Ford Galaxy / Ford S-MAX. Manual — part 429

Starting System - 1.8L Duratorq-TDCi
(74kW/100PS) - Lynx/1.8L Duratorq-
TDCi (92kW/125PS) - Lynx - Start Inhibit
Switch

S-MAX/Galaxy 2006.5 (02/2006-)

Print

Removal and Installation

Removal

CAUTION: Make sure that the clutch pedal remains in the rest position.

Installation

CAUTION: Make sure that the clutch pedal remains in the rest position.

1.

1. To install, reverse the removal procedure.

Starting System - 2.0L Duratorq-TDCi
(85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-
TDCi (103kW/140PS) - DW, Emission
Requirements: Stage IV - Starting System

S-MAX/Galaxy 2006.5 (02/2006-)

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Diagnosis and Testing

General Equipment

Principles of Operation

The starter motor function is controlled by a starter relay. The starter relay is operated by
the ignition switch.

Battery voltage is supplied to the ignition switch from battery junction box (BJB) fuse F17.
When the ignition switch is turned to position III, battery voltage is supplied to the starter
relay coil. The starter relay coil circuit is completed by a ground circuit through the
powertrain control module (PCM). The ground circuit will only be available when the PCM
receives the correct signal from the passive anti-theft system (PATS).

When the starter relay coil is energized, the starter relay contacts close and battery voltage
is supplied to the starter motor solenoid circuit from BJB fuse F15. The starter motor
solenoid circuit is completed by a ground circuit through the starter motor casing.

The starter motor solenoid has two functions. The first is to supply the starter motor with a
high energy switch between the battery positive terminal and the starter motor windings.
The second is to act as a mechanical clutch between the starter motor drive gear and the
flywheel ring gear.

Battery voltage is supplied to the starter motor solenoid contact through a fused wire. The
ground circuit is completed using the starter motor casing and the engine/transmission
ground wire.

Inspection and Verification

1. 1. Verify the customer concern.

2. 2. Visually inspect for obvious signs of mechanical or electrical damage.

3. 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. 4. If the cause is not visually evident, verify the symptom and refer to the Symptom

Chart.

Visual Inspection Chart

Symptom Chart

Worldwide Diagnostic System (WDS)

Mechanical

Electrical

Starter motor

Fuse(s)

Wiring harness(es)

Electrical connector(s)

Relay(s)

Switch(es)

Battery

Symptom

Possible

Sources

Action

The engine does

Battery

*

REFER to: Charging System (414-00, Diagnosis and

*

not crank and the
relay does not click

Testing).

Circuit(s)
Starter

relay

Ignition

switch

PCM
BJB

*
*

*

*
*

GO to Pinpoint Test

A.

*

PATS

*

REFER to: Anti-Theft - Passive (419-01B, Diagnosis and

Testing).

*

The engine does
not crank but the
relay clicks

Battery

*

REFER to: Charging System (414-00, Diagnosis and

Testing).

*

Circuit(s)
Starter

relay

Starter

motor

*
*

*

GO to Pinpoint Test

B.

*

The engine cranks
slowly

Battery

*

REFER to: Charging System (414-00, Diagnosis and

Testing).

*

Battery

cable

Starter

motor

*

*

GO to Pinpoint Test

C.

*

Unusual starter
motor noise

Starter

motor

*

INSPECT the starter motor for alignment or cracked

casing. Make sure the mounting bolts are tightened. If
necessary, INSTALL a new starter motor.
REFER to:

Starter Motor

(303-06A Starting System - 2.0L

Duratec-HE (107kW/145PS) - MI4/2.0L Duratec-HE Flex
Fuel (107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4, Removal and Installation) /
Starter Motor (303-06B Starting System - 2.5L Duratec-ST
(VI5), Removal and Installation) /
Starter Motor (303-06C Starting System - 1.8L Duratorq-
TDCi (Kent) Diesel, Removal and Installation) /
Starter Motor (303-06D Starting System - 2.0L Duratorq-
TDCi (DW) Diesel, Removal and Installation).
TEST the system for normal operation.

*

Flywheel

ring gear

*

CHECK the flywheel ring gear. INSTALL a new flywheel

ring gear as necessary.

*

The starter motor
spins but the
engine does not
crank

Starter

motor

*

REMOVE the starter motor. INSPECT the starter motor

gear for damage. INSTALL a new starter motor as
necessary.
REFER to:

Starter Motor

(303-06A Starting System - 2.0L

Duratec-HE (107kW/145PS) - MI4/2.0L Duratec-HE Flex
Fuel (107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4, Removal and Installation) /
Starter Motor (303-06B Starting System - 2.5L Duratec-ST
(VI5), Removal and Installation) /
Starter Motor (303-06C Starting System - 1.8L Duratorq-
TDCi (Kent) Diesel, Removal and Installation) /
Starter Motor (303-06D Starting System - 2.0L Duratorq-
TDCi (DW) Diesel, Removal and Installation).
TEST the system for normal operation.

*

Flywheel

ring gear

*

INSPECT the flywheel ring gear for missing teeth. CHECK

the starter motor for correct mounting. If the concern
persists, INSTALL a new starter motor.
REFER to:

Starter Motor

(303-06A Starting System - 2.0L

Duratec-HE (107kW/145PS) - MI4/2.0L Duratec-HE Flex
Fuel (107kW/145PS) - MI4/2.3L Duratec-HE

*

Pinpoint Tests

NOTE: Use a digital multimeter for all electrical measurements.

(118kW/160PS) - MI4, Removal and Installation) /
Starter Motor (303-06B Starting System - 2.5L Duratec-ST
(VI5), Removal and Installation) /
Starter Motor (303-06C Starting System - 1.8L Duratorq-
TDCi (Kent) Diesel, Removal and Installation) /
Starter Motor (303-06D Starting System - 2.0L Duratorq-
TDCi (DW) Diesel, Removal and Installation).
TEST the system for normal operation.

PINPOINT TEST A : THE ENGINE DOES NOT CRANK AND THE RELAY DOES
NOT CLICK

TEST CONDITIONS

DETAILS/RESULTS/ACTIONS

A1: CHECK THE STARTER RELAY COIL FOR VOLTAGE

Disconnect Starter Relay R1.

1

Ignition switch in position III.

2

Measure the voltage between the BJB starter relay
R1 connector pin 1, circuit CDC35D (BU/WH),

harness side and ground.

3

Is the voltage greater than 10 volts?
Yes

GO to A3

.

No

GO to A2

.

A2: CHECK CIRCUIT CDC35D (BU/WH) AND CDC35F (BU/WH) FOR CONTINUITY

Ignition switch in position 0.

1

Disconnect Ignition Switch C2DC32.

2

Measure the resistance between the BJB starter relay
R1 connector pin 1, circuit CDC35D (BU/WH),

harness side and the ignition switch C2DC32 pin 7,
circuit CDC35F (BU/WH), harness side.

3

Is the resistance less than 1 ohm?
Yes

INSTALL a new ignition switch. TEST the system for
correct operation.

No

REPAIR circuit CDC35D (BU/WH) or circuit CDC35F
(BU/WH) as necessary. TEST the system for normal
operation.

A3: CHECK THE STARTER RELAY COIL FOR GROUND

Measure the resistance between the BJB starter relay
R1 connector pin 2, circuit CDC12A (YE), and

ground.

1