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

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. 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) (for manual vehicles), or circuit 33 (WH/PK) (for automatic vehicles) and ground, while holding the key in the START position.
  
  Fig 1: Checking Starter Motor Relay Coil For Voltage
  Courtesy of FORD MOTOR CO.
- Is the voltage greater than 10 volts?
Yes : Go to B7.

No : For automatic transmissions, Go to B4.

For manual transmissions, Go to B2.
B2 CHECK CIRCUIT 33 (WH/PK) FOR VOLTAGE AT THE CLUTCH SWITCH OR JUMPER
- Key in OFF position.
- Disconnect: Clutch Pedal Switch C257.
- Key in START position.
- Measure the voltage between clutch pedal switch C257 pin 1, circuit 33 (WH/PK) and ground, while holding the key in the START position.
  
  Fig 2: Checking Circuit 33 (WH/PK) For Voltage At Clutch Switch Or Jumper
  Courtesy of FORD MOTOR CO.
- Is the voltage greater than 10 volts?
Yes : Go to B3.

No : Go to
B3 CHECK CIRCUIT 1093 (TN/RD) FOR AN OPEN
- Key in OFF position.
- Measure the resistance between clutch pedal switch C257 pin 2, circuit 1093 (TN/RD) and the starter motor relay pin 86, circuit 1093 (TN/RD).
  
  Fig 3: Checking Circuit 1093 (TN/RD) For Open
  Courtesy of FORD MOTOR CO.
- Is the resistance less than 5 ohms?
Yes : INSTALL a new clutch pedal switch. TEST the system for normal operation.

No : REPAIR circuit 1093 (TN/RD). TEST the system for normal operation.
B4 CHECK FOR VOLTAGE AT FUSE 31
- Key in OFF position.
- Disconnect: Fuse 31.
- Key in START position.
- Measure the voltage between central junction box fuse 31, circuit 1522 (DG) and ground, while holding the key in the START position.
  
  Fig 4: Checking Voltage At Fuse 31
  Courtesy of FORD MOTOR CO.
- Is the voltage greater than 10 volts?
Yes : REPAIR circuit 1522 (DG). TEST the system for normal operation.

No : Go to
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 pin B4, circuit 1050 (LG/VT) and ground.
  
  Fig 5: Checking Circuit 1050 (LG/VT) For Voltage
  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 1522 (DG). 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 OFF position.
- Measure the voltage between starter motor relay pin 85, circuit 57 (BK) (for manual vehicles) or circuit 262 (BN/PK) (for automatic vehicles) and pin 86, circuit 1093 (TN/RD) or circuit 33 (WH/PK).
  
  Fig 6: Checking Relay Ground Circuit For Open
  Courtesy of FORD MOTOR CO.
- Is the voltage greater than 10 volts?
Yes : INSTALL a new starter motor relay. TEST the system for normal operation.

No : Manual only - REPAIR circuit 57 (BK). TEST the system for normal operation.

Automatic only - Go to B8.
B8 CHECK CIRCUIT 262 (BN/PK)

Key in OFF position.
Disconnect: PCM C1381a.
Measure the resistance between the starter motor relay socket pin 85, circuit 262 (BN/PK) and the PCM C1381a pin 4, circuit 262 (BN/PK).

Fig 7: Checking Circuit 262 (BN/PK)
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 262 (BN/PK). CLEAR the DTCs. TEST the system for normal operation.