2001 Cougar Workshop Manual

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1 Page 1 of 7 SECTION : Starting System 2001 Cougar Workshop Manual DIAGNOSIS AND TESTING Procedure revision date: 09/14/2001 Starting System Refer to Wiring Diagrams Section for schematic and connector information. Special Tool(s) Digital Volt Ohm Meter or equivalent 105-R0051 Starter, Alternator, Battery, Regulator, Electrical Tester or equivalent S.A.B.R.E. Inspection and Verification 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart Mechanical Starter motor. Battery. Electrical Fuse 10 (20A). Wiring harness(es). Electrical connectors. 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 concern is not visually evident, verify the symptom and refer to the Symptom Chart. Symptom Chart Symptom Chart Condition Possible Sources Action Engine does not crank but relay clicks Engine does not crank and relay does not click Engine cranks slowly Unusual starter motor noise The starter spins but the engine does not crank Starter motor Relay. Circuit Fuse. Relay. Circuit. Ignition switch. Circuitry. Flywheel ring gear. GO to Pinpoint Test A. GO to Pinpoint Test B. GO to Pinpoint Test C. CHECK flywheel ring gear. REFER to Section INSPECT starter motor for alignment, cracked case. Make sure the mounting bolts are tightened. If necessary, INSTALL a new starter motor. INSPECT the flywheel ring gear for missing teeth. CHECK starter motor for correct mounting. If concern persists, INSTALL a new starter motor. Pinpoint Tests PINPOINT TEST A: THE ENGINE DOES NOT CRANK AND THE RELAY CLICKS CONDITIONS A1 CHECK THE BATTERY DETAILS/RESULTS/ACTIONS Check the battery. REFER to Section Is the battery OK? GO to A2. A2 CHECK THE STARTER RELAY INSTALL a new battery. TEST the system for normal operation.

2 Page 2 of 7 Carry out the ISO mini relay component test. For additional information refer to the wiring diagrams. Is the relay OK? GO to A3. A3 CHECK VOLTAGE TO STARTER RELAY INSTALL a new starter relay. TEST the system for normal operation. Measure the voltage between starter relay C52 pin 3, harness side and ground. GO to A4. A4 CHECK THE STARTER MOTOR If the headlamps operate, INSTALL a new battery junction box. TEST the system for normal operation. Otherwise, REPAIR circuit 30-DA3. TEST the system for normal operation. Perform the starter motor no-load test. REFER to Starter Motor -Load Test in this section. Is the starter OK? INSTALL the starter motor, GO to A5. A5 CHECK THE STARTER MOTOR FEED INSTALL a new starter motor. TEST the system for normal operation. Measure the voltage between the positive battery terminal and starter motor 30 terminal with the ignition key in the III (start) position. Is the voltage less than 0.5 volts? REPAIR circuit 50-BB10. TEST the system for normal operation. INSTALL a new positive battery cable. TEST the system for normal operation. PINPOINT TEST B: THE ENGINE GOES NOT CRANK AND THE RELAY DOES NOT CLICK CONDITIONS B1 CHECK THE BATTERY DETAILS/RESULTS/ACTIONS Check the battery. REFER to Section Is the battery OK? GO to B2.

3 Page 3 of 7 B2 CHECK SWITCHED POWER TO THE STARTER RELAY INSTALL a new battery. TEST the system for normal operation. Measure the voltage between starter relay C52 pin 2, harness side and ground with the ignition key in the III (start) position. GO to B3. GO to B4. B3 CHECK GROUND SIGNAL FOR THE STARTER RELAY Measure the resistance between starter relay C52 pin 1, harness side and ground with the ignition key in the III (start) position. INSTALL a new starter relay. TEST the system for normal operation. B4 CHECK DIODE If manual transmission, GO to B6. If automatic transmission, GO to B9. Diode C61 Measure the voltage between the diode C61 pin 1, harness side and ground with the ignition key in the III (start) position INSTALL a new diode. TEST the system for normal operation. B5 CHECK CIRCUIT 50 BB11 FOR OPEN GO to B5. Ignition Switch C456 Measure the resistance between ignition switch C456 pin 5, circuit 50-BB11 (GY/WH), harness side and diode C61 pin 1, harness side.

4 Page 4 of 7 INSTALL a new ignition switch. TEST the system for normal operation. B6 CHECK CIRCUIT TO CLUTCH PEDAL Start Inhibit Switch C1919 Measure the voltage between start inhibit switch C1919 pin 2, circuit 31S-BB12 (BK/YE), harness side and ground with the ignition key in the III (start) position. GO to B7. B7 CHECK START INHIBIT SWITCH Measure the resistance between the start inhibit switch pin 1 and pin 2, component side. te the reading with the clutch pedal pressed in and with the pedal released. Is the resistance less than 5 ohms with the clutch pedal pressed, and greater than 10,000 ohms with the pedal released? GO to B8. B8 CHECK CIRCUIT 31 - BB6 ADJUST the start inhibit switch. REPEAT this Pinpoint Test, if necessary INSTALL a new start inhibit switch. TEST the system for normal operation. PCM C421 Measure the resistance between start inhibit switch C1919 pin 1, circuit 31-BB6 (BK), harness side and PCM C421 pin 18, circuit 31S-BB12 (BK/YE), harness side.

Page 5 of 7 B9 CHECK SIGNAL TO TRANSMISSION RANGE SENSOR INSTALL the start inhibit switch. GO to B12. REPAIR circuit 31-BB6 (BK) and 31S-BB12 (BK/YE). TEST the system for normal operation.

5 Page 5 of 7 B9 CHECK SIGNAL TO TRANSMISSION RANGE SENSOR INSTALL the start inhibit switch. GO to B12. REPAIR circuit 31-BB6 (BK) and 31S-BB12 (BK/YE). TEST the system for normal operation. TR Sensor C438 Measure the voltage between TR sensor C438 pin 4, circuit 31S-BB12 (BK/GN), harness side and ground with the ignition key in the III (start) position. GO to B10. B10 CHECK CIRCUIT 31S - PF9 PCM C421 Measure the resistance between TR sensor C438 pin 9, circuit 31S-PF9 (BK/GN), harness side and PCM C421 pin 18, circuit 31S-PF9 (BK/GN), harness side. GO to B11. B11 CHECK TR SENSOR Measure the resistance between the TR sensor pin 4 and pin 9, component side.

6 Page 6 of 7 CONNECT the TR sensor. GO to B12. B12 CHECK COIL SIDE CIRCUIT ADJUST the TR sensor. REFER to Section If the concern persists, INSTALL a new TR sensor. Install the EEC V 104-Pin Breakout Box. Using a test meter lead, connect pin 18 and pin 77 of the EEC V 104-Pin Breakout Box. Momentarily turn the ignition key to the III (start) position. Did the starter motor turn the engine? For vehicles with anti-theft, REFER to Section B. For vehicles without anti-theft; INSTALL a new PCM. TEST the system for normal operation. GO to pinpoint test A. PINPOINT TEST C: THE ENGINE CRANKS SLOWLY CONDITIONS C1 CHECK THE STARTER MOTOR LOAD DETAILS/RESULTS/ACTIONS Perform the starter motor load test on the starter motor, REFER to Starter Motor Load Test in this section. Is the starter motor OK? GO to C2. C2 CHECK FOR VOLTAGE DROP INSTALL a new starter motor. TEST the system for normal operation Measure the voltage between starter motor B terminal, component side and the positive battery terminal with the ignition key in the III (start) position. Is the voltage less than 0.5 volts? GO to C3. C3 CHECK FOR GROUND CONNECTION CLEAN and TIGHTEN all positive battery cable connections. TEST the system for normal operation. If the concern persists, INSTALL a new positive battery cable. Measure the voltage between the starter motor case and battery negative terminal with the ignition key in the III (start) position. Is the voltage less than 0.5 volts? DIAGNOSE the battery and charging system. REFER to Section CLEAN and TIGHTEN all negative battery cable connections, starter motor mounting and body to engine ground strap. TEST the system for normal operation. If the concern persists, INSTALL a new negative battery cable. Component Tests Starter Motor - Load The battery must be fully charged before performing the Starter Motor Load Test. For battery inspection and testing; REFER to Section

7 Page 7 of 7 1. Set the parking brake and shift the transmission into NEUTRAL. 2. To prevent the engine from starting, disconnect the ignition coil electrical connector. 3. NOTE: Make sure that the rheostat is at the maximum counterclockwise position. Connect Starter Alternator, Battery Regulator Electrical Tester (SABRE). 4. Connect the remote starter switch across the starter relay S-and battery terminal. 5. Turn the key to II (run). 6. Crank the engine with the remote starter switch and determine the exact reading on the voltmeter. 7. Stop cranking the engine and reduce the resistance of the carbon pile rheostat until the voltmeter indicates the same reading as obtained in step 6. The ammeter will indicate the starter current draw under load. Check this with the value listed in General Specifications. Starter Motor - -Load 1. Remove the starter motor; Refer to Starter Motor in this Section. 2. Connect Starter Alternator, Battery Regulator Electrical Tester (SABRE) to a fully charged battery, and a remote starter switch to the starter motor. 3. Engage the remote starter switch. The pinion should shift to the crank position and the starter motor should operate smoothly. 4. While the starter motor is operating, check the voltmeter and ammeter readings. 5. The voltage should be greater than 11.0 volts and the amperage should be no more than 70 amps. 6. If the voltage is lower than specified, or if the amperage is higher than specified; refer to Symptom Chart - Starter Motor -Load Test Results to determine the cause and corrective action. Symptom Chart - Starter Motor - -Load Test Results Symptom Chart Condition Possible Sources Action rmal current and speed Current flow with test circuit switch open Failure to operate with very little or no current Failure to operate with high current Low speed with high current Low speed with normal or low current High speed with high current Switches. Wiring. Solenoid contacts. Solenoid winding. Field circuit. Armature coil or commutator bars. Brush springs or brushes. Bearing or drivetrain. Terminals or fields. Bushings, gear reduction unit, armature shaft, pole shoe or driveshaft. Armature. Armature or fields. Connections, leads or commutator. Solenoid winding. Field circuit. Armature coils or commutator bars. Brush springs or brushes. Fields. RECHECK battery, switches and wiring, including voltage drop tests, if cranking starter motor operation on engine is slow or sluggish. TEST and, if necessary, INSTALL a new solenoid assembly. INSPECT and TEST solenoid assembly. INSPECT and TEST frame and field coil assembly. INSPECT armature. INSPECT brushes and brush springs. INSPECT bearing, armature, driveshaft and related drive parts. INSPECT and TEST frame and field coil assembly, solenoid assembly and brush installations for shorts. INSPECT bearing, armature, driveshaft and gear reduction gears. INSPECT and TEST armature. INSPECT and TEST frame and field coil assembly and armature. INSPECT internal wiring, electrical connections and armature commutator. INSPECT and TEST solenoid assembly. INSPECT and TEST frame and field coil assembly. INSPECT armature. INSPECT brushes and brush springs. INSPECT and TEST field and frame assembly.

2000 F-150 Workshop Manual

Page 1 of 14 SECTION 303-06: Starting System 2000 F-150 Workshop Manual DIAGNOSIS AND TESTING Procedure revision date: 06/17/1999 Starting System Refer to Wiring Diagrams Cell 20, Starting System for schematic