Starting System - Diagnosis and Testing

Inspection and Verification

The diagnosis in this manual assumes a certain level of skill and knowledge of Ford-approved diagnostic procedures.
REFER TO: Diagnostic Methods (100-00 General Information, Description and Operation).

1. 1
   Verify the customer concern by operating the starting system.
2. 2
   Before diagnosing or repairing the starting system, check the following:

• Check the battery for loose, damaged or corroded connections.
• Check the alternator for loose, damaged or corroded connections.
• Fusible links
• Check the engine and battery ground connections for loose, damaged or corroded connections.
• High-current BJB for loose or corroded connections
• Wiring, Terminals or Connectors

1. 1
   Check the battery condition and state of charge.
   Refer to: Battery (414-01 Battery, Mounting and Cables, Diagnosis and Testing).
2. 2
   Check for abnormal current draw with the ignition off.
   Refer to: Battery Drain Test (414-01 Battery, Mounting and Cables, General Procedures).
3. 3
   Remove the accessory drive belt.
   Refer to: Accessory Drive Belt (303-05B Accessory Drive – 1.6 L EcoBoost (132 kW/180 L hp) – Sigma, Removal and Installation).
   Make sure the crankshaft and each of the components driven by the accessory drive belt rotate freely and are not seized or damaged.
4. 4
   If any aftermarket accessories have been added to the vehicle, make sure they are correctly connected.
5. 5
   If an obvious cause for an observed or reported concern is found, correct it (if possible) before proceeding.

Diagnostic Trouble Code Charts

The diagnosis described in this manual assumes a certain level of skill and knowledge of diagnostic methods specific to Ford.
Refer to: Diagnostic Methods (100-00 General Information, Description and Operation)
for information on these practices.

PCM Diagnostic Trouble Code Chart

BCM Diagnostic Trouble Code Chart

RFA Trouble Code Chart

Symptom Chart

Symptom Chart: Starting System

The diagnosis described in this manual assumes a certain level of skill and knowledge of diagnostic methods specific to Ford.
Refer to: Diagnostic Methods (100-00 General Information, Description and Operation)
for information on these practices.

Symptom Chart

Pinpoint Tests

Engine Does Not Crank

For circuit and connector information, refer to Wiring Diagrams Cell 20.

For circuit and connector information, refer to Wiring Diagrams Cell 90.

Normal Operation and Fault Symptoms

Refer to: Starting System - System Operation and Component Description (Starting System 303-06B - 1.6 L EcoBoost (132 kW/180 L PS) - Sigma, Description and Operation).

DTC Fault Trigger Conditions

Possible Sources

• Battery
• Battery Cables
• Starter motor
• BJB Starter Relay

Visual Inspection and Preliminary Diagnosis

• Inspect the high-current connections at the BJB.
• Check BJB fuse 10 (30 A).
• Check the BJB MEGA 1 high-current fuse (450A).
• Inspect the CPP switch.
• Inspect the passive key.

A1 INSPECT AND VERIFY CONCERN

Perform the Inspection and Verification procedure in this section. Was an obvious cause for the observed or reported concern found? Yes If necessary, repair the cause. No GO to A2

A2 CHECK THE MESSAGE CENTER FOR KEY NOT DETECTED MESSAGE

Check the message center by pressing the engine start/stop button. Key Not Detected Message? Yes Diagnosis of the "Key Not Found" message. Refer to: Passive Anti-Theft System (PATS) (419-01C Passive Anti-Theft System (PATS) - Vehicles With: Keyless Entry and Push Button Start, Diagnosis and Testing). No GO to A3

A3 CHECK IPC (INSTRUMENT PANEL CLUSTER) OPERATION

Observe the IPC operation by pressing the engine start/stop button. Do Any IPC Indicators Illuminate? Yes GO to A5 No GO to A4

A4 CHECK SCAN TOOL COMMUNICATION

The ignition is on. Using a scan tool, perform the network test. Do the BCM, IPC and RFA modules pass the network test? Yes Diagnosis of "No Power Supply". Refer to: Steering Wheel and Column Electrical Components (211-05 Steering Wheel and Column Electrical Components, Diagnosis and Testing). No REFER TO: Communication Network (418-00 Communication Network, Diagnosis and Testing).

A5 RETRIEVE DTCS

The ignition is on. Using the diagnostic scan tool, perform the self-test: RFA BCM PCM Were any Diagnostic Trouble Codes (DTCs) retrieved on-demand during the self-test? Yes For all RFA module DTCs: Refer to: Remote Function Actuator (RFA) Module (419-10 Multifunction Electronic Modules, Diagnosis and Testing). For PCM DTC P0830, GO to A19. For PCM DTC P06E9, GO to A6. No GO to A6

A6 CHECK PCM (POWERTRAIN CONTROL MODULE) CLUTCH PEDAL AT OR NEAR BOTTOM (CPP_BOT) PID (PARAMETER IDENTIFICATION)

Using a diagnostic scan tool, view the PCM Parameter Identifications (PIDs). Monitor the PCM CPP_BOT PID while fully depressing and releasing the clutch pedal. Does the PID change from NO to YES when the clutch pedal is fully depressed? Yes GO to A7 No GO to A19.

A7 CHECK PCM (POWERTRAIN CONTROL MODULE) ENGINE CRANK WIRE (ENG_CRANK) PID (PARAMETER IDENTIFICATION)

Make sure the transmission is in NEUTRAL. Using a diagnostic scan tool, view the PCM Parameter Identifications (PIDs). Monitor the PCM ENG_CRANK PID while pressing the engine start/stop button and depressing the clutch pedal. Does the PID change from inactive to active? Yes GO to A8 No GO to A18

A8 CHECK STARTER RELAY OPERATION

NOTICE: The following step uses a test light to simulate normal circuit loads. Use only the test light recommended in the Special Service Tools table at the beginning of this section. To avoid damaging connector terminals, use the Flex Probe Kit to connect the test light probe to the vehicle. Do not use the test light probe directly on any connector. Remove the BJB starter relay. Action: Positive lead Measurement/Action Negative lead BJB starter relay Pin 1 BJB starter relay Pin 2 Make sure the transmission is in NEUTRAL. While pressing the engine start/stop button and depressing the clutch pedal, observe the indicator light. Does the indicator light illuminate when the ignition button and brake pedal are pressed? Yes GO to A9 No GO to A16

A9 CHECK STARTER RELAY VOLTAGE

Ignition OFF. Action: Positive lead Measurement/Action Negative lead BJB starter relay Pin 3 Ground Is the voltage greater than 11 volts? Yes GO to A10 No CHECK the BJB fuse 10 (30A) for correct operation. If OK, REPAIR the circuit for an open. If not OK, REFER to the Wiring Diagrams manual to determine possible causes of the circuit short.

A10 CHECK STARTER RELAY STARTER OPERATION

Ignition OFF. Make sure the transmission is in NEUTRAL. Action: Click to display the connectors Positive lead Measurement/Action Negative lead BJB starter relay Pin 3 BJB starter relay Pin 5 Did the starter engage and the engine start? Yes INSTALL a new starter relay. No GO to A11

A11 CHECK BATTERY GROUND CABLE

Action: Positive lead Measurement/Action Negative lead Ground G100 Is the voltage greater than 11 volts? Yes GO to A12 No CLEAN or INSTALL a new battery negative cable, as necessary. Refer to: Battery Monitor Sensor (414-01 Battery, Mounting and Cables, Removal and Installation).

A12 CHECK STARTER GROUND

Action: Positive lead Measurement/Action Negative lead Starter motor housing Is the voltage greater than 11 volts? Yes GO to A13 No CLEAN the starter mounting flange and ENSURE the starter is installed correctly. Refer to: Starter Motor (Starting System 303-06B - 1.6 L EcoBoost (132 kW/180 L PS) - Sigma, Removal and Installation).

A13 CHECK STARTER VOLTAGE

Action: Click to display the connectors Positive lead Measurement/Action Negative lead C197A-1 Ground Is the voltage greater than 11 volts? Yes GO to A14 No CLEAN or INSTALL a new battery positive cable, as necessary.

A14 CHECK STARTER OPERATION

Ignition OFF. In this section, check the starter positive circuit. Was an obvious cause found? Yes If necessary, repair the cause. No GO to A15

A15 CHECK FOR STARTER CRANK INPUT

Install the BJB starter relay. Disconnect starter motor C197B-1 ("S" terminal). Press the engine start/stop button and depress the clutch pedal. Action: Click to display the connectors Positive lead Measurement/Action Negative lead C197B-1 Ground Is the voltage greater than 11 volts? Yes CLEAN the starter solenoid "S" terminal and starter solenoid connector. CHECK the wiring and starter for loose or intermittent connection. No REPAIR the circuit for an open.

A16 CHECK PCM (POWERTRAIN CONTROL MODULE) STARTER RELAY CIRCUITS FOR A SHORT TO GROUND

Ignition OFF. Disconnect ACM C240A. Disconnect the PCM C1915B. Action: Click to display the connectors Positive lead Measurement/Action Negative lead C1915B-43 Ground C1915B-62 Ground Is the resistance greater than 10000 ohms? Yes GO to A17 No REPAIR the faulty circuit.

A17 CHECK PCM (POWERTRAIN CONTROL MODULE) STARTER RELAY CIRCUITS FOR AN OPEN

Action: Click to display the connectors Positive lead Measurement/Action Negative lead C1915B-43 Starter relay BJB Pin 2 C1915B-62 Starter relay BJB Pin 1 Is the resistance less than 3 ohms? Yes GO to A23 No REPAIR the faulty circuit.

A18 CHECK THE VOLTAGE IN THE PCM (POWERTRAIN CONTROL MODULE) KEY FOB DETECTION CIRCUIT

Ignition OFF. Disconnect the PCM C1915B. While holding the engine start/stop button, measure: Click to display connectors Positive lead Measurement/Action Negative lead C1915B-47 Ground Is the voltage greater than 11 volts? Yes GO to A23 No REPAIR the circuit.

A19 CHECK THE TRANSMISSION (CLUTCH PEDAL POSITION) SWITCH

Ignition OFF. Disconnect the PCM C1915B. With the clutch pedal fully depressed, measure: Click to display connectors Positive lead Measurement/Action Negative lead C1915B-30 Ground Is the resistance less than 3 ohms? Yes GO to A23 No GO to A20

A20 CHECK THE TRANSMISSION (CLUTCH PEDAL POSITION) GROUND CIRCUIT FOR AN OPEN

Disconnect the CPP Switch C2353. Action: Click to display the connectors Positive lead Measurement/Action Negative lead C2353-2 Ground Is the resistance less than 3 ohms? Yes GO to A21 No REPAIR the circuit.

A21 CHECK THE TRANSMISSION (CLUTCH PEDAL POSITION) SWITCH CIRCUIT FOR AN OPEN

Action: Click to display the connectors Positive lead Measurement/Action Negative lead C1915B-30 C2353-1 Is the resistance less than 3 ohms? Yes GO to A22 No REPAIR the circuit.

A22 CHECK THE CLUTCH START CIRCUIT FOR A SHORT TO GROUND

Ignition OFF. Disconnect the RFA C3503B. Disconnect the PCM C1915B. Action: Click to display the connectors Positive lead Measurement/Action Negative lead C1915B-30 Ground Is the resistance greater than 10000 Ohms? Yes GO to A23 No REPAIR the circuit.

A23 CHECK THE PCM (POWERTRAIN CONTROL MODULE) OPERATION

Ignition OFF. Disconnect and inspect all PCM connectors. Repair: corrosion (install new connectors or terminals - clean the module contacts) damaged or bent terminals/pins - install new terminals/pins pushed-out pins - install new pins as necessary Connect the PCM connectors. Make sure they are fully seated and locked. Operate the system and determine if the concern is still present. Is the concern still present? Yes CHECK OASIS for any applicable Technical Service Bulletins (TSBs). If a TSB exists for this concern, STOP this test and FOLLOW the TSB instructions. If no TSBs apply to this concern, Click here to access the guided routine (PCM). No The system is currently operating correctly. The concern may have been caused by module connections. ADDRESS the root cause of any connector or terminal issues.

Abnormal Starter Motor Noise

Normal Operation and Fault Symptoms

Proper starter operation depends on correct starter installation to the engine, correct engagement of the starter ring gear with the flexplate, and correct operation of the starter assembly (internal gears, bearings).

Possible Sources

• Engine
• Starter motor
• Starter Mounting

Visual Inspection and Preliminary Diagnosis

• Inspect the starter.
• Inspect the starter mounting.

B10E5:11

For wiring diagrams and connector information, refer to Wiring Diagrams Cell 23.

Normal Operation and Fault Symptoms

The wake-up control circuit wakes the PCM before engine start. The PCM must wake up before the start request so it has time to complete its initialization. The wake-up control circuit is controlled by the BCM. The BCM activates the wake-up control circuit when: the driver door is open, the key is inserted into the ignition lock, or the ignition is ON or in the START position.

DTC Fault Trigger Conditions

Possible Sources

• BCM
• PCM
• Wiring, Terminals or Connectors

C1 CHECK THE PCM (POWERTRAIN CONTROL MODULE) FOR A SHORT TO GROUND

Ignition OFF. Disconnect the PCM C1915B. The ignition is on. Using the diagnostic scan tool, clear the continuous diagnostic trouble codes (DTCs) from the BCM. Using a scan tool, perform the BCM self-test. Is BCM Diagnostic Trouble Code B10E5:11 present? Yes GO to C2 No GO to C6

C2 CHECK THE PCM (POWERTRAIN CONTROL MODULE) WAKE-UP SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE

Ignition OFF. Disconnect C2280D. The ignition is on. Action: Click to display the connectors Positive lead Measurement/Action Negative lead C1915B-28 Ground Is there voltage present? Yes REPAIR the circuit. No GO to C3

C3 CHECK THE PCM (POWERTRAIN CONTROL MODULE) WAKE-UP SIGNAL CIRCUIT FOR A SHORT TO GROUND

Ignition OFF. Action: Click to display the connectors Positive lead Measurement/Action Negative lead C1915B-28 Ground Is the resistance greater than 10000 Ohms? Yes GO TO C4 No REPAIR the circuit.

C4 CHECK THE PCM (POWERTRAIN CONTROL MODULE) WAKE-UP SIGNAL CIRCUIT FOR AN OPEN

Ignition OFF. Action: Click to display the connectors Positive lead Measurement/Action Negative lead C1915B-28 C2280D-9 Is the resistance less than 3 ohms? Yes GO to C5 No REPAIR the circuit.

C5 CHECK THE BCM (BODY CONTROL MODULE) OPERATION

Ignition OFF. Disconnect and inspect all BCM connectors. Repair: corrosion (install new connectors or terminals - clean the module contacts) damaged or bent terminals/pins - install new terminals/pins pushed-out pins - install new pins as necessary Reconnect the BCM connectors. Make sure they are fully seated and locked. Operate the system and determine if the concern is still present. Is the concern still present? Yes CHECK OASIS for any applicable Technical Service Bulletins (TSBs). If a TSB exists for this condition, STOP this test and FOLLOW the TSB instructions. If no TSB resolves the condition, INSTALL a new BCM. REFER TO: Body Control Module (BCM) (419-10 Multifunction Electronic Modules, Removal and Installation). No The system is currently operating correctly. The concern may have been caused by module connections. ADDRESS the root cause of any connector or terminal issues.

C6 CHECK THE PCM (POWERTRAIN CONTROL MODULE) OPERATION

Ignition OFF. Disconnect and inspect all PCM connectors. Repair: corrosion (install new connectors or terminals - clean the module contacts) damaged or bent terminals/pins - install new terminals/pins pushed-out pins - install new pins as necessary Connect the PCM connectors. Make sure they are fully seated and locked. Operate the system and determine if the concern is still present. Is the concern still present? Yes CHECK OASIS for any applicable Technical Service Bulletins (TSBs). If a TSB exists for this concern, STOP this test and FOLLOW the TSB instructions. If no TSBs apply to this concern, Click here to access the guided routine (PCM). No The system is currently operating correctly. The concern may have been caused by module connections. ADDRESS the root cause of any connector or terminal issues.

Component Test(s)

Starter - Positive Circuit Test

1. 1
   Make sure the battery is fully charged.
   REFER TO: Battery Charging (414-01 Battery, Mounting and Cables, General Procedures).
2. 2
   Perform the battery drain test.
   REFER TO: Battery Drain Test (414-01 Battery, Mounting and Cables, General Procedures).
3. 3
   Connect a remote starter switch between the starter solenoid "S" terminal and the battery positive terminal.
4. 4
   Connect the positive lead of the digital multimeter to the positive battery terminal. Connect the negative lead to the starter solenoid terminal "M".

1. 1
   Place the transmission selector lever in the Park or Neutral position.
2. 2
   Activate the remote starter switch. Read and record the voltage. The voltage reading must be 0.5 volts or less.
3. 3
   If the voltage reading is 0.5 V or less, perform the Starter - Ground Circuit Test in this section.
4. 4
   If the voltage reading is above 0.5 volts, this indicates excessive resistance in the connections, the positive battery cable, or the starter solenoid. Disconnect the cables from the starter solenoid terminals "B", "S" and "M". Clean the cables and connections and reconnect the cables to the correct terminals. Repeat steps 3 through 6.
5. 5
   If the voltage reading is still greater than 0.5 volts when checking at terminal "M", move the negative lead of the digital multimeter to starter solenoid terminal "B" and repeat step 5.
6. 6
   If the voltage reading at terminal "B" is less than 0.5 volts, the problem is in the starter solenoid connections or the solenoid contacts. Install a new starter.
   REFER TO: Starter (303-06B Starting System - 1.6 L EcoBoost (132 kW/180 L PS) - Sigma, Removal and Installation).
7. 7
   If the voltage reading at solenoid terminal "B" is greater than 0.5 volts after cleaning the cables and connections at the solenoid, the problem is in the positive battery cable connection or in the positive battery cable itself. Clean the positive battery cable connection. If this does not resolve the concern, install a new positive battery cable.

Starter - Ground Circuit Test

Slow cranking can be caused by high resistance in the ground or the starter circuit. This procedure tests the voltage drop in the ground circuit.

1. 1
   Connect a remote starter switch between the starter solenoid "S" terminal and the battery positive terminal.
2. 2
   Connect the positive lead of the digital multimeter to the starter housing (the connection must be clean, free of rust or grease). Connect the negative lead to the negative battery terminal.
3. 3
   Place the transmission selector lever in the Park or Neutral position.
4. 4
   Activate the remote starter switch and crank the engine. Read and record the voltage reading. The reading must be 0.5 volts or less.

1. 1
   If the voltage reading is greater than 0.5 volts, clean the negative battery cable connections at the battery, the body ground connections, and the starter ground. Retest.
2. 2
   If the voltage reading is greater than 0.5 volts, install a new negative battery cable.
   REFER TO: Battery Monitor Sensor (414-01 Battery, Mounting and Cables, Removal and Installation).
3. 3
   If the voltage reading is less than 0.5 volts and the engine still cranks slowly, install a new starter.
   REFER TO: Starter (303-06B Starting System - 1.6 L EcoBoost (132 kW/180 L PS) - Sigma, Removal and Installation).