Pinpoint Test B: The Engine Does Not Crank And The Relay Does Not Click

WARNING: This page is about a different car, the 2005 Ford Econoline. However, it is still accessible from the selected car via links, so may be relevant.

B1 CHECK THE STARTER MOTOR RELAY COIL FOR VOLTAGE
- Disconnect: Starter Motor Relay.
- Key in START position.
- Measure the voltage between starter motor relay pin 86, circuit 1093 (TN/RD) (6.8L only) or circuit 32 (RD/LB) (4.6L and 5.4L only) and ground while holding the key in the START position.
  
  Fig 1: Measuring Voltage Between Relay Connector And Ground
  Courtesy of FORD MOTOR CO.
- Is the voltage greater than 10 volts?
- Yes : GO to B7.
- No : GO to B2.
B2 CHECK FOR VOLTAGE AT FUSE 33
- Key in OFF position.
- Disconnect: Fuse 33.
- Key in START position.
- Measure the voltage between central junction box (CJB) fuse 33, circuit 33 (WH/PK) and ground while holding the key in the START position.
  
  Fig 2: Measuring Voltage Between Central Junction Box (CJB) Fuse 33, Circuit 33 (WH/PK) And Ground
  Courtesy of FORD MOTOR CO.
- Is the voltage greater than 10 volts?
- Yes : For 4.6L and 5.4L only, GO to B3.
  For 6.8L only, REPAIR circuit 1093 (TN/RD) for an open. TEST the system for normal operation.
- No : GO to B5.
B3 CHECK CIRCUIT 1093 (TN/RD)
- Key in OFF position.
- Disconnect the transmission range sensor electrical connector.
- Measure resistance from fuse 33 to transmission range (TR) sensor circuit 1093 (TN/RD).
- Is the resistance less than 5 ohms?
- Yes : GO to B4.
- No : REPAIR circuit 1093 (TN/RD) for open.
B4 CHECK CIRCUIT 32 (RD/LB)
NOTE: For 4.6L and 5.4L only.
- Measure resistance from transmission range (TR) sensor connector to relay pin 86, circuit 32 (RD/LB).
  
  Fig 4: Measuring Resistance From Transmission Range (TR) Sensor Connector To Relay Pin 86, Circuit 32 (RD/LB)
  Courtesy of FORD MOTOR CO.
- Is the resistance less than 5 ohms?
- Yes : ADJUST the transmission range sensor. If sensor is aligned correctly, INSTALL a new TR sensor.
- No : REPAIR circuit 32 (RD/LB) for an open.
B5 CHECK CIRCUIT 1050 (LG/VT) FOR VOLTAGE
- Key in OFF position.
- Disconnect: Ignition Switch C250.
- Key in ON position.
- Measure the voltage between ignition switch connector C250, circuit 1050 (LG/VT) and ground.
  
  Fig 5: Measuring Voltage Between Ignition Switch Connector C250, Circuit 1050 (LG/VT) And Ground
  Courtesy of FORD MOTOR CO.
- Is the voltage greater than 10 volts?
- Yes : GO to B6.
- No : REPAIR circuit 1050 (LG/VT). TEST the system for normal operation.
B6 CHECK THE IGNITION SWITCH
- Carry out the ignition switch component test.
- Does the ignition switch test good?
- Yes : REPAIR circuit 33 (WH/PK). TEST the system for normal operation.
- No : INSTALL a new ignition switch. TEST the system for normal operation.
B7 CHECK THE RELAY GROUND CIRCUIT FOR AN OPEN
- Key in START position.
- Measure the voltage between the starter motor relay pin 85, circuit 57 (BK) and pin 86, circuit 32 (RD/LB).
- Measure the voltage between the starter motor relay pin 85, circuit 1419 (LG/YE) and pin 86, circuit 1093 (TN/RD).
- Is the voltage greater than 10 volts?
- Yes : INSTALL a new starter motor relay. TEST the system for normal operation.
- No : For 4.6L and 5.4L only, REPAIR circuit 57 (BK) for an open.
For 6.8L only, GO to B8.
B8 CHECK CIRCUIT 1419 (LG/YE) FOR AN OPEN
- Key in OFF position.
- Disconnect: Powertrain Control Module (PCM) C175.
- Measure the resistance between the starter motor relay pin 85, circuit 1419 (LG/YE) and PCM C175-2, circuit 1419 (LG/YE).
  
  Fig 7: Measuring Resistance Between Starter Motor Relay Pin 85, Circuit 1419 (LG/YE) And PCM C175-2, Circuit 1419 (LG/YE)
  Courtesy of FORD MOTOR CO.
- Is the resistance less than 5 ohms?
- Yes : INSTALL a new PCM. TEST the system for normal operation.
- No : REPAIR circuit 1419 (LG/YE) for an open. TEST the system for normal operation.