(ref-4452-S29653838092000062800000) under BENCH TESTS. If starter motor tests okay, install original starter motor and go to next step. If starter motor does not test okay, replace starter motor and check system operation.
6. Install starter relay. Connect voltmeter between battery positive terminal and battery cable connection at starter motor. Measure voltage with ignition switch in START position. If voltage is more than.5 volt, replace battery positive cable. If voltage is.5 volt or less, repair Gray/Black wire between starter relay and starter motor.

Scheme 5

Scheme 6

1. Verify battery condition. Battery voltage should be 12 volts or more. Load test battery at approximately one-half cold cranking amperage rating. See load tester manufacturer's instructions. If battery voltage is less than 12 volts or loaded battery voltage is less than 9.6 volts, service battery or charging system as necessary.
2. Remove starter relay from power distribution box in engine compartment. Measure voltage between starter relay harness connector terminal No. 86 and ground with ignition switch in START position. If battery voltage is present, go to next step. If battery voltage is not present, go to step 4.
3. Measure resistance between starter relay harness connector terminal No. 85 and ground with ignition switch in START position. If resistance is less than 5 ohms, install new starter relay and check system operation. If resistance is 5 ohms or greater, go to step 6 (manual transmission) or step 9 (automatic transmission).
4. Remove starter diode from power distribution box. (Scheme 5) Measure voltage between both diode connector terminals and ground with ignition switch in START position. If battery voltage is present at either terminal, install new diode and check system operation. If battery voltage is not present, go to next step.
5. Disconnect ignition switch. Measure resistance between ignition switch connector C456 terminal No. 5 (Gray/White wire) and both diode connector terminals in power distribution box. See «WIRING DIAGRAMS»(ref-4452-S42109915622000062800000). If resistance is 5 ohms or less on one terminal, replace ignition switch. See appropriate STEERING COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT. If resistance is greater than 5 ohms on both terminals, repair open Gray/White wire between ignition switch and power distribution box.
6. Install starter relay. Disconnect start inhibit switch, located on clutch pedal bracket. Measure voltage between start inhibit switch harness connector Black/Yellow wire and ground with ignition switch in START position. If battery voltage is present, go to next step. If battery voltage is not present, repair Black/Yellow wire and check system operation.
7. Measure resistance between start inhibit switch terminals. Resistance should be less than 5 ohms with clutch pedal depressed, and greater than 100,000 ohms with clutch pedal released. If resistance is as specified, go to next step. If resistance is not as specified, adjust start inhibit switch and retest. If resistance is still not as specified, replace start inhibit switch.
8. Disconnect PCM harness connector C421, located underneath center console. Measure resistance between PCM harness connector terminal 82 and start inhibit switch terminal No. 1 (Black/Yellow wire). (Scheme 6) If resistance is less than 5 ohms, reconnect start inhibit switch and go to step 12. If resistance is 5 ohms or greater, repair Black/Yellow wire between PCM connector and start inhibit switch connector.
9. Install starter relay. Disconnect Transmission Range (TR) sensor. Measure voltage between TR sensor connector terminal No. 3 (Black/Yellow wire) and ground with ignition switch in START position. If battery voltage is present, go to next step. If battery voltage is not present, repair Black/Yellow wire and check system operation.
10. Disconnect PCM 104-pin connector C421. Measure resistance of Black/Green wire between PCM connector terminal No. 82 and TR sensor connector terminal No. 6. (Scheme 6) If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or greater, repair Black/Green wire and check system operation.
11. Measure resistance between TR sensor terminal No. 3 (Black/Yellow wire) and terminal No. 6 (Black/Green wire). If resistance is 5 ohms or less, reconnect TR sensor harness connector and go to next step. If resistance is greater than 5 ohms, adjust TR sensor using Sensor Alignment Tool (T94P-70010-AH). Recheck resistance. If resistance is still not as specified, replace TR sensor.
12. Install EEC-V PCM breakout box. Connect a jumper wire between breakout box pins No. 82 and No. 77. Momentarily turn ignition switch to START position. If starter motor does not activate, go to «STARTER DOES NOT CRANK & RELAY CLICKS»(ref-4452-S26776439162000062800000). If starter motor activates, and vehicle is equipped with anti-theft system, go to appropriate ANTI-THEFT SYSTEMS article. If starter motor activates, and vehicle is not equipped with anti-theft system, replace PCM and check system operation.