Starting System — 2.0L Duratec-HE (MI4)/2.

3L
303-06-1 Duratec-HE (MI4) 303-06-1
.

SECTION 303-06 Starting System — 2.0L Duratec-HE

(MI4)/2.3L Duratec-HE (MI4)
VEHICLE APPLICATION:2008.50 Mondeo
CONTENTS PAGE

DESCRIPTION AND OPERATION

Starting System (Component Location).............................................................................. 303-06-2
Starting System (System Operation and Component Description).................................... 303-06-6

DIAGNOSIS AND TESTING

Starting System.................................................................................................................. 303-06-13
Principles of Operation....................................................................................................... 303-06-13
Inspection and Verification.................................................................................................. 303-06-13
Symptom Chart................................................................................................................... 303-06-13
Pinpoint Tests..................................................................................................................... 303-06-14

REMOVAL AND INSTALLATION

Starter Motor................................................................................................... (26 204 0) 303-06-22
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DESCRIPTION AND OPERATION

Starting System – Component Location

1.6L Duratec 16V Ti-VCT (Sigma)

E97217

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DESCRIPTION AND OPERATION
2.0L Duratec HE(MI4)

E97218

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DESCRIPTION AND OPERATION
2.3L Duratec-HE (MI4) engine with 6-speed automatic transmission (AWF21)

E97219

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DESCRIPTION AND OPERATION
2.5L Duratec (VI5)

E97220

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DESCRIPTION AND OPERATION

Starting System – System Operation and Component Description

Control Diagram

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DESCRIPTION AND OPERATION
Starter system with ignition key

A B

10

11

8 6

E97384

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DESCRIPTION AND OPERATION
Item Description Item Description
A Vehicles with manual transaxle. 7 Starter relay
B If equipped with an automatic transaxle. 8 Starter motor
1 Ignition key 9 Stoplight Switch
Comments: Comments:
With transponder for PATS (passive If equipped with an automatic transaxle.
anti-theft system)
10 TCM (transmission control module)
2 PATS Comments:
If equipped with an automatic transaxle.
3 Ignition lock
11 Starting deactivation relay
4 GEM (generic electronic module)
Comments:
5 PCM (powertrain control module) If equipped with an automatic transaxle.
6 Battery

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DESCRIPTION AND OPERATION

Keyless starting system (vehicles with manual transmission)

2
3 4

5
6

10
9

E97428

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DESCRIPTION AND OPERATION
Item Description Item Description
1 Start/stop button 5 Radio frequency receiver
Comments:
2 CPP (clutch pedal position) switches
Signal is only executed in GEM
Comments:
Switches when the clutch pedal is 6 GEM
operated
7 PCM
3 Keyless vehicle module
8 Starter relay
4 Electronic steering lock with mount -
9 Starter motor
passive key and PATS transmitter/receiver
unit 10 Battery
Comments:
for emergency start function

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DESCRIPTION AND OPERATION

Keyless starting system (vehicles with automatic transmission)

2 3

4
5

9
8

10
7

12
11

E97429

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DESCRIPTION AND OPERATION
Item Description Item Description
1 Start/stop button 5 GEM
2 Keyless vehicle module 6 Stoplight Switch
3 Electronic steering lock with mount - 7 TCM
passive key and PATS transmitter/receiver
8 Starting deactivation relay
unit
Comments: 9 PCM
for emergency start function
10 Starter relay
4 Radio frequency receiver
Comments: 11 Starter motor
Signal is only executed in GEM 12 Battery

System Operation

Smart Start
The PCM enables the starting process when a key In this case, there is a passive key mount on the
providing a valid code is read via the PATS. This steering wheel. A PATS transmission/reception
code is then verified in the GEM and compared unit is attached to this.
with the saved code. If this code is recognized as To start the engine, the passive key must be
correct, synchronization with other modules is inserted into the passive key mount. The Start/Stop
carried out. After successful synchronization, the button can then be used to turn on the ignition and
engine is cleared to start in the PCM. The PCM start the engine as normal. To deactivate the
connects earth to the starter relay, which then PATS, a transponder is fitted in the passive key,
connects power to the starter solenoid. As soon which is read by the transmission/reception unit.
as the engine reaches a certain speed, the PCM
disconnects the starter relay and so turns off the
starter. This protects the starter.
If the engine does not turn or turns only slowly, the
starting process is aborted by the PCM.
The starter is not activated if:
• the engine is running (i.e. the engine speed is
above a particular value),
• the PATS does not permit the engine to be
started,
• the clutch pedal is not operated (vehicles with
manual transmission),
• the gear selector level is not set to P or N
(vehicles with automatic transmission),
• the brake pedal is not operated (vehicles with
automatic transmission).

Emergency starting function

If the keyless vehicle system is unable to recognize
the passive key, the vehicle can be started via the
emergency starting function.

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DIAGNOSIS AND TESTING

Starting System
General Equipment Battery voltage is supplied to the starter motor
solenoid contact through a fused wire. The ground
Ford approved diagnostic tool
circuit is completed using the starter motor casing
and the engine/transmission ground wire.
Principles of Operation
Inspection and Verification
The starter motor function is controlled by a starter
relay. The starter relay is operated by the ignition 1. Verify the customer concern.
switch.
2. Visually inspect for obvious signs of mechanical
Battery voltage is supplied to the ignition switch or electrical damage.
from engine junction box (EJB) fuse F17. When 3. If an obvious cause for an observed or reported
the ignition switch is turned to position III, battery concern is found, correct the cause (if possible)
voltage is supplied to the starter relay coil. The before proceeding to the next step
starter relay coil circuit is completed by a ground
4. If the cause is not visually evident, verify the
circuit through the powertrain control module
symptom and refer to the Symptom Chart.
(PCM). The ground circuit will only be available
when the PCM receives the correct signal from the
passive anti-theft system (PATS). Visual Inspection Chart
When the starter relay coil is energized, the starter Mechanical Electrical
relay contacts close and battery voltage is supplied • Starter motor • Fuse(s)
to the starter motor solenoid circuit from EJB fuse
F15. The starter motor solenoid circuit is completed • Wiring harness(es)
by a ground circuit through the starter motor casing. • Electrical
connector(s)
The starter motor solenoid has two functions. The
first is to supply the starter motor with a high energy • Relay(s)
switch between the battery positive terminal and • Switch(es)
the starter motor windings. The second is to act as • Battery
a mechanical clutch between the starter motor drive
gear and the flywheel ring gear.

Symptom Chart

Symptom Possible Sources Action

• The engine does not crank and • Battery • REFER to: Charging System
the relay does not click (414-00 Charging System -
General Information,
Diagnosis and Testing).
• Circuit(s) • GO to Pinpoint Test A.
• Starter relay
• Ignition switch
• PCM
• EJB

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DIAGNOSIS AND TESTING
Symptom
• The engine does not crank but • Battery
the relay clicks
• The engine cranks slowly
• Unusual starter motor noise
• The starter motor spins but the • Starter motor
engine does not crank
Pinpoint Tests
NOTE: Use a digital multimeter for all electrical
measurements.
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Possible Sources Action
• PATS • REFER to: Anti-Theft - Passive
(419-01 Anti-Theft - Passive,
Diagnosis and Testing).
• REFER to: Charging System
(414-00 Charging System -
General Information,
Diagnosis and Testing).
• Circuit(s) • GO to Pinpoint Test B.
• Starter relay
• Starter motor
• Battery • REFER to: Charging System
(414-00 Charging System -
General Information,
Diagnosis and Testing).
• Battery cable • GO to Pinpoint Test C.
• Starter motor
• 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.
TEST the system for normal
operation.
• Flywheel ring gear • CHECK the flywheel ring gear.
INSTALL a new flywheel ring
gear as necessary.
• REMOVE the starter motor.
INSPECT the starter motor
gear for damage. INSTALL a
new starter motor as neces-
sary. TEST the system for
normal operation.
• 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. TEST the system for
normal operation.
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DIAGNOSIS AND TESTING
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
1 Disconnect Starter Relay R1.
2 Ignition switch in position III.
3 Measure the voltage between the EJB starter
relay R1 connector pin 1, circuit A_CDC35D
V
(BU/WH), harness side and ground.
• Is the voltage greater than 10 volts?
→ Yes
GO to A3.
→ No
GO to A2.

E60181

A2: CHECK CIRCUIT A_CDC35D (BU/WH) AND A_CDC35F (BU/WH) FOR CONTINUITY
1 Ignition switch in position 0.
2 Disconnect Ignition Switch C2DC32.
3 Measure the resistance between the EJB starter
relay R1 connector pin 1, circuit A_CDC35D
(BU/WH), harness side and the ignition switch
C2DC32 pin 7, circuit A_CDC35F (BU/WH),
harness side.
• Is the resistance less than 1 ohm?
→ Yes
INSTALL a new ignition switch. TEST the
system for correct operation.
E75332 → No
REPAIR circuit A_CDC35D (BU/WH) or circuit
A_CDC35F (BU/WH) as necessary. TEST the
system for normal operation.
A3: CHECK THE STARTER RELAY COIL FOR GROUND
1 Ignition switch in position III.

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DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between the EJB 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.
→ No
For vehicles with 1.6L Duratec 16V Ti-VCT
E75125 (Sigma) engine, GO to A4.
For vehicles with 1.8L Duratorq TDCi (Kent)
Diesel engine or 2.0L Duratorq TDCi (DW)
Diesel engine, GO to A5.
For vehicles with 2.0L Duratec HE (MI4)
engine, GO to A6.
For vehicles with 2.5L Duratec ST (VI5)
engine, GO to A7.
A4: CHECK CIRCUIT CDC12A (YE) FOR CONTINUITY
1 Ignition switch in position 0.
2 Disconnect PCM C1E104-J.
3 Measure the resistance between the EJB starter
relay R1 connector pin 2, circuit CDC12A (YE)
and the PCM C1E104-J pin F4, circuit CDC12A
(YE), harness side.
• Is the resistance less than 1 ohm?
→ Yes
Using the Ford approved diagnostic tool ,
CHECK for current DTCs. CORRECT all
DTCs. TEST the system for normal operation.
If the concern persists, INSTALL a new PCM.
E91026
TEST the system for normal operation.
→ No
REPAIR the circuit. TEST the system for
normal operation. If the concern persists,
INSTALL a new EJB. TEST the system for
normal operation.
A5: CHECK CIRCUIT CDC12A (YE) FOR CONTINUITY
1 Ignition switch in position 0.
2 Disconnect PCM C1E108-J-K2 (Vehicles with
1.8L Duratorq TDCi (Kent) Diesel engine).
3 Disconnect PCM C1E108-C-K2 (Vehicles with
2.0L Duratorq TDCi (DW) Diesel engine).

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DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the resistance between the EJB starter
relay R1 connector pin 2, circuit CDC12A (YE)
and the PCM connector pin K2, circuit CDC12A
(YE), harness side.
• Is the resistance less than 1 ohm?
→ Yes
Using the Ford approved diagnostic tool,
CHECK for current DTCs. CORRECT all
DTCs. TEST the system for normal operation.
If the concern persists, INSTALL a new PCM.
E75126
TEST the system for normal operation.
→ No
REPAIR the circuit. TEST the system for
normal operation. If the concern persists,
INSTALL a new EJB. TEST the system for
normal operation.
A6: CHECK CIRCUIT CDC12A (YE) FOR CONTINUITY
1 Ignition switch in position 0.
2 Disconnect PCM C1E104-E.
3 Measure the resistance between the EJB 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 Ford approved diagnostic tool,
CHECK for current DTCs. CORRECT all
DTCs. TEST the system for normal operation.
If the concern persists, INSTALL a new PCM.
E75128
TEST the system for normal operation.
→ No
REPAIR the circuit. TEST the system for
normal operation. If the concern persists,
INSTALL a new EJB. TEST the system for
normal operation.
A7: CHECK CIRCUIT A_CDC35G (BU/WH) FOR CONTINUITY
1 Ignition switch in position 0.
2 Disconnect PCM C1E108-B.

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DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the resistance between the EJB starter
relay R1 connector pin 1, circuit A_CDC35G
(BU/WH), harness side and the PCM C1E108-
B pin 17, circuit A_CDC35G (BU/WH), harness
side.
• Is the resistance less than 1 ohm?
→ Yes
GO to A8.
→ No
E75333 REPAIR circuit A_CDC35G (BU/WH). TEST
the system for normal operation. If the concern
persists, INSTALL a new EJB. TEST the
system for normal operation.
A8: CHECK CIRCUIT CDC12A (YE) FOR CONTINUITY
1 Disconnect EJB C1E108-B.
2 Measure the resistance between the EJB 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 Ford approved diagnostic tool,
CHECK for current DTC's. CORRECT all
DTC's. TEST the system for normal operation.
If the concern persists, INSTALL a new PCM.
E75334
TEST the system for normal operation.
→ No
REPAIR circuit CDC12A (YE). TEST the
system for normal operation. If the concern
persists, INSTALL a new EJB. 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
1 Ignition switch in position III.

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DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between the starter motor
solenoid C1DC35-B-1 circuit CDC35B (GN/RD),
V
component side and ground.
• Is the voltage greater than 10 volts?
→ Yes
GO to B2.
→ No
GO to B3.
VUE0019332

B2: CHECK CIRCUIT SBF01A (RD) FOR VOLTAGE DROP

1 Ignition switch in position III.
2 Measure the voltage between starter motor
solenoid C1DC35-A-1 circuit SBF01A (RD),
V 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,
VUV2601160
INSTALL a new starter motor. TEST the
system for normal operation.
→ No
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
1 Disconnect Starter Relay R1.

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DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between the EJB starter
relay R1 connector pin 3 and ground.
V
• Is the voltage greater than 10 volts?
→ Yes
GO to B4.
→ No
INSTALL a new EJB. TEST the system for
normal operation.

E75130

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

1 Ignition switch in position 0.
2 Measure the resistance between the EJB 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 EJB. TEST the system for
correct operation.
E91811
→ No
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
1 CHECK the battery using a battery tester.
• Is the battery voltage and condition OK?
→ Yes
GO to C2.
→ No
CHARGE or install a new battery as required.
CHECK the charging system using the Ford
approved diagnostic tool. TEST the system
for normal operation.
C2: CHECK CIRCUIT SBF01A (RD) FOR VOLTAGE DROP
1 Ignition switch in position III.

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DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between starter motor
solenoid C1DC35-A-1 circuit SBF01A (RD),
V component side and the battery positive
terminal.
• Is the voltage less than 2 volts?
→ Yes
GO to C3.
→ No
CLEAN and TIGHTEN all battery positive
VUV2601160 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.
C3: CHECK FOR GROUND CONNECTION
1 Ignition switch in position III.
2 Measure the voltage between the starter motor
housing and the battery negative terminal.
• Is the voltage less than 2 volts?
V → Yes
INSTALL a new starter motor. TEST the
system for normal operation.
→ No
CLEAN and TIGHTEN all battery negative
cable connections and starter motor mount-
VUV9510063 ings. TEST the system for normal operation.
If the concern persists, INSTALL a new battery
negative cable. TEST the system for normal
operation.

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REMOVAL AND INSTALLATION

Starter Motor(26 204 0)

5. 1. Torque: 40 Nm
Removal 2. Retighten the bolts.
Torque: 40 Nm
NOTE: Removal steps in this procedure may
contain installation details.
1. Disconnect the battery ground cable.
Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
2. Raise and support the vehicle.
Refer to: Lifting (100-02 Jacking and Lifting,
Description and Operation).
E66021
3.
6. Discard the starter motor gasket.

E65299

E66022
4. 1. Torque: 6 Nm
2. Torque: 12 Nm
3. Torque: 20 Nm Installation
1. To install, reverse the removal procedure.
2

E65420

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