Starting System: Other Mercury Monterey VIII

Starter Motor

The starter motor

1. is a permanent-magnet, direct drive, 12V dc motor.
2. has an integral starter solenoid.

Starter Relay

The starter relay

1. is a mini ISO relay that switches power to the starter solenoid to engage the starter motor.
2. receives a START signal from the ignition switch.

Possible Causes

An engine that does not crank can be caused by the following

1. Battery
2. Fuse(s)
3. Ignition switch
4. Starter relay
5. Anti-theft system
6. Circuitry

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1. A1 CHECK FOR PATS DTCS NOTE: The PATS system 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?
2. A2 CHECK THE BATTERY Check the battery condition and charge. Refer to «BATTERY, MOUNTING AND CABLES»(ref-234519) . Is the battery OK? Yes : GO to A3 . No : CHARGE or INSTALL a new battery as necessary. REFER to «BATTERY, MOUNTING AND CABLES»(ref-234519) . TEST the system for normal operation.
3. A3 CHECK THE BATTERY GROUND CABLE Measure the voltage between the positive battery post and the battery ground cable connection on the engine. Is the voltage greater than 10 volts? Yes : GO to A4 . No : INSTALL a new battery ground cable. REFER to «BATTERY, MOUNTING AND CABLES»(ref-234519) . TEST the system for normal operation.
4. A4 CHECK THE STARTER MOTOR GROUND Measure the voltage between the battery positive post and the starter motor case. Is the voltage greater than 10 volts? Yes : GO to A5 . No : CLEAN the starter motor mounting flange and make sure the starter motor is correctly mounted. TEST the system for normal operation.
5. A5 CHECK THE POWER SUPPLY TO THE STARTER MOTOR Measure the voltage between starter motor B-pin and ground. Is the voltage greater than 10 volts? Yes : GO to A6 . No : INSTALL a new positive battery cable. REFER to «BATTERY, MOUNTING AND CABLES»(ref-234519) . TEST the system for normal operation.
6. A6 CHECK THE STARTER MOTOR B-PIN Connect a fused (30A) jumper wire to the B-terminal of the starter motor. Momentarily connect the other lead of the jumper wire to the starter motor S-terminal. Did the starter motor engage and the engine crank? Yes : GO to A7 . No : INSTALL a new starter motor. REFER to «STARTER MOTOR»(ref-234491-S24586955342006061000000) . TEST the system for normal operation.
7. A7 CHECK THE START INPUT TO THE STARTER MOTOR Disconnect: Starter Motor C197a. Measure the voltage between starter motor C197a, circuit 113 (YE/LB), harness side and ground, while placing the ignition switch in the START position. Key in START position. Is the voltage greater than 10 volts? Yes : CLEAN the starter motor S-terminal and connector. CHECK the wiring and the starter motor for a loose or intermittent connection. TEST the system for normal operation. No : GO to A8 .
8. A8 CHECK THE START INPUT TO THE STARTER RELAY Disconnect: Starter Relay. Make sure the vehicle is in PARK or NEUTRAL. Turn the ignition switch to START and hold. Measure the voltage between starter relay C1017 pin 86, circuit 33 (WH/PK), harness side and ground. Is the voltage greater than 10 volts? Yes : GO to A9 . No : GO to A13 .
9. A9 CHECK THE BATTERY SUPPLY TO THE STARTER INTERRUPT RELAY Measure the voltage between starter relay pin 30, circuit 1050 (LG/VT), harness side and ground. Is the voltage greater than 10 volts? Yes : GO to A10 . No : REPAIR the circuit. TEST the system for normal operation.
10. A10 CHECK THE GROUND SIGNAL TO THE STARTER RELAY Measure the voltage between starter relay pin 85, circuit 1419 (LG/YE) and pin 86, circuit 33 (WH/PK), while placing the ignition switch in the START position. Is the voltage greater than 10 volts? Yes : GO to A12 . No : GO to A11 .
11. A11 CHECK CIRCUIT 1419 (LG/YE) FOR AN OPEN Disconnect: PCM C175. Measure the resistance between starter relay pin 85, circuit 1419 (LG/YE), harness side and PCM C175-44, circuit 1419 (LG/YE), harness side. Is the resistance less than 5 ohms? Yes : INSTALL a new PCM. No : REPAIR the circuit. TEST the system for normal operation.
12. A12 CHECK CIRCUIT 113 (YE/LB) FOR AN OPEN Disconnect: Starter Motor C197b. Measure the resistance between starter relay pin 87, circuit 113 (YE/LB), harness side and starter motor C197b, circuit 113 (YE/LB), harness side. Is the resistance less than 5 ohms? Yes : INSTALL a new starter relay. TEST the system for normal operation. No : REPAIR the circuit. TEST the system for normal operation.
13. A13 CHECK THE START INPUT TO SJB FUSE 3 (10A) Disconnect: SJB Fuse 3 (10A). Measure the voltage between SJB fuse 3 (10A) input cavity and ground, while placing the ignition switch in the START position. Is the voltage greater than 10 volts? Yes : GO to A14 . No : GO to A16 .
14. A14 CHECK CIRCUIT 32 (RD/LB) FOR AN OPEN Connect: Fuse 3 (10A). Disconnect: Digital TR Sensor C167. Measure the voltage between digital TR sensor C167-12, circuit 32 (RD/LB), harness side and ground, while placing the ignition switch in the START position. Is the voltage greater than 10 volts? Yes : GO to A15 . No : REPAIR the circuit. TEST the system for normal operation.
15. A15 CHECK CIRCUIT 33 (WH/PK) FOR AN OPEN Measure the resistance between digital TR sensor C167-10, circuit 33 (WH/PK), harness side and starter interrupt relay pin 86, circuit 33 (WH/PK), harness side. Is the resistance less than 5 ohms? Yes : CHECK the digital TR sensor alignment. REFER to «AUTOMATIC TRANSAXLE/TRANSMISSION»(ref-234499) . If digital TR sensor is aligned correctly, INSTALL a new digital TR sensor. TEST the system for normal operation. No : REPAIR the circuit. TEST the system for normal operation.
16. A16 CHECK THE POWER SUPPLY TO THE IGNITION SWITCH Disconnect: Ignition Switch C250. Measure the voltage between ignition switch C250-B4, circuit 1050 (LG/VT), harness side and ground. Is the voltage greater than 10 volts? Yes : GO to A17 . No : REPAIR the circuit. TEST the system for normal operation.
17. A17 CHECK THE IGNITION SWITCH Carry out the ignition switch component test. Refer to «COMPONENT TESTING»(ref-233794) . Did the ignition switch pass the component test? Yes : REPAIR circuit 1522 (DG). TEST the system for normal operation. No : INSTALL a new ignition switch. REFER to «STEERING COLUMN SWITCHES»(ref-234529) . TEST the system for normal operation.

Unusual starter noise can be caused by the following

1. Loose starter motor mounting bolts or brackets
2. Worn or damaged flywheel ring gear
3. Worn or damaged starter motor drive gear

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 detect a high resistance between the wiring connector and the component.

Scheme 20

1. Make sure the battery is fully charged. Carry out a battery load test. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-234519) .
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»(ref-234491-S00613769532006061000000) Component Test.
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. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-234519) .

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 21

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 22