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

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1 2001 F-350 Applies to: Gasoline Report a problem with this article Subarticles Inspection and Verification Symptom Chart Pinpoint Tests Component Tests SECTION A: Starting System Gasoline Engines 2001 F-Super Duty /Excursion/F-53 Motorhome Chassis Workshop Manual DIAGNOSIS AND TESTING Procedure revision date: 06/21/2000 Starting System Refer to Wiring Diagrams Cell 20 (F-Super Duty /Excursion, F-53 Motorhome Chassis), Starting System for schematic and connector information. Special Tool(s) 73III Automotive Meter 105-R0057 or equivalent ARBST Battery and Electrical System Tester 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 Electrical 1/25

2 Starter motor Starter motor solenoid Brackets 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 and the relay does click Battery. Fuse. Starter motor/solenoid. Ignition switch. Circuit. GO to Pinpoint Test A. The engine does not crank and the relay does not click Fuse. Battery. Starter relay. Ignition switch. Digital transmission range (TR) sensor. Starter solenoid. Clutch pedal position (CPP) switch. Circuit. GO to Pinpoint Test B. The engine cranks slowly Battery. Starter motor/solenoid. Circuit. GO to Pinpoint Test C. Unusual starter noise Starter mounting. Starter motor. Incorrect starter drive engagement. GO to Pinpoint Test D. 2/25

3 Pinpoint Tests PINPOINT TEST A: THE ENGINE DOES NOT CRANK AND THE RELAY DOES CLICK CONDITIONS DETAILS/RESULTS/ACTIONS A1 CHECK THE VOLTAGE TO THE STARTER RELAY Measure the voltage between the starter relay terminal and ground. Is the voltage greater than 12.5 volts? GO to A2. REPAIR the battery to starter relay cable. TEST the system for normal operation. A2 CHECK THE VOLTAGE TO THE STARTER MOTOR SOLENOID Measure the voltage between the starter motor solenoid positive terminal and ground. Is the voltage 12.5 volts or greater? 3/25

4 GO to A3. 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. A3 MANUALLY JUMP THE STARTER MOTOR Connect one end of a fused (15A) 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. TEST the system for normal operation. NOTE: Starter will not engage ring gear unless S-terminal is powered. Connect one end of a fused (15A) 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. 4/25

5 A5 CHECK THE CONTINUITY OF THE CIRCUIT INSTALL a new starter motor. TEST the system for normal operation. Starter Motor/Starter Motor Solenoid Relay Switch Measure the resistance between the starter relay to starter solenoid and the S-terminal. Is the resistance less than 5 ohms? INSPECT for poor connections, if OK INSTALL a new starter relay. TEST the system for normal operation. INSTALL a new starter motor/starter relay harness. TEST the system for normal operation. PINPOINT TEST B: THE ENGINE DOES NOT CRANK AND THE RELAY DOES NOT CLICK CONDITIONS DETAILS/RESULTS/ACTIONS B1 CHECK BATTERY JUNCTION BOX FUSE 20 (SUPER DUTY) OR FUSE 116 (EXCURSION) 5/25

6 Is the fuse OK? REINSTALL fuse. GO to B2. INSTALL a new fuse. GO to B15. B2 CHECK CENTRAL JUNCTION BOX FUSE 20 (15A) Fuse 20 (15A) Is Fuse 20 (15A) OK? GO to B3. B3 CHECK CIRCUIT 32 (RD/LB) FOR VOLTAGE INSTALL a new Fuse 20 (15A). GO to B18. Measure the voltage between central junction box pin 19, circuit 32 (RD/LB) and ground while holding the key in the START position. 6/25

7 Is the voltage greater than 10 volts? GO to B6. GO to B4. B4 CHECK CIRCUIT 32 (RD/LB) FOR OPEN Ignition Switch C269 Measure the resistance between central junction box pin 19, circuit 32 (RD/LB) and ignition switch connector C269 pin STA, circuit 32 (RD/LB) harness side. 7/25

8 Is the resistance less than 5 ohms? GO to B5. B5 CHECK CIRCUIT 1050 (LG/VT) FOR OPEN REPAIR circuit 32 (RD/LB). TEST the system for normal operation. Power Distribution Box Fuse 20 (50A) On Super Duty vehicles, measure the resistance between ignition switch connector pin C269 pin B4, circuit 1050 (LG/VT), and power distribution box Fuse 20 (50A), circuit 1050 (LG/VT). 8/25

9 On Excursion, measure the resistance between ignition switch connector pin C269 pin B4, circuit 1050 (LG/VT) and power distribution box Fuse 116 (50A) circuit 1050 (LG/VT). Is the resistance less than 5 ohms? INSTALL a new ignition switch. TEST the system for normal operation. B6 CHECK THE VOLTAGE TO THE STARTER RELAY COIL REPAIR circuit 1050 (LG/PK). TEST the system for normal operation. Verify that the vehicle is in PARK. Measure the voltage between the starter solenoid, circuit 1093 (TN/RD) harness side, and ground while momentarily turning the ignition switch to START. Is the voltage greater than 10 volts? INSTALL a new starter solenoid. TEST the system for normal operation. If the vehicle is equipped with automatic transmission, GO to B7. B7 CHECK CIRCUIT 1093 (TN/RD) FOR OPEN If the vehicle is equipped with manual transmission, GO to B /25

10 Digital TR Sensor C1012 Measure the resistance between digital TR sensor connector C1012 pin 12, circuit 1093 (TN/RD) harness side, and starter relay connector circuit 1093 (TN/RD) harness side. Is the resistance less than 5 ohms? GO to B8. REPAIR circuit 1093 (TN/RD). TEST the system for normal operation. B8 CHECK DIGITAL TRANSMISSION RANGE (TR) SENSOR ADJUSTMENT Carry out the digital TR sensor adjustment. Refer to Section Is the digital TR sensor adjusted correctly? GO to B9. ADJUST the digital TR as necessary. TEST the system for normal operation. B9 CHECK DIGITAL TRANSMISSION RANGE (TR) SENSOR OPERATION Connect a fused (10A) jumper wire between the digital TR sensor connector C1012 pin 12 harness side, circuit 1093 (TN/RD) and the digital TR sensor connector C1012 pin 10, circuit 325 (DB/OG) harness side. 10/25

11 Does the vehicle start? INSTALL a new digital TR sensor. TEST the system for normal operation. For Super Duty, GO to B10. For Excursion, REPAIR circuit 33 (WH/PK). B10 CHECK CIRCUIT 325 (DB/OG) FOR OPEN CPP Switch C261 Measure the resistance between digital TR sensor connector C1012 pin 10, circuit 325 (DB/OG) harness side and clutch pedal position (CPP) switch connector C261 pin 2, circuit 325 (DB/OG) harness side. Is the resistance less than 5 ohms? 11/25

12 GO to B11. B11 CHECK CLUTCH PEDAL POSITION (CPP) SWITCH REPAIR circuit 325 (DB/OG). TEST the system for normal operation. Measure the resistance between clutch pedal position (CPP) switch jumper terminals 1 and 2. Is the resistance less than 5 ohms? GO to B14. B12 CHECK CIRCUIT 325 (DB/OG) INSTALL a new CPP switch. TEST the system for normal operation. Starter Relay CPP Switch C261 Measure the resistance between starter relay connector circuit 325 (DB/OG) harness side and clutch pedal position (CPP) switch 12/25

13 connector C261 pin 2, circuit 325 (DB/OG) harness side. Is the resistance less than 5 ohms? RECONNECT the starter solenoid. GO to B13. B13 CHECK CLUTCH PEDAL POSITION (CPP) SWITCH OPERATION REPAIR circuit 325 (DB/OG). TEST the system for normal operation. Connect a fused (10A) jumper wire between CPP switch connector C261 pin 5, circuit 33 (WH/PK) harness side and CPP switch connector C261 pin 6, circuit 481 (WH/PK) harness side and between CPP switch connector C261 pin 1, circuit 33 (WH/PK) harness side and CPP switch connector C261 pin 2, circuit 325 (DB/OG) harness side. Does the vehicle start? INSTALL a new CPP switch. REFER to Section A. TEST the system for normal operation. GO to B /25

14 B14 CHECK CIRCUIT 33 (WH/PK) FOR OPEN Fuse Junction Panel C243 Measure the resistance between fuse power distrubition panel connector C243 pin 4, circuit 33 (WH/PK) harness side and clutch pedal position (CPP) switch connector C261 pin 1, circuit 33 (WH/PK) harness side. Is the resistance less than 5 ohms? INSTALL a new power distrubition panel. TEST the system for normal operation. B15 RECHECK FUSE 20 (50A) REPAIR circuit 33 (WH/PK). TEST the system for normal operation. Fuse 20 (50A) Is Fuse 20 (Super Duty) or Fuse 116 (Excursion) OK? System is OK. 14/25

15 GO to B16. B16 CHECK CIRCUIT 1050 (LG/PK) FOR SHORT Ignition Switch C269 Measure the resistance between the ignition switch connector C269 pin B4, circuit 1050 (LG/PK) harness side and ground. Is the resistance greater than 10,000 ohms? GO to B17. B17 CHECK CIRCUIT 32 (RD/LB) FOR SHORT REPAIR circuit 1050 (LG/PK). TEST the system for normal operation. Fuse 20 (15A) Measure the resistance between ignition switch C269 pin STA, circuit 32 (RD/LB) harness side and ground. 15/25

16 Is the resistance greater than 10,000 ohms? INSTALL a new ignition switch. TEST the system for normal operation. B18 RECHECK FUSE 20 (15A) REPAIR circuit 32 (RD/LB). TEST the system for normal operation. Fuse 20 (15A) Is Fuse 20 (15A) OK? System is OK. B19 CHECK STARTER SOLENOID FOR SHORT INSTALL a new Fuse 20 (15A). GO to B /25

17 Starter Relay Momentarily place the ignition switch in the START position. Fuse 20 (15A) Is Fuse 20 (15A) OK? INSTALL a new starter relay. TEST the system for normal operation. B20 CHECK CIRCUIT 33 (WH/PK) FOR SHORT INSTALL a new Fuse 20 (15A). GO to B20. CPP Switch C261 Measure the resistance between clutch pedal position (CPP) switch connector C261 pin 1, circuit 33 (WH/PK) harness side, and ground. 17/25

18 Is the resistance greater than 10,000 ohms? If the vehicle is equipped with automatic transmission, GO to B21. If the vehicle is equipped with manual transmission, GO to B23. B21 CHECK CIRCUIT 325 (DB/OG) FOR SHORT REPAIR circuit 33 (WH/PK). TEST the system for normal operation. Digital TR Sensor C1012 Measure the resistance between the digital TR sensor connector C1012 pin 10, circuit 325 (DB/OG) harness side and ground. Is the resistance greater than 10,000 ohms? GO to B22. B22 CHECK CIRCUIT 1093 (TN/RD) FOR SHORT REPAIR circuit 325 (DB/OG). TEST the system for normal operation. Measure the resistance between digital TR sensor connector C1012 pin 12, circuit 1093 (TN/RD) harness side and ground. 18/25

19 Is the resistance greater than 10,000 ohms? INSTALL a new digital TR sensor. TEST the system for normal operation. B23 CHECK CIRCUIT 325 (DB/OG) FOR SHORT REPAIR circuit 1093 (TN/RD). TEST the system for normal operation. Starter Relay Measure the resistance between clutch pedal position (CPP) switch C261 pin 2 and ground. Is the resistance greater than 10,000 ohms? INSTALL a new CPP switch. TEST the system for normal operation. 19/25

20 REPAIR circuit 325 (DB/OG). TEST the system for normal operation. PINPOINT TEST C: THE ENGINE CRANKS SLOWLY CONDITIONS DETAILS/RESULTS/ACTIONS C1 CHECK THE VOLTAGE TO THE STARTER Measure the voltage between the starter motor solenoid positive terminal and ground. Is the voltage 12.5 volts or greater? GO to C2. 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. C2 CHECK MOTOR GROUND CIRCUIT Carry out the Motor Ground Circuit test; refer to Component Tests in this section. Is the ground OK? INSTALL a new starter motor. TEST the system for normal operation. 20/25

21 REPAIR the ground circuit as necessary. TEST the system for normal operation. PINPOINT TEST D: UNUSUAL STARTER NOISE CONDITIONS DETAILS/RESULTS/ACTIONS D1 CHECK THE STARTER MOTOR MOUNTING Inspect the starter motor mounting brackets for cracks. Check the starter motor mounting bolts for loosness. 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 tostarter Motor in this section. Inspect the starter motor for damage. Is the starter motor damaged? INSTALL a new starter motor. REFER to Starter Motor in this section. TEST the system for normal operation. CHECK the starter drive. REFER to Component Tests, Starter Drive Test in this section. INSTALL a new starter motor. TEST the system for normal operation. 21/25

22 Component Tests Starter Motor Load Test WARNING: When repairing the starter motor or carrying out other under-hood 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 vehicle lines and a new protective cap must be installed after repairing. Be sure to disconnect the battery ground cable before repairing 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 using Alternator, Regulator, Battery and Starter Tester (ARBST). Refer to Section for the test procedure. 2. Disconnect the ignition coil connector from the ignition coil. 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 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 73III Automotive Meter 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. 22/25

23 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 or the starter solenoid. 7. CAUTION: 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. Install a new 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 the 73III Automotive Meter 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 install a new 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. 23/25

24 Touch the positive lead from the battery to the S-terminal and verify that the starter drive 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, install a new starter motor. 7. 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, install a new starter motor. Load Test The starter Load Test will identify open or shorted windings and a possible rubbing starter motor armature 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, an Alternator, Regulator, Battery and Starter Tester (ARBST), 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 ARBST 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, install a new starter motor. 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, install a new starter motor. Relay Component Test Mini ISO Relay 24/25

25 Use the 73III Automotive Meter 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, install a new 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, install a new 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, install a new relay. 25/25

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