Test A: Engine Does Not Crank & Relay Clicks (Diesel)
WARNING: This page is about a different car, the 2002 Ford Pickup, 2002 Ford F550 Super Duty, 2002 Ford F450 Super Duty, 2002 Ford Excursion, and 2002 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
- Turn ignition switch to LOCK position. Connect a remote starter switch between starter motor relay connector (Tan/Red or Dark Blue/Orange wire) and battery cable starter motor relay terminal (Red cable). Press remote starter switch. If relay did not close, go to next step. If relay closed, but engine did not crank, go to step 3. If starter cranked engine, go to step 5 (A/T) or step 7 (M/T).
- Measure resistance between starter motor relay case and ground. If resistance is less than 5 ohms, replace starter motor relay. Check system operation. If resistance is 5 ohms or more, clean connection between relay case and ground. Check system operation.
- Connect a remote starter switch between starter terminal "S" (Yellow/Light Blue wire) and starter terminal "B" (Red cable). See Fig 1. On M/T models, depress clutch pedal. On all models, press remote starter switch. If engine did not crank, go to next step. If starter cranked engine, repair open on Yellow/Light Blue wire between starter motor relay and starter. Check system operation.
- Disconnect all starter wiring. Measure resistance of starter solenoid between terminal "S" and solenoid case. If resistance is about .95 ohm, replace starter. Check system operation. If resistance is not about .95 ohm, replace starter solenoid. Check system operation.
- Disconnect Digital Transmission Range (DTR) sensor harness connector. Measure voltage between DTR sensor harness connector terminal No. 10 (Dark Blue/Orange wire) and ground while holding ignition key in START position. See Fig 2. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open on Dark Blue/Orange wire between DTR sensor and ignition switch. Check system operation.
- Connect DTR sensor harness connector. Using DVOM, backprobe between ground and DTR sensor harness connector terminal No. 12 (Tan/Red wire) while holding ignition key in START position. If voltage is more than 10 volts, repair open on Tan/Red wire between DTR sensor and starter motor relay. Check system operation. If voltage is 10 volts or less, check DTR sensor adjustment. See DIGITAL TRANSMISSION RANGE SENSOR under ADJUSTMENTS. If adjustment is okay, replace DTR sensor. See DIGITAL TRANSMISSION RANGE SENSOR under ADJUSTMENTS. Check system operation. If adjustment is needed, adjust as necessary. Check system operation.
- Disconnect Clutch Pedal Position (CPP) switch harness connector. Measure voltage between CPP switch connector terminal No. 1 (White/Pink wire) and ground. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open on White/Pink wire between CPP switch and ignition switch. Check system operation.
- Depress clutch pedal. Measure resistance between CPP switch terminals No. 1 and 2 (component side). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, replace CPP switch. Check system operation.
- Measure resistance of Dark Blue/Orange wire between CPP switch connector terminal No. 2 and starter motor relay. If resistance is less than 5 ohms, problem was not found. Repair by symptom. See SYMPTOM INDEX table. If resistance is 5 ohms or more, repair open in Dark Blue/Orange wire between CPP switch and starter motor relay. Check system operation.