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Ford Galaxy / Ford S-MAX. Manual - part 424

Starter

relay

Ignition

switch

PCM
BJB

*
*

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

The engine cranks
slowly

Battery

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

Testing).

Battery

cable

Starter

motor

GO to Pinpoint Test

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

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
(118kW/160PS) - MI4, Removal and Installation) /
Starter Motor (303-06B Starting System - 2.5L Duratec-ST

Pinpoint Tests

NOTE: Use a digital multimeter for all electrical measurements.

(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.

Ignition switch in position III.

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

harness side and ground.

Is the voltage greater than 10 volts?
Yes

GO to A3

GO to A2

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

Ignition switch in position 0.

Disconnect Ignition Switch C2DC32.

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.

Is the resistance less than 1 ohm?
Yes

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

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.

Is the resistance less than 1 ohm?
Yes

INSTALL a new starter relay. TEST the system for
normal operation.

For vehicles with 1.8L Duratorq TDCi (Kent) Diesel
and 2.0L Duratorq TDCi (DW) Diesel,

GO to A4

For vehicles with 2.0L Duratec HE (MI4),

GO to A5

For vehicles with 2.5L Duratec ST (VI5),

GO to A6

A4: CHECK CIRCUIT CDC12A (YE) FOR CONTINUITY

Ignition switch in position 0.

Disconnect PCM C1E108-K.

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

C1E108-K pin K2, circuit CDC12A (YE), harness side.

Is the resistance less than 1 ohm?
Yes

Using the WDS, CHECK for current DTCs. CORRECT
all DTCs. TEST the system for normal operation. If
the concern persists, INSTALL a new PCM. TEST the
system for normal operation.

REPAIR the circuit. TEST the system for normal
operation. If the concern persists, INSTALL a new
BJB. TEST the system for normal operation.

A5: CHECK CIRCUIT CDC12A (YE) FOR CONTINUITY

Ignition switch in position 0.

Disconnect PCM C1E104-E.

Measure the resistance between the BJB starter relay
R1 connector pin 2, circuit CDC12A and the PCM

C1E104-E pin L2, circuit CDC12A (YE), harness side.

Is the resistance less than 1 ohm?
Yes

Using the WDS, CHECK for current DTCs. CORRECT

all DTCs. TEST the system for normal operation. If
the concern persists, INSTALL a new PCM. TEST the
system for normal operation.

REPAIR the circuit. TEST the system for normal
operation. If the concern persists, INSTALL a new
BJB. TEST the system for normal operation.

A6: CHECK CIRCUIT CDC35G (BU/WH) FOR CONTINUITY

Ignition switch in position 0.

Disconnect PCM C1E108-B.

Measure the resistance between the BJB starter relay
R1 connector pin 1, circuit CDC35G (BU/WH),

harness side and the PCM C1E108-B pin 17, circuit
CDC35G (BU/WH), harness side.

Is the resistance less than 1 ohm?
Yes

GO to A7

REPAIR circuit CDC35G (BU/WH). TEST the system
for normal operation. If the concern persists,
INSTALL a new BJB. TEST the system for normal
operation.

A7: CHECK CIRCUIT CDC12A (YE) FOR CONTINUITY

Disconnect BJB C1E108-B.

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

side and the PCM C1E108-B pin 9, circuit CDC12A
(YE), harness side.

Is the resistance less than 1 ohm?
Yes

Using the WDS, CHECK for current DTC's. CORRECT
all DTC's. TEST the system for normal operation. If
the concern persists, INSTALL a new PCM. TEST the
system for normal operation.

REPAIR circuit CDC12A (YE). TEST the system for
normal operation. If the concern persists, INSTALL a
new BJB. TEST the system for normal operation.

PINPOINT TEST B : THE ENGINE DOES NOT CRANK BUT THE RELAY CLICKS

TEST CONDITIONS

DETAILS/RESULTS/ACTIONS

B1: CHECK CIRCUIT CDC35B (GN/RD) FOR VOLTAGE

Ignition switch in position III.

Measure the voltage between the starter motor
solenoid C1DC35-B-1 circuit CDC35B (GN/RD),

component side and ground.

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