2000 F-150 Workshop Manual

Size: px

Start display at page:

Download "2000 F-150 Workshop Manual"

Gabriel Lambert
5 years ago
Views:

1 Page 1 of 14 SECTION : 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 and connector information. Special Tool(s) 73 Digital Multimeter 105-R0051 or equivalent Starter,Alternator, Battery, Regulator and Electrical Tester (SABRE) or equivalent Inspection and Verification 1. Verify the customer concern by operating the starting system. 2. Visually inspect for obvious signs of mechanical and electrical damage; refer to the following chart. Visual Inspection Chart Mechanical Starter motor Starter motor solenoid Brackets Electrical Battery Open fuse Damaged wiring harness Loose or corroded connections 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. Symptom Chart SYMPTOM CHART Condition Possible Sources Action The engine does not crank or the relay clicks The engine does not crank and the relay does not click The engine cranks slowly Unusual starter noise The starter spins but the engine does not crank Battery. Fuse. Starter motor/solenoid. Ignition switch. Circuit. Fuse. RAP module. Ignition switch. Digital transmission range (TR) sensor. Starter relay. Clutch pedal position (CPP) switch. Circuit. Battery. Fuse. Starter motor/solenoid. Ignition switch. Circuit. Starter mounting. Starter motor. Incorrect starter drive engagement. Starter motor. Damaged flywheel/ring gear teeth. GO to Pinpoint Test A. GO to Pinpoint Test B. GO to Pinpoint Test C. GO to Pinpoint Test D. INSPECT the starter motor mounting and engagement. REPAIR as necessary. INSPECT the flywheel/ring gear for damaged, missing or worn teeth. REPAIR as necessary. Pinpoint Tests PINPOINT TEST A: THE ENGINE DOES NOT CRANK OR THE RELAY CLICKS CONDITIONS A1 CHECK THE VOLTAGE TO THE STARTER RELAY DETAILS/RESULTS/ACTIONS

2 Page 2 of 14 Measure the voltage between the starter relay terminal 30 and ground. Is the voltage greater than 12.5 volts? GO to A2. A2 CHECK THE VOLTAGE TO THE STARTER MOTOR SOLENOID REPAIR the battery to starter relay cable (14300). TEST the system for normal operation. Measure the voltage between the starter motor solenoid positive terminal and ground. Is the voltage 12.5 volts or greater? GO to A3. A3 MANUALLY JUMP THE STARTER MOTOR REPAIR the circuit between the battery and the starter solenoid. CLEAN and TIGHTEN the connections at the battery terminals. TEST the system for normal operation. Connect one end of a jumper wire to the positive terminal of the battery and touch the other end to the starter solenoid S- terminal. Does the starter solenoid engage? GO to A4. A4 CHECK THE STARTER MOTOR INSTALL a new starter motor. TEST the system for normal operation. Connect one end of a jumper wire to the positive terminal of the battery and touch the other end to the starter motor terminal. Does the starter motor spin? GO to A5. A5 CHECK THE CONTINUITY OF THE CIRCUIT REPLACE the starter motor (11002). TEST the system for normal operation.

3 Page 3 of 14 Starter Relay Starter Motor/Starter Motor Solenoid Relay Switch Measure the resistance between the starter relay to starter solenoid positive cable. REPLACE the starter relay. TEST the system for normal operation. REPAIR the circuit in question. TEST the system for normal operation. PINPOINT TEST B: THE ENGINE DOES NOT CRANK AND THE RELAY DOES NOT CLICK CONDITIONS B1 CHECK FUSE 20 (50A) DETAILS/RESULTS/ACTIONS Fuse 20 (50A) Is fuse 20 (50A) OK? REINSTALL Fuse 20 (50 A). GO to B2. B2 CHECK FUSE 21 (15A) REPLACE Fuse 20 (50A). GO to B20. Fuse 21(15A) Is fuse 21 (15A) OK? GO to B3. B3 CHECK CIRCUIT 32 (R/LB) FOR VOLTAGE REPLACE Fuse 21 (15A). GO to B23. Measure the voltage between fuse junction panel Fuse 21 (15A) pin 2, circuit 32 (R/LB) and ground while holding the key in the START position. Is the voltage greater than 10 volts? GO to B6. B4 CHECK CIRCUIT 32 (R/LB) FOR OPEN GO to B4.

4 Page 4 of 14 Ignition Switch C250 Measure the resistance between fuse junction panel Fuse 21 (15A) pin 2, circuit 32 (R/LB), and ignition switch connector pin C250-STA, circuit 32 (R/LB). GO to B5. B5 CHECK CIRCUIT 1050 (LG/P) FOR OPEN REPAIR circuit 32 (R/LB). TEST the system for normal operation. Fuse 20 (50A) Measure the resistance between ignition switch connector Pin C250-B5, Circuit 1050 (LG/P), and power distribution box Fuse 20 (50A), Circuit 1050 (LG/P). B6 CHECK THE VOLTAGE TO THE STARTER RELAY COIL REPLACE the ignition switch. TEST the system for normal operation. REPAIR Circuit 1050 (LG/P). TEST the system for normal operation. Measure the voltage between the starter relay terminal 86, Circuit 1093 (T/R), and ground while momentarily turning the ignition switch to START. Is the voltage greater than 10 volts? REPLACE the starter relay. TEST the system for normal operation. If the vehicle is equipped with automatic transmission, GO to B7. B7 CHECK CIRCUIT 1093 (T/R) FOR OPEN If the vehicle is equipped with manual transmission, GO to B12. Digital TR Sensor C182 or TR Sensor C182 Measure the resistance between digital TR sensor connector Pin C182-12, Circuit 1093 (T/R) or TR sensor connector Pin C182-1, Circuit 1093 (T/R), and starter relay connector Pin 86, Circuit 1093 (T/R).

5 Page 5 of 14 GO to B8. B8 CHECK DIGITAL TRANSMISSION RANGE (DTR) SENSOR ADJUSTMENT REPAIR Circuit 1093 (T/R). TEST the system for normal operation. Carry out the digital transmission range (TR) sensor adjustment or transmission range (T/R) sensor adjustment; REFER to Section A. Is the digital TR or TR sensor adjusted correctly? GO to B9. ADJUST the digital TR or TR sensor as necessary. TEST the system for normal operation. B9 CHECK DIGITAL TRANSMISSION RANGE (DTR) SENSOR OR TRANSMISSION RANGE (TR) SENSOR OPERATION Connect a jumper wire between DTR sensor connector Pin C182-12, Circuit 1093 (T/R) or TR sensor connector Pin C182-1, Circuit 1093 (T/R) and DTR sensor connector Pin C182-10, Circuit 325 (DB/O) or TR sensor connector Pin C182-4, Circuit 325 (DB/O). Does the vehicle start? REPLACE the DTR sensor or TR sensor. TEST the system for normal operation. B10 CHECK CIRCUIT 325 (DB/O) FOR OPEN GO to B10. CPP Switch C231 Measure the resistance between digital TR sensor connector Pin C182-10, Circuit 325 (DB/O) or TR sensor connector Pin C182-4, Circuit 325 (DB/O) and clutch pedal position (CPP) switch connector Pin C231-2, Circuit 325 (DB/O). B11 CHECK CLUTCH PEDAL POSITION (CPP) SWITCH GO to B11. REPAIR Circuit 325 (DB/O). TEST the system for normal operation. Measure the resistance between clutch pedal position (CPP) switch terminals 1 and 2.

6 Page 6 of 14 B12 CHECK CIRCUITS 325 (DB/O) AND 1093 (T/R) If the vehicle is equipped with remote anti-theft personality (RAP), GO to B15. If the vehicle is not equipped with RAP, GO to B14. REPLACE the CPP switch. TEST the system for normal operation. Starter Relay CPP Switch C231 Measure the resistance between starter relay connector Pin 86, Circuit 1093 (T/R) and clutch pedal position (CPP) switch connector Pin C231-2, Circuit 325 (DB/O). B13 CHECK CLUTCH PEDAL POSITION (CPP) SWITCH OPERATION RECONNECT the starter relay. GO to B13. REPAIR Circuit 1093 (T/R) or Circuit 325 (DB/O). TEST the system for normal operation. Connect a jumper wire between CPP switch connector Pin C231-5, Circuit 33 (W/PK) and CPP switch connector Pin C231-6, Circuit 481 (W/PK) and between CPP switch connector Pin C231-1, Circuit 33 (W/PK) and CPP switch connector Pin C231-2, Circuit 325 (DB/O). Does the vehicle start? REPLACE the CPP switch; REFER to Section TEST the system for normal operation. B14 CHECK CIRCUIT 33 (W/PK) FOR OPEN If the vehicle is equipped with remote anti-theft personality (RAP), GO to B15. If the vehicle is not equipped with RAP, GO to B14. Fuse Junction Panel C243 Measure the resistance between fuse junction panel connector Pin C243-29, Circuit 33 (W/PK) and clutch pedal position (CPP) switch connector Pin C231-1, Circuit 33 (W/PK).

7 Page 7 of 14 Is the resistance less than 5 ohms? REPLACE the fuse junction panel. TEST the system for normal operation. B15 CHECK CIRCUIT 326 (W/P) FOR POWER REPAIR Circuit 33 (W/PK). TEST the system for normal operation. Starter Interrupt Relay While holding the key in the START position, measure the voltage between starter interrupt relay connector Pin 86, Circuit 326 (W/P) and ground and between starter interrupt relay connector Pin 30, Circuit 326 (W/P) and ground. Is the voltage greater than 10 volts? GO to B17. B16 CHECK CIRCUIT 326 (W/P) GO to B16. Fuse Junction Panel C243 Measure the resistance between starter interrupt relay connector Pin 86, Circuit 326 (W/P) and fuse junction panel connector Pin C243-29, Circuit 326 (W/P) and between starter interrupt relay connector Pin 30, Circuit 326 (W/P) and fuse junction panel connector Pin C243-29, Circuit 326 (W/P). REPLACE the fuse junction panel. TEST the system for normal operation. B17 CHECK STARTER INTERRUPT RELAY REPAIR Circuit 326 (W/P). TEST the system for normal operation. Carry out the Relay Component Test; refer to Component Tests in this section. Is the starter interrupt relay OK? GO to B18. B18 CHECK CIRCUIT 33 (W/PK) FOR OPEN REPLACE the starter interrupt relay. TEST the system for normal operation. Measure the resistance between starter interrupt relay Pin 87A, Circuit 33 (W/PK) and clutch pedal position (CPP) switch connector Pin C231-1, Circuit 33 (W/PK).

8 Page 8 of 14 Is the resistance less than 5 ohms? GO to B19. B19 CHECK CIRCUIT 342 (LG/P) FOR OPEN REPAIR Circuit 33 (W/PK). TEST the system for normal operation. RAP C257 Measure the resistance between remote anti-theft personality (RAP) module connector Pin C257-9, Circuit 342 (LG/P) and starter interrupt relay connector Pin 85, Circuit 342 (LG/P). REPLACE the RAP module. TEST the system for normal operation. B20 RECHECK FUSE 20 (50A) REPAIR Circuit 342 (LG/P). TEST the system for normal operation. Fuse 20 (50A) Is Fuse 20 (50A) OK? System is OK. B21 CHECK CIRCUIT 1050 (LG/P) FOR SHORT GO to B21. Ignition Switch C250 Measure the resistance between the ignition switch connector Pin C250-B5, Circuit 1050 (LG/P) and ground. GO to B22. B22 CHECK CIRCUIT 32 (R/LB) FOR SHORT REPAIR Circuit 1050 (LG/P). TEST the system for normal operation.

9 Page 9 of 14 Fuse 21 (15A) Measure the resistance between ignition switch C250-STA and ground. REPLACE the ignition switch. TEST the system for normal operation. B23 RECHECK FUSE 21(15A) REPAIR Circuit 32 (R/LB). TEST the system for normal operation. Momentarily place the ignition switch to the START position. Fuse 21(15A) Is Fuse 21 (15A) OK? System is OK. B24 CHECK STARTER RELAY FOR SHORT REPLACE Fuse 21 (15A). GO to B24. Starter Relay Momentarily place the ignition switch to the START position. Fuse 21 (15A) Is Fuse 21 (15A) OK? REPLACE the starter relay. TEST the system for normal operation. B25 CHECK STARTER INTERRUPT RELAY If the vehicle is equipped with RAP, REPLACE Fuse 21 (15A) and GO to B25. If the vehicle is not equipped with RAP, GO to B28. Starter Interrupt Relay Momentarily place the ignition switch to the START position.

10 Page 10 of 14 Fuse 21 (15A) Is Fuse 21 (15A) OK? REPLACE the starter interrupt relay. TEST the system for normal operation. B26 CHECK CIRCUIT 326 (W/P) FOR SHORT GO to B26. Measure the resistance between starter interrupt relay connector Pin 86, Circuit 326 (W/P) and ground and between starter interrupt relay connector Pin 30, Circuit 326 (W/P) and ground. GO to B27. B27 CHECK CIRCUIT 342 (LG/P) FOR SHORT REPAIR Circuit 326 (W/P). TEST the system for normal operation. RAP C231 Measure the resistance between starter interrupt relay connector Pin 85, Circuit 342 (LG/P), and ground. GO to B28. B28 CHECK CIRCUIT 33 (W/PK) FOR SHORT REPAIR Circuit 342 (LG/P). TEST the system for normal operation. CPP Switch C231 Measure the resistance between clutch pedal position (CPP) switch connector Pin C231-1, Circuit 33 (W/PK), and ground. If the vehicle is equipped with automatic transmission, GO to B29. If the vehicle is equipped with manual transmission, GO to B32. REPAIR Circuit 33 (W/PK). TEST the system for normal operation.

11 Page 11 of 14 B29 CHECK CLUTCH PEDAL POSITION (CPP) SWITCH FOR SHORT Measure the resistance between starter relay connector Pin 86, Circuit 1093 (T/R), and ground. REPLACE the clutch pedal position (CPP) switch. TEST the system for normal operation. B30 CHECK CIRCUIT 325 (DB/O) FOR SHORT GO to B30. Digital TR Sensor C182 or TR Sensor C182 Measure the resistance between the digital TR sensor connector Pin C182-10, Circuit 325 (DB/O), or TR sensor connector Pin C182-4, Circuit 325 (DB10), and ground. GO to B31. B31 CHECK CIRCUIT 1093 (T/R) FOR SHORT REPAIR Circuit 325 (DB/O). TEST the system for normal operation. Measure the resistance between digital TR sensor connector Pin C182-12, Circuit 1093 (T/R) or TR sensor connector Pin C182-1, Circuit 1093 (T/R), and ground. B32 CHECK CIRCUITS 1093 (T/R) AND 325 (DB/O) FOR SHORT REPLACE the digital TR sensor or TR sensor. TEST the system for normal operation. REPAIR Circuit 1093 (T/R). TEST the system for normal operation. Starter Relay Measure the resistance between clutch pedal position (CPP) switch C231-2 and ground.

12 Page 12 of 14 REPLACE the CPP switch. TEST the system for normal operation. REPAIR Circuit 1093 (T/R) and/or Circuit 325 (DB/O). TEST the system for normal operation. PINPOINT TEST C: THE ENGINE CRANKS SLOWLY CONDITIONS C1 CHECK THE VOLTAGE TO THE STARTER DETAILS/RESULTS/ACTIONS Measure the voltage between the starter motor solenoid positive terminal and ground. Is the voltage 12.5 volts or greater? GO to C2. C2 CHECK MOTOR GROUND CIRCUIT REPAIR the circuit between the battery and the starter solenoid. CLEAN and TIGHTEN the connections at the battery terminals. TEST the system for normal operation. Carry out the Motor Ground Circuit test; refer to Component Tests in this section. Is the ground OK? REPLACE the starter motor. TEST the system for normal operation. REPAIR the ground circuit as necessary. TEST the system for normal operation. PINPOINT TEST D: UNUSUAL STARTER NOISE CONDITIONS D1 CHECK THE STARTER MOTOR MOUNTING DETAILS/RESULTS/ACTIONS Inspect the starter motor mounting brackets for cracks. Check the starter motor mounting bolts for looseness. Is the starter motor mounted correctly? GO to D2. REINSTALL the starter motor correctly. REFER to Starter Motor in this section. D2 INSPECT THE STARTER MOTOR Remove the starter motor; refer to Starter Motor in this section. Inspect the starter motor for damage. Is the starter motor damaged?

13 Page 13 of 14 REPLACE the starter motor. TEST the system for normal operation. CHECK the starter drive. REFER to Component Tests, Starter Drive Test in this section. REPLACE the starter motor. TEST the system for normal operation. Component Tests Starter Motor Load Test WARNING: When servicing the starter motor or carrying out other underhood work in the vicinity of the starter motor, be aware that the heavy gauge battery input lead at the starter solenoid is "electrically hot" at all times. CAUTION: A protective cap or boot is provided over the battery input terminal on all car lines and must be replaced after repair. Be sure to disconnect the battery ground cable before repair the starter motor. 1. Before carrying out this test inspection, check the battery to determine its state of charge. Carry out a load test of the battery (10653) using the Starter,Alternator, Battery, Regulator and Electrical Tester (SABRE). Refer to Section for the test procedure. 2. Disconnect the ignition coil connector from the ignition coil (12029). 3. Connect the ARBST tester to the vehicle using the amperage lead clipped around the positive battery cable. 4. Measure the amperage of the starter motor while activating the starting system. 5. A correctly operating starter motor will draw from 130 to 190 amps of current. Voltage Drop Tests The following test procedures will be carried out with the starter motor on the vehicle. Motor Feed Circuit NOTE: Make all multimeter connections at the component terminal rather than the cable or wiring terminal. 1. Disconnect the ignition coil connector from the ignition coil. 2. Connect a remote starter switch between the starter solenoid S-terminal and the battery positive (+) post. 3. Connect the positive (+) lead of the 73 Digital Multimeter to the battery positive (+) post. Connect the negative (-) lead of the multimeter to the starter solenoid M-terminal. 4. Engage the remote starter switch. The multimeter reading should be 0.5 volt or less. 5. If the voltage at the M-terminal is greater than 0.5 volt, move the multimeter negative (-) lead to the starter solenoid B-terminal and repeat the test. 6. If the voltage reading at the B-terminal is less than 0.5 volt, the problem is either in the connections at the starter solenoid (11390) or the starter solenoid. 7. NOTE: When disconnecting the plastic hard shell connector at the starter solenoid S-terminal, grasp the plastic connector, depress the plastic tab, and pull off the lead assembly. Do not pull on the lead wire or damage may result. Remove the wires at the starter solenoid B-, S-, and M-terminals. Clean the connections and install the cables. Apply dielectric grease to inhibit corrosion to the S-terminal. Repeat Steps 1 through 5 above. If the reading is still higher than 0.5 volt at the M-terminal and 0.5 volt or lower at the B-terminal, the problem is in the starter solenoid. Replace the starter motor. Refer to Starter Motor in this section. 8. If the voltage taken at the starter solenoid B-terminal is greater than 0.5 volt, the problem is either the positive (+) battery cable connection or the positive (+) battery cable. Motor Ground Circuit NOTE: Make all multimeter connections at the component terminal rather than the cable or wiring terminal. 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: 1. Disconnect the ignition coil connector from the ignition coil. 2. Connect a remote starter switch between the starter solenoid S-terminal and the battery positive (+) terminal. 3. Connect the positive (+) lead of a 73 Digital Multimeter 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. 4. Engage the remote starter switch and read the voltage. The reading should be 0.2 volt or less. 5. If the voltage drop is greater than 0.2 volt, clean the negative (-) battery cable connections at the battery and chassis. Also, clean the engine ground cable connection at the cable mounting bracket. If the voltage drop is still excessive, repair or replace the battery ground cable. Starter Drive Test 1. Remove the starter motor. Refer to Starter Motor in this section. 2. Secure the starter motor in a vise. 3. Connect the battery ground cable of a fully charged battery to the case of the starter motor. 4. CAUTION: Do not leave the positive lead of the battery connected to the starter motor S-terminal for more than 10 seconds. Touch the positive lead from the battery to the S-terminal and verify that the starter drive (11350) ejects. 5. Remove the positive lead from the starter motor. The ejected starter drive should return to its original position. 6. If the starter drive does not eject and return to position, replace the starter motor.

14 Page 14 of Check the starter drive. It should turn freely in one direction, and positively engage to the armature when turned in the opposite direction. If not as specified, replace the starter motor. Load Test The starter Load Test will identify open or shorted windings and a possible rubbing starter motor armature (11005) or bent starter motor armature shaft. 1. WARNING: Make sure that the starter motor is securely mounted on a bench because the starter motor may move or jump when it is energized. Connect a fully charged battery, a Starter, Alternator, Battery, Regulator and Electrical Tester (SABRE) and a remote starter switch to the starter motor. Connect the remote starter switch between the battery positive (+) post and the starter motor S-terminal. Connect the starter motor B-terminal to the battery positive (+) post. Connect the SABRE positive (+) terminal and negative (-) terminal to the corresponding battery post. Make sure that the battery and starter motor are grounded. 2. Engage the remote starter switch. 3. The starter motor should eject the starter drive and run smoothly. If the starter motor does not run smoothly, replace it. 4. While the starter motor is running, check the voltmeter and ammeter. 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 the 11.0 volts, or the amperage is higher than 70 amps, replace the starter motor. Relay Component Test Mini ISO Relay Use the 73 Digital Multimeter to check for continuity between terminal 85 and all other terminals. If resistance is 5 ohms or less between terminal 85 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 86 and 30 directly to the positive battery terminal. Use the 73 Digital Multimeter set in the volts position to check for voltage at terminal 87A. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 85 and ground the jumper wire to a know good ground. Check for voltage at terminal 87. If battery voltage is not indicated, replace the relay.

DIAGNOSIS AND TESTING Procedure revision date: 06/21/2000

DIAGNOSIS AND TESTING Procedure revision date: 06/21/2000 2001 F-350 Applies to: Gasoline Report a problem with this article Subarticles Inspection and Verification Symptom Chart Pinpoint Tests Component Tests SECTION 303-06A: Starting System Gasoline Engines