Ford Falcon. Manual — part 192

303-06-5 Starting

System 303-06-5

DIAGNOSIS AND TESTING

Starting System

Symptom Chart

Symptom Chart - Starting System

Condition

Source

Action

Loose connections in starter solenoid

Starter Motor Cranks Slowly

GO to Pinpoint Test A.

battery feed or ground circuit.
Undercharged battery. (Battery acid in
all cells should have a specific gravity
reading greater than 1.20, with all cells
within 10 points variation).
Malfunctioning starter motor.
Voltage drop on power cable.

Starter Motor Does Not Crank But

Loose or corroded connections at

GO to Pinpoint Test B.

starter solenoid.

Starter Solenoid Operates

Undercharged battery
Malfunctioning starter motor.
Main power cable open circuit.

Starter Motor Does Not Crank and

Loose or corroded battery cable

GO to Pinpoint Test C.

connections.

Starter Solenoid Does Not Click

Undercharged battery.
Faulty TR/NDS (neutral drive switch).
Faulty ignition circuit grounds.
Malfunctioning starter motor.
Poor earth circuit.

Starter Motor Spins But Does Not

Malfunctioning starter drive.

GO to Pinpoint Test D.

Crank Engine

Damaged flywheel.

Unusual Starter Motor Noise During

Starter motor improperly mounted.

GO to Pinpoint Test E.

Malfunctioning starter motor.

Starter Motor Overrun

Improper starter drive engagement to
flywheel.

Starter Motor Remains Engaged and

Battery cable touching solenoid

GO to Pinpoint Test F.

S-terminal (defective or mispositioned

Runs with Engine

battery cable).
Shorted turns in starter solenoid.

Worn or damaged ring gear.

Inspect ring gear repair or replace as

Starter Motor Noisy in Operation

Drive end bush or commutator end

required.

bush dry/not lubricated.

Clean and lubricate bushes as

Excessive clutch dust (Manual

required.

Transmission)

Pinpoint Tests

PINPOINT TEST A : THE STARTER MOTOR CRANKS SLOWLY

Test Step

Result / Action to Take

A1

CHECK BATTERY CONNECTIONS

Inspect the battery terminals for loose or corroded connections.

Yes

Go to A2

Test voltage drop between battery negative terminal to case of starter
motor, should be < 300mV.

No

CLEAN and TIGHTEN battery cable

Are the battery terminals clean and tight?

connections.

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303-06-6 Starting

System 303-06-6

DIAGNOSIS AND TESTING (Continued)

Test Step

Result / Action to Take

A2

CHECK BATTERY

Check the battery state of charge.

Yes

Go to A3

Battery acid in all cells should have a specific gravity reading greater
than 1.20, with all cells within 10 points variation.

No

CHARGE or REPLACE the battery.

Load test the battery.

Is the battery OK?

A3

CHECK STARTER MOTOR CONNECTIONS

Inspect the starter motor terminals for loose or corroded connections.

Yes

Go to A4

Test voltage drop between battery postive terminal to solenoid main
terminal, should be <350mV.

No

CLEAN and TIGHTEN starter motor

Are starter motor terminal connections clean and tight?

connections.

A4

CHECK STARTER MOTOR

Check the starter cranking current draw, using a suitable digital

Yes

multimeter and current clamp or by following starter load test

REMOVE starter and test.

procedure detailed in Components Tests of this section.

REPAIR or REPLACE.

Is the current draw lower than Specification?

No

Go to A5

A5

CHECK CURRENT DRAW

Remove the stater motor and check the starter current draw with no

Yes

load, using a suitable digital multimeter and current clamp or by

Engine has excessive friction. Refer to Section

following starter no load test procedure detailed in this section.

303-01.

Is the current draw to Specification?

No

Test starter REPAIR or REPLACE.

PINPOINT TEST B : STARTER MOTOR DOES NOT CRANK BUT STARTER SOLENOID OPERATES

Test Step

Result / Action to Take

B1

CHECK STARTER MOTOR CONNECTIONS

Inspect the starter motor terminals for loose or corroded connections.

Yes

Go to B2

Are starter motor terminal connections clean and tight?

No

CLEAN and TIGHTEN starter motor
connections.

B2

CHECK BATTERY

Check the battery state of charge.

Yes

Go to B3

Battery acid in all cells should have a specific gravity reading greater
than 1.20, with all cells within 10 points variation.

No

CHARGE or REPLACE the battery.

Load test the battery.

Is the battery OK?

B3

CHECK SOLENOID

By-pass the solenoid with a heavy jumper cable.

Yes

REPLACE solenoid.

Does the engine crank now?

No

Go to B4

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303-06-7 Starting

System 303-06-7

DIAGNOSIS AND TESTING (Continued)

Test Step

Result / Action to Take

B4

CHECK STARTER ENGAGEMENT

Yes

Engine locked up. Refer to Section 303-01.

Is the starter engagement firm?

No

Remove starter and test.
REPAIR or REPLACE.

PINPOINT TEST C : THE STARTER MOTOR DOES NOT CRANK/THE SOLENOID DOES NOT CLICK

Test Step

Result / Action to Take

C1

CHECK BEM SMARTLOCK STATE

Use WDS to monitor the theft status (THEFT _ S) PID.

Yes

Go to C2

With the ignition switched on is the BEM status “moblised”?

No

Refer Section 419-10 (BEM).

C2

CHECK FUSES

Ensure vehicle is in Park or Neutral (Auto. Trans.).

Yes

REPLACE and RETEST.

Check all fuses in the vehicle.

No

Check all fuses in the vehicle.

Go to C3

C3

CHECK ENGINE ENABLE INPUT

Use WDS to monitor the engine enable input signal No (ATS) EEC

Yes

PID.

Problem exists in ‘Smartshield’ system or
communication between EEC and BEM.

With the ignition switched on is the ATS signal being received by
the EEC?

No

Go to C4

C4

CHECK BATTERY CONNECTIONS

Inspect the battery terminals for loose or corroded connections.

Yes

Go to C5

Are the battery terminals clean and tight?

No

CLEAN and TIGHTEN battery cable
connections.

C5

CHECK BATTERY

Check the battery state of charge.

Yes

Go to C6

Battery acid in all cells should have a specific gravity reading greater
than 1.20, with all cells within 10 points variation.

No

CHARGE or REPLACE the battery.

Load test the battery.

Is the battery OK?

C6

CHECK POWER SUPPLY TO STARTER MOTOR

Key in OFF position.

Yes

Go to C9

Disconnect the starter motor solenoid terminal 50 (connector C-11).

No

Key in START position.

Go to C7

Measure the voltage at Connector C-11

Is the voltage greater than 10 volts?

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303-06-8 Starting

System 303-06-8

DIAGNOSIS AND TESTING (Continued)

Test Step

Result / Action to Take

C7

CHECK POWER SUPPLY TO STARTER MOTOR

With the vehicle in park and the handbrake on, bridge the starter relay

Yes

across its switching circuit (relay pins 30 AND 87) with a heavy

Go to C10

jumper cable.

No

Does the starter crank now?

Go to C8

C8

CHECK THE STARTER CIRCUIT

Check continuity of circuit from fuse block to starter relay and from

Yes

starter relay to starter motor solenoid.

Go to C9

Is the circuit OK?

No

Rectify and Retest.

C9

CHECK THE SOLENOID

With the vehicle in park and the handbrake on, bridge the starter

Yes

motor battery connection to the solenoid terminal.

REPLACE solenoid. Retest.

Does the engine crank?

No

No Test starter motor.
REPAIR or REPLACE.

C10

CHECK POWER BETWEEN IGN & STARTER RELAY

With ignition switched to the start position, check the voltage at the

Yes

starter motor relay (winding input).

Go to C11

Is there greater than 8 volts?

No

Check continuity of circuit from fuse through
ignition switch to relay.
Rectify and Retest.

C11

CHECK EEC STARTER RELAY SWITCHING

Use the WDS to monitor the starter relay enable starter signal

Yes

(ENABLE_ S) EEC PID.

Go to C12

With the ignition switched to the start postion is the signal “

No

ON”?

Perform further EEC diagnostic tests.
Refer to Section 303-14.

C12

CHECK STARTER CIRCUIT

Ensure vehicle is in Park or Neutral (Auto. Trans.).

Yes

Replace starter motor.

Check continuity of circuit from, EEC;

Starter relay

No

Rectify and Retest.

Inhibitor switch

Ground

Is the circuit OK?

PINPOINT TEST D : THE STARTER SPINS BUT THE ENGINE DOES NOT CRANK

Test Step

Result / Action to Take

D1

CHECK BATTERY

Check the battery state of charge.

Yes

Go to D2

Is the battery OK?

No

CHARGE or REPLACE the battery.

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