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Test A: Engine Does Not Crank Or Relay Clicks

WARNING: This page is about a different car, the 2002 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
  1. Ensure battery is fully charged and has sufficient capacity. Ensure battery terminals are clean and tight. If battery is okay, go to next step. If problem is found, replace battery as necessary.
  2. Turn ignition switch to LOCK position. Remove starter relay from battery junction box. Test starter relay. See STARTER RELAY  under COMPONENT TESTS. If starter relay is okay, go to next step. If starter relay is defective, replace starter relay.
  3. Measure voltage between ground and starter relay connector terminal No. 30 (Yellow wire). See Fig 1. If voltage is greater than 10 volts, go to next step. If voltage is not greater than 10 volts, replace battery junction box. Check system operation.
  4. Install starter relay. Disconnect PCM connector 175. Connect a jumper wire between ground and PCM connector terminal No. 44 (Dark Blue/Orange wire). Turn ignition switch to START position. If engine cranks, see appropriate ANTI-THEFT SYSTEMS article in ACCESSORIES & EQUIPMENT. If engine does not crank, go to next step.
  5. Turn ignition switch to LOCK position. Disconnect the starter relay. Measure the resistance in Dark Blue/Orange wire between central junction box and PCM connector 175. Connect positive voltmeter lead to starter relay connector terminal No. 85 and negative voltmeter lead to PCM connector terminal No. 44. If resistance is less than 5 ohms, go to next step. If resistance is more than 5 ohms, ensure starter relay diode is not at fault, repair circuit between starter relay and PCM as necessary.
  6. Install starter relay. Connect PCM connector 175. Turn ignition switch to RUN position. On M/T vehicles, ensure clutch pedal is depressed completely. On A/T vehicles, ensure transmission is in Park. On all models, turn ignition switch to START position. Measure voltage between ground and starter relay connector terminal No. 86 (Tan/Red wire). If voltage is greater than 10 volts, go to next step. If voltage is not greater than 10 volts, go to step  9 (A/T) or step  13 (M/T).
  7. Turn ignition switch to LOCK position. Disconnect starter motor solenoid "S"connector. See Fig 2. Measure the resistance of the White/Pink wire between starter motor solenoid terminal "S" connector and starter relay connector terminal No. 87. If resistance is less than 5 ohms, go to next step. If resistance is greater than 5 ohms, repair circuit in White/Pink wire between starter relay and starter motor. Check system operation.
  8. Install starter relay. Connect starter motor solenoid "S" connector. Perform STARTER GROUND CIRCUIT TEST  under ON-VEHICLE TESTING. If starter motor ground circuit is okay, perform VOLTAGE DROP TEST  under ON-VEHICLE TESTING. If starter motor ground is not okay, repair or replace battery ground cable and/or engine ground cable as needed. Check system operation.
  9. Ensure the transaxle linkage is adjusted properly. If linkage adjustment is okay, go to next step. If linkage adjustment is not okay, adjust linkage. Check system operation.
  10. Check Digital Transmission Range (DTR) sensor adjustment. See DIGITAL TRANSMISSION RANGE SENSOR  under ADJUSTMENTS. If adjustment is okay, go to next step. If out of adjustment, adjust DTR sensor as necessary. Check system operation.
  11. Disconnect DTR sensor harness connector. Turn ignition switch to START position. Measure voltage between ground and DTR sensor harness connector terminal No. 9 (Tan/Light Blue wire). See Fig 3. If voltage is greater than 10 volts, go to next step. If voltage is not greater than 10 volts, repair power distribution circuit as necessary (Tan/Light Blue wire). See POWER DISTRIBUTION in SYSTEM WIRING DIAGRAMS article ELECTRICAL. Check system operation.
  12. Turn ignition switch to LOCK position. Remove starter relay from Battery Junction Box (BJB). Measure resistance between DTR sensor harness connector terminal No. 4 (Tan/Red wire) and starter relay connector terminal No. 86. See Fig 1 and Fig 3 . If resistance is less than 5 ohms, replace DTR sensor. If resistance is greater than 5 ohms, repair Tan/Red wire between DTR sensor and BJB. Check system operation.
  13. Disconnect Clutch Pedal Position (CPP) switch harness connector. Turn ignition switch to START position. Measure voltage between ground and CPP switch harness connector terminal No. 1 (Tan/Light Blue wire). See Fig 4. If voltage is greater than 10 volts, go to next step. If battery voltage is not greater than 10 volts, repair power distribution circuit as necessary (Tan/Light Blue wire). See POWER DISTRIBUTIONin SYSTEM WIRING DIAGRAMS article in ELECTRICAL. Check system operation.
  14. Turn ignition switch to LOCK position. Measure resistance in Tan/Red wire between CPP switch harness connector terminal No. 2 and starter relay connector terminal No. 86. See Fig 1 and Fig 4 . If resistance is less than 5 ohms, replace CPP switch. Check system operation. If resistance is greater than 5 ohms, repair Tan/Red wire between CPP switch and starter relay. Check system operation.
Fig 1: Identifying Starter Relay Connector Terminals
G97J28125Courtesy of FORD MOTOR CO.
Fig 2: Identifying Starter Motor Terminals
G98J12277Courtesy of FORD MOTOR CO.
Fig 3: Identifying Digital Transmission Range Sensor Harness Connector Terminals
G00038729Courtesy of FORD MOTOR CO.
Fig 4: Identifying Clutch Pedal Position Harness Connector Terminals
G99E02176Courtesy of FORD MOTOR CO.
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