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Ford Galaxy / Ford S-MAX. Manual - part 425

Is the voltage greater than 10 volts?
Yes

GO to B2

GO to B3

B2: CHECK CIRCUIT SBF01A (RD) FOR VOLTAGE DROP

Ignition switch in position III.

Measure the voltage between starter motor
solenoid C1DC35-A-1 circuit SBF01A (RD),

component side and the battery positive terminal.

Is the voltage less than 2 volts?
Yes

CLEAN and TIGHTEN all battery positive cable
connections. TEST the system for normal operation.
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 (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.

CLEAN and TIGHTEN all battery positive cables
connections. TEST the system for normal operation.
If the concern persists, INSTALL a new battery to
starter motor solenoid cable. TEST the system for
normal operation.

B3: CHECK THE STARTER RELAY CONTACT CIRCUIT FOR VOLTAGE

Disconnect Starter Relay R1.

Measure the voltage between the BJB starter relay
R1 connector pin 3 and ground.

Is the voltage greater than 10 volts?
Yes

GO to B4

INSTALL a new BJB. TEST the system for normal
operation.

B4: CHECK CIRCUIT CDC35 (BU/WH) FOR CONTINUITY

Ignition switch in position 0.

Measure the resistance between the BJB starter
relay R1 connector pin 5 and the starter motor

solenoid C1DC35-B pin 1, circuit CDC35B (BU/WH).

Is the resistance less than 1 ohm?
Yes

INSTALL a new starter relay. TEST the system for
normal operation. If the concern persists, INSTALL
a new BJB. TEST the system for correct operation.

REPAIR circuit CDC35A (BU/WH) or circuit CDC35B
(BU/WH) as necessary. TEST the system for correct
operation.

PINPOINT TEST C : THE ENGINE CRANKS SLOWLY

TEST CONDITIONS

DETAILS/RESULTS/ACTIONS

C1: CHECK THE BATTERY VOLTAGE AND CONDITION

CHECK the battery using a battery tester.

Is the battery voltage and condition OK?
Yes

GO to C2

CHARGE or install a new battery as required.
CHECK the charging system using WDS. TEST the
system for normal operation.

C2: CHECK CIRCUIT SBF01A (RD) FOR VOLTAGE DROP

Ignition switch in position III.

Measure the voltage between starter motor
solenoid C1DC35-A-1 circuit SBF01A (RD),

component side and the battery positive terminal.

Is the voltage less than 2 volts?
Yes

GO to C3

C3: CHECK FOR GROUND CONNECTION

Ignition switch in position III.

Measure the voltage between the starter motor
housing and the battery negative terminal.

Is the voltage less than 2 volts?
Yes

INSTALL a new starter motor.
REFER to:

Starter Motor

(303-06A Starting System

CLEAN and TIGHTEN all battery negative cable
connections and starter motor mountings. TEST the
system for normal operation. If the concern
persists, INSTALL a new battery negative cable.
TEST the system for normal operation.

Starting System - 2.5L Duratec
(162kW/220PS) - VI5 - Starter Motor

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

Removal and Installation

Removal

NOTE: Removal steps in this procedure may contain installation details.

Installation

1. Refer to:

Battery Disconnect and Connect

(414-

01 Battery, Mounting and Cables, General
Procedures).

2. Refer to:

Air Cleaner

(303-12C Intake Air

Distribution and Filtering - 2.5L Duratec
(162kW/220PS) - VI5, Removal and Installation).

4. Torque: 10 Nm

5. Torque: 12 Nm

6. Torque: 50 Nm

1. To install, reverse the removal procedure.

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