Ford Falcon. Manual — part 191

303-06-1 Starting

System 303-06-1

SECTION : 303-06 Starting System

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-06-2

DESCRIPTION AND OPERATION

Starting System — 6 Cylinder (Bosch) . . . . . . . . . . . . . . . . . . . . .303-06-3

General Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-06-3

Description

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-06-3

Operation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-06-3

Roadside Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-06-3

Jump

Starting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-06-3

Connecting and Starting Procedure . . . . . . . . . . . . . . . . . . . . . .303-06-4

Engine

Starting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-06-4

DIAGNOSIS AND TESTING

Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-06-5

Symptom Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-06-5

Pinpoint

Tests

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-06-5

Component

Tests

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-06-9

GENERAL PROCEDURES

Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-06-12

REMOVAL AND INSTALLATION

Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-06-14

DISASSEMBLY AND ASSEMBLY

Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-06-15

Starter Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . ...303-06-16

Solenoid Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-06-16

Drive End Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-06-16

Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-06-16

303-06-2 Starting

System 303-06-2

SPECIFICATIONS

General Specifications

Description

Specification

Solenoid Burn off reserve

0.8 - 1.4mm

Solenoid Pre-stressed tension of

12

± 3N

reset spring for moving contact
Solenoid Pre-stressed tension of

19N

contact pressure spring
Solenoid Pre-stressed tension of

45

± 7N

plunger spring with 9mm plunger

clearance
Solenoid Total spring force

113N

Commutator Runout

0.1mm

Commutator minimum size

31.2mm

Commutator laminations runout

0.5mm

Starter current draw

Load

=<300A

No Load

=<8-A

Torque Specifications

Description

Nm

Starter Retaining bolts

21 - 27

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303-06-3 Starting

System 303-06-3

DESCRIPTION AND OPERATION

battery

Starting System — 6 Cylinder (Bosch)

inhibitor switch (auto trans)

The starting system includes the permanent magnet

electrical circuitry incorporating the ignition switch,

gear-reduction starter with a solenoid-actuated drive,

BEM and EEC V (’smartshield’), starter diode and

the battery, a remote control starter switch (part of the

resistor. (Refer schematics section of this

ignition switch), the neutral start switch (automatic

manual).

transmission), the starter relay, the heavy circuit

wiring, the body electronics module (BEM) and the

Operation

power train control module (PCM).

Turning the ignition to the IGN or ACC position

Turning the ignition switch to the START position

activates the BEMs ’smartshield’ system (Refer to

actuates the starter relay, through the starter control

Section 419-10.) and disarms the engine

circuit. The starter relay then connects the battery to

immobilisation. If the inhibitor switch is closed, the

the starter solenoid, causing it to energize.

circuit is completed and current flows through the

When the starter solenoid is energized, a magnetic

starter relay. This, in turn, completes the circuit from

field is created in the solenoid windings. The iron

the battery to the starter solenoid. This connects the

plunger core is drawn into the solenoid coil and a

battery to the starter motor. The starter utilizes an

lever connected to the drive assembly engages the

integral positive engagement drive.

drive pinion gear into the flywheel ring gear. When the The electrical circuit also incorporates a starter diode

plunger is pulled all the way in, its contact disk closes and starter resistor connected to ground. This

the circuit between the battery and motor feed

completes the starter solenoid circuit through ground

terminals. This sends current to the motor and the

after the solenoid is switched off to prevent any

drive pinion gear cranks the flywheel to start the

voltage surges at the solenoid caused by back EMF.

engine. When current flows to the motor, the solenoid

pull-in coil is bypassed and the hold-in coil keeps the

Roadside Service

drive pinion gear engaged with the flywheel until the

ignition switch is released from the START position.

Jump Starting

An overrunning clutch in the drive assembly protects

To avoid damage to the vehicle and battery or the

the starter from excessive speeds during the brief

possibility of personal injury, follow these instructions

period before the driver releases the ignition switch

and precautions:

from the START position (as the engine starts).

CAUTION: Hydrogen and oxygen gases are

General Service

produced during normal battery operation. The

gas mixture can explode if flames, sparks, or

Description

cigarettes are brought near the battery in an

The function of the starting system is to crank the

enclosed space, always provide ventilation and

engine at a high enough speed to permit it to start.

shield your eyes.

The system contains the following components:

Keep out of reach of children. Batteries contain

sulphuric acid. Avoid contact with skin, eyes or

starter motor and solenoid

clothing. Also, shield your eyes when working

near the battery to protect against possible

splashing of the acid solution. In case of acid

contact with skin, eyes or clothing, flush

immediately with water for a minimum of fifteen

minutes. If acid is swallowed, drink large

quantities of milk or water, followed by milk of

magnesia, a beaten egg, or vegetable oil. Call a

physician immediately.
NOTE: If instructions are not observed, damage to

electronic components may result. Ensure the battery

to be used for boosting is 12-volt and that the

negative terminal is grounded.
Remove the filler vent caps from both batteries and

place damp cloth over batteries. If the booster battery

is installed in another vehicle, do not allow the two

Item

Description

vehicles to touch. Turn off all unnecessary electrical

1

Terminal 30

loads. Select neutral gear on manual transmission, or

2

Terminal 50

’P’ (Park) position in automatic transmission, and

3

Magnets

engage the parking brake on both vehicles.

starter relay

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303-06-4 Starting

System 303-06-4

DESCRIPTION AND OPERATION (Continued)

Connecting and Starting Procedure

Connect the jumper leads in the exact sequence as

illustrated.

Connect end of jumper lead to the positive (+)

terminal of the discharged battery. (Red lead if

coloured).
Connect the other end of the same jumper lead to

the positive (+) terminal of the booster battery.
Connect end of second jumper lead (Black if

coloured) to the negative (-) terminal of the

booster battery.
Connect the other end of the second jumper lead

to the engine of the vehicle with the discharged

battery - NOT TO THE NEGATIVE TERMINAL

OF THE DISCHARGED BATTERY.

Take care that the jumper clamps do not touch each

other or any metal on either vehicle, and are clear of

cooling fans and drive belt.
Do not lean over the battery when making

connections.

Engine Starting

First start the engine in the vehicle with the booster

battery and let it run for a few minutes. Then start the

engine in the vehicle with the discharged battery.
Leave the jumper leads connected until the engine

reaches idle speed (at least 1 minute) – otherwise

damage to the electrical system may occur.
Switch heater fan to boost position to ‘load’ the

vehicle’s electrical system prior to disconnecting the

jumper cables.
Disconnect the cables in reverse order.
Do not disconnect or change over the discharged

battery while the engine is running – damage to the

electrical system may occur.

WARNING: Jump starting could be

dangerous if done incorrectly.

Do not attempt a jump-start if the discharged

battery is frozen or if the battery fluid level is low,

as the battery may rupture or explode.

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