303-064 Starting System - 2.5L Duratee-HE (122kW/165PS) - Mid 2015 2016 Ranger ICA Description and Operation Procedure reson date 07/15/2015 Starting System - Overview Starting System ‘The starting system controls the cranking of the engine. The starter motor is enabled by the starter relay when the relay is activated by the PCM. The BCM receives inputs from the ignition switch, transmission and the BOM before activating the starter relay {o initiate cranking of the engine. Cenk $2016 Fort Mater Comsary303-064 Starting System - 2.5L Duratee-HE (122kW/165PS) - Mid 2015 2016 Ranger ICA Description and Operation Procedure reson date 07/15/2015 Starting System - System Operation and Component Description ‘System Operation ‘System Diagram seco Network Message Chart Module Network Input Messages Powertrain Control Modul (em) Broadcast Message Originating Module Message Purpose Tgnition status BOM Provides the PCM with ignition mode, Starting System This vehicle is equipped with a BATS that disables the engine from starting if an unprogrammed PATS key is used or an invalid PCM ID is received. The PATS is controlled by the CM. If there is a PATS concer that disables the tengine, the IPC displays the corresponding message in the message center. Refer to: Perimeter Anti-Theft Alarm - System Operation and Component Description (419-01A Perimeter Anti-Theft ‘Alarm, Deseription and Operation), Under normal operation, when the ignition is tumed to START, the PCM receives the following inputs: + Request to crank engine message from the BCM + PATS enable message from the BCM + Voltage from the run/start relay * Correct transmission atk or neutral input from the automatic transmission When the PCM receives the correct inputs, voltage and ground is supplied to the starter relay coil. When the starter relay coil is energized, It provides voltage to the starter solenoid, allowing the starter motor to crank the engine. ‘The PCM disengages the starter once an engine Revolutions Per Minute (RPM) threshold is reached, a set crank time Is exceeded or the janition is tuned OFF.Component Description Integrated Keyhead Transmitter (IKT) Refer to: A ‘Alarm, Description and Operation), Passive Anti-Theft Transceiver Refer to: i-Theft System (PATS) - (419-018 Passive Ant ‘Theft System (PATS), Description and Operation). Ignition Switch Refer to: Steering Wheel and Column Electrical Components (211-05 Steering Column Switches) Powertrain Control Module (PCM) ‘The PCM provides power and ground to the staiter relay to initiate cranking of the engine. Copyrae 2018 Fora eter Company086A Stating Systom -2.5L Dutac HE (OKWIIBSES)- 2015-2046 RangorIOA Dissosis ar Testing rere evo dle OOS 0018 ‘starting System Inspection and Verifeaion essa ne mara asa a cata sl ian ole of Fuso dap patos to: Dagnoste toss (10000 Ganeralieematen Descapicn an Operate) 1. Very th customer concer 2 Chock the ban foreos, damaged or corded conectons 3. Chock he star erloose, mages cr cored connects 4. Chace ne natty constion ad state erage. REFER fo natty (4140 Sate, Moutbng and Cables, Dignsis and Testing) 5 Remove to acossor dive bt REFER to Accessuy Dive Bal GO2OSA Accessory Dive 251 Duo HE (1244 165PS) - M4, Removal a insta), \eniy he crrksra sd ach ct he components crven oy te cessor dive bat tate and ae not sazed o: 6 Ixy attest accessories have been ads tothe vehicle, make sue they are ety wed 7 tn obvious cause fran coseved reported conc seus, cone the case f posse Detorepreceen, ore chart Diagnostics in tis manual assume a coin ski lve ans knonlede of Fors-sectic daancstcpractoes REFER lo Diagn Meth (10000 General rerraton Descepen ar Cpa) emote chat ‘Te | Deseron etn CED] Engine Stator to argo ar, Rt Porn CanlEmiaene Dapnose (PUED) manu We ego dove ol cork GO Fetomerce Puntos = Posso [cutcn Poca AT Creu] Go 0 Pepa TEA 2 | Stare Mot Disabled Tas DTG seis nthe BGM when the ge fas bash civkad br were han a lal 0 seconds wad along suiciend Engine Cravk Tne To tie foto start coo. Diajose al Ober DTCs and syretans. Check the charg system votage and carer Loe nocossay. loa to DT P2535 |lgnten Svich ‘Sina Tes Ron Stet Poston [reat Hon rar nee REFER to Excwonc Engine Contols-Vericles Bult Fon: 17-06:2015 (209-14 Electenc Engine Conus -26L Dut: bres IE ci2akw 1858) Ni ‘BoM DTC chart Dr Description “aien erica TT | aM warowp Sonat GrcatSrotto [Ground REFER to: Passive Aci Tht System (ETS) (0-018 Passive Art Theft Stam (PATS) [iearsis an Test eriaATS | POM warowp Sonar Creat Sron Batexy or Open REFER to: Passive Tet Syste (PATS) (4-018 Passive Anti-Theft System (PATS), Diapesis an Testing) lat omer pres | REFER to: Bony Cont Mole MD (8-10 Mulino Electonic Maes, Diagnosis end festa) Symptom Charts) ‘symptom Chart Starting System Diagrests in tris manu essume a can sil eval and knoodge of Fre specic ésaostic races. REFER to Dagnsic Msheds 10000 Gene rtomaten bescrBien an beat) ‘Symotom Chart Condon Possible Sources ‘Ratons The one cove ret am [Rete tote Prpant | GOT Rpont TA festest Regyecasonwn | + pas eter 19 Ponarian Cantor Emissions Dagheae (PCIED) ma 1 Ee pune Fos pu ay 2 guvstat aay 1 State + ies aaa vararese [Rte omePreort | GOmPacaLTALD The sate spnsbur ie [Slater motor INSPECT Ihe sates moto mow and eae REPAIR os noosa Jane dees rt crark [Damaged naeiate [INSPECT te renpiate ror Garaged, missing wom eth REPAIR as pceSSaty The starr does net ~ Siaterreley [REMOVE the sate relay ihe erie sors crank, INSTALL a naw reay. ine egne Corton Jssemaage om tie fect | > Wir, to ciak, REPAIR crcut OB813(GY/EN) fore shat 0 valine Pinpoint Testis) Engine Does Not Crank ‘foro Wing Diagrams Cll 20 fo schematic an comscer infomation ‘Normal Operation and Fault Conditions REFER to: Sating Sistem. Systm Ons and Gamponar Desc (20-04 Stating System? SL Duc HE (Z2KWII65PS)-NI4, Description nd Open) DIC Fault Tigger Conions ‘Die | Deception Fault Tigger Conditons Poae9|Enane Sister |Nowngre taion decid rng crank event Petomaree Pe50 | Chtch Pada [Seis when the POA eves venice speed pa ndcaling vice moval and doesnot Gees th sichinginel om Creat Ina lten pal poten sen Possible Sours + Baty 1 Baty cottes 1 Stator meter 1 Bue sanorralay ‘Views ngpection and Diagnostic Pr-checks Inspect the Run's lay 1 efect eaghcurert £18 conection 1 Mery tho RUE ase Ts 2OA), 1 Vey the BEM tse 73 A) 1 Trepet ts ntogratedKoyrcad Tansmitr (KT) PINPOINT TESTA : ENGINE DOES NOT CRANK. NOTE: Nake sve bay vane Terran TD v's wi fo ae ing Ps DA Tes INOTE: Do rt rave atten charger aac dr vil eta. [at_ PERFORM INSPECTION AND VERIFICATION Prom irspection end Veriton procedure inthis socion wae an cbvius eaute for an observed or reported coneeen found? en [Cree th case a recosaany Ne [G01 [Ad VERIFY THE BCid (BODY CONTROL MODULE) AND PCH [POWERTRAIN CONTROL MODULE) PASS THE NETWORK TEST Tanto ON. Using a agnostic sn, pom the Netwok Test. Die the BCM and ECM pass the Network Test? REFER o- Communcatons Neus (418-00 Mode Canmuntations Netwerk, Diagnosis and Testngh[AS_RETRIEVE DIAGNOSTIC TROUBLE CODES (TCS) Using Gagroste scan ion, peor BC and POM sists Are ry Diagnostic Trouble Codes (OTC) prevent? [Yea [Foran BCR Diapost Tous Coes (TOS) reer To he BUM OT Ghat nhs Son Fo al her POM Diannsic Toute Caves (OTC) REFER to lecteic Eng Corrs - Veni Bul From: 17.08.2015 (03-14 lecknic Engine Cotes -2 5. Dulac HE fizaxiiteoPs) =) [looms OOOSOOCOCCCCCC~‘™Y [Ad CHECK BCM BODY CONTROL NODULE] IGN_SV/_STATE PID (PARAMETER IDENTIFICATION) Using a dagpostc scar fo, vow tho RCM Paareta Iorticatons Ds) Monto tno CM PID IGN’ SW. STATE whie iuming te enon Sch tom OFF to START. ‘Does the PID change tom Of to Start when te ignition switchs tamed fom OFF o START? Yee [Ses No [DIAGNOSE No pone A Stat PREFER to sloughs ad Column Elects Comeananis (21-05 stotng Coun Switches, Diagnosis and Test) [aS CHECK THE PCN POWERTRAIN CONTROL MODULE) IN GEAR-TRANSNISSION IS APPLYING A LOAD TO ENGINE (N_GEAR)PID PARAMETER IDENTIFICATION) Using a dagposte scar ion, vow he BGM PaaratarIoottcstons Ds) Mote tho CM PID INGEAR. whic rang tho gsr selec m PARK and than NEUTRAL [Does the PIO read Non both postions? ves [om Ne REFER to: Diagnostic Tite Cote Charts (207-01 Aarts Tnsmssion -6-Speed Auloratc Tarsmisson REO, Cannas ard [stra [Aé_CHECK THE PCM POWERTRAIN CONTROL MODULE) ENGINE GRANKING (ENG_CRANK] PIO PARAMETER IDENTIFICATION) Take sure tho ransmssion in PARK of NEUTRAL, Using a dagrost scan fo, onthe BOM Parameter Iartiicatons Ds) Monte tho BOM PID ENG CRANK wile tra fhogrten sto tho START postion Does the PID change rom Inactive to Active? free [oowat No_[edwaa [AT_CHEGK THE STARTER RELAY CONTROL OPERATION NOTICE: The following sep uses a tet ight to simulate normal crcl loads, Use only he fst ight recommended in the Special Tool able at he begining of tie section. To veld connecter terminal Gamage, ue te Flex Probe Wi forte tet ight probe connection tthe veicie Do not use the tet light probe cect on any connector. Femove tho BIB star oy. 1 CoS meee | |s00S|basFr eutomaticransmsion, make sure te transmission im PARK oc NEUTRAL Formanua vansmssen Ty aggly the ccnp ‘Win ling the key nthe START potion, coger he tst itt ows the et ight luminate when the ky isin the START position? free [oom No [oowais [AB CHECK THE VOLTAGE TO THE STARTER RELAY Tease BEBE Positive Lead ‘Measurement Adlon | Negative Load 40, F39 (E38 = [wa] = Ground wa co md Meo Olan Ce ase starter ray in’ Ite vttge pester than 1 vols? free [eos INo [VERIFY fe Bul fine 19 BOA) © OK ITOK REPAIR Th rot Toran Goan Irmo OK REFER To he Wing Danan naa To sity te posse causes of Ie chcul shar [AS_CHECK THE STARTER MOTOR OPERATION AT THE STARTER RELAY Tgnuon OFF ‘ithe tanmissin in PARK ce NEUTRAL, momenialy comect fase pe ir REBRRBB IL) |RRRRSAB IL coSaest|e | |jo0s a Dic the starr engage and the engine crak? [Yee [INSTALL anon cater ay ino _[sowan [At0_ CHECK THE BATTERY GROUND CABLES easeFT| ave | Ground C1006 i nets gts = a eee a RTE = a ma sai = is ® ave oe sees reenans nt =o eee eee = aa aS a [ERaTA CE ana) the voltage greater than 1 vols? fee [ooeat INSTALL aren postive ttt cate ReerfoBaley Cates [AIS_CHECK THE STARTER MOTOR FOR CORRECT OPERATION arom State Mojor-Postve Cieut Testa Ts eacton Was en obvious cause found?es_|corect me caso a nessa No [GOwaie [atd CHECK FOR STARTINPUTAT THE STARTER ‘Conect Bu state ay Discomedt Sater ston COT. NOTE: Formaruaransmsson ‘aly eooy dhe lich ped Whe lig the key inthe START psiton, messue Poskve Led Wassuremant/ Aeon Negaive Lead ERTCTTS Tara me Gard ste vatge greater than 1 vols? Yee [CLEAN ra sate somiod "5 eral and SaaS Cennwco” CHIEGK Te wg and Te at WRG Tras OF cert comecton REPAIR te cru fora ope [AT CHECK THE PCH (POWERTRAIN CONTROL MODULE) STARTER RELAY CONTROL CIRCUITS FOR A SHORT TO GROUND, ignten OFF Discomect POM C1758 Messe Postive Lead Measurement” Acton negative lad iE a Gains iE a Grind lar the reistances greater than 10,000 ohms? vee [Soa [No [REPAIR to eto cron [ATG CHECK THE POM (POWERTRAIN CONTROL MODULE) STARTER RELAY CONTROL CIRCUITS FOR AN OPEN sue Petve Lead essurement Reon Negative ead ‘Cree a [aus sate aay in CRBS a [BiB state ray pn? Are the resistances ess than 3 ohms? fee [sows No [REPAIR tha wacad crea [AIT CHECK THE CPP [CLUTCH PEDAL POSITION) SWITCH Tgnton OFF Discomect BoM C17EB ‘White aly aging the Cc pd, ease Poutive ead Measurement? Acton egatve Lad Gi o Gant athe resatance lees han 3 ohms? Yea [Ow No [sows|AY8_ CHECK THE CPP (CLUTCH PEDAL POSITION) GROUND CIRCUITFOR AN OPEN. Disconect OPP switch C2353. Massie Pontive Lead esaurement/ Beton Negative Lead CHEE o ‘Gone othe resatance oss han 3 ohme? yes [owas No [REPAIR te creat [ato CHECK THE CPP (CLUTCH PEDAL POSITION) SWITCH CIRCUIT FOR AN OPEN ass Poutive Lead Measurement Acton Negative Lead Crea n Caan athe resotance less han 3 ohms? [Yee_[INSTALL enon GBB cnitch No [REAR te orbat [A20_ CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION igntien OFF Discoect and inspect al BGM connor Ropar crest nay coma ena cen roars) 1 cemages orbere pre nstal now tomas 1 ttabetene\nral san pn ae nace econo! the PCM conectos. Make Sue they seat anatch comety (pert he Systm ara determine he concen is stl preset the concern ail present? Yes [OHECK OASIS fay aptcabio Tecnica Sevico Balin TSBs) 11a TSB ts fr ths concars DISCONTINUE Ws tot ard FOLLOW the 138 auciors Ito Teena Service Bula (183s) aes sconce, INSTALL @ Now PCRL REFER wo Eoustan Cont Magis (POA Gs 4A Becronc Engoe Cont 2S. Duoe HE (i22W 1855) -Ni, Removal ed station [No_| he syst opting covet a ns time, The concen may have bouncaised by mode conneclons, ADDRESS te To case of ay conactr opin ssine ‘Unusual Starter Noise ‘Normal Operation and Fult Conditions Corect starter epoton reson coct mounting oho starr oto ergn, alent of te stare ng ge to te expat and comet tunctonng othe stater essen nema gers, bess) Possible Sources + Engine Slater motor 1 Sister meter mating Views nepection and Diagnostic Pre-checks + Inspect tho stair motor 4 Inspect he States ter mounting PINPOINT TEST: UNUSUAL STARTER NOISE. [Bi_ CHECK THE STARTER MOUNTING Inspect the stare meutng Eos oseeas Is the starter motor mounted corecty? Io] NSTALL te satermccr corey, REFER io Saar Mtr (309.088 Star Syston -2SL Due HE (ZAKW/ISPS) M4, Removal nds).[82 CHECK FOR STARTER NORE ight OFF Connect amet stare sich between te starter solenad C17A (Stemi ae CHO7C-1 (tring) Engage the sro and vei) the nose s ce esate paratin I the noi duet the starter engagement? (Yea REFER to. Sere Mato vs Gea apt Fae Rina Gea nsecton (OO-0A String System - 25 Deter HE [Gazi eee), General Proceces) Ino REFER o Exaaa Goan Engrs 56m -Geealnomatn, Dagens). | cnteve dagross 256 er to Ving Diagrams Col 20 fo schematic nd comet infomaton, [Normal Operation and Fault Conations When einen s tune tothe START poston the POM reeiyes votage sig onthe crank detect cicut The BOM then stepies vote and gcd to {he'slrter fay cal en Be routed puts have been rece DTC Fault Tiager Conon bre Description Fault Tigger Conditons P2535 pion Swen Run Start Postion Gacut gn | Ths DT sets when the PGM 0c votae on he unk cetect Gcut whee eno sari, Posable Sources cM Igrton swatch ‘hina tomas or comectos PINPOINT TESTC : OTC 2595, [Ci_ RETRIEVE DIAGNOSTIC TROUBLE CODES (TCS) Tgnten ON. Using a diagnostic scan to, pero ECM sates Is DTC P2595 recorded? fvee [Owe [no |For a Echt Dagrosic Teabe Cooes (OTCS) 'erlotha POM DTC Ghat athe sacton [C2_ CHECK THE CRANK DETECT CIRCUIT FOR A SHORT TO VOLTAGE WITH PCM POWERTRAIN CONTROL MODULE) DISCONNECTED Tgnten OFF Discomect POM C1788 Ianton ON. Mosse Posive Lead Massurement/ Acton Negative lad CS ne Gand any vattage present? fies [ower Ino [eos [ES_ CHECK THE CRANK DETECT CIRCUIT FOR A SHORT TO VOLTAGE WITH IGNITION SWITCH DISCONNECTED Igntcn OFF Disconect gion switch C250, MoneePotive Lead | CBS L any valtage present? [eowae INSTALL a now anton ston REFER to. unt Sits (21-05 Steeing Colurn Stches, Remove and instal. [C4 CHECK THE CRANK DETECT CIRCUIT FOR A SHORT TO VOLTAGE WITH BCM (BODY CONTROL NODULE) DISCONNECTED Tanto OFF Disconect BOM CZ2EOF. Manse Pee Lead essurement/ Aeon Negative Lead = — = any voltage present? [fee [REPAR he creat Ino [eats [Cé_CHECK FOR CORRECT PCM (POINERTRAIN CONTROL MODULE) OPERATION Discorect ond nopect al PGN cenecios Ropar Te cans init naw comects or taming - ean moa prs) 5 eran arte gna ne oman 1 pind pata pn a ces Recomoc al comacins. Mako suo they Seat ond ch core, partes sstem ard domi I he concen St ese sth conoern stil present? fYes [CHECK QRSIS o-any sepia Toannca SoviceBulsrs (TSG5) Wa TSR axes kx wis cence, DISCONTINUE te lest arg FOLLOW the TSH isruciors, fro Teena Sevce Bulere (780s) cares tus corcem, INSTALL tow PCM, REFER to Putin Cot Nhl PC) GA Peco Ere Corts 7 Due HE C2AWIEPS)- Mi Ino} ne syste sopra corey atts Une. Te concen may have Das) asad by moodle ComarlaTs ADDRESS Te fax cause ot ary comer’ op sues, (Ce CHECK FOR CORRECT CM [BODY CONTROL MODULE) OPERATION Discomect and inspect al BGM connector Repar cones nts new constr taminas - lan mode prs) 1 rue ober prenatal now torres 1 usted pine ntl en pn as ace econo! al capers, Mako sss they saat eel lc comet, (prt the system ar etm the concern ssl presen athe concern sil present? [Yes [GHECK QRSIS ary sppcatleYochned Savice Busirs S65) Va ISB ois lis concen DISCONTINUE Te stand FOLLOW to TSB nsvuctrs. I no Tchncal Sovice Bulli (TSss) ages Ins concer, INSTALL 2 now SCM REFER to Body Conia Ncsle CM) -Lsp (10-0 Mutfncionelecrenc Meals Remeval adsl) REFER to Bod Canta Nols CML BHD (610-0 Mutuncten Elston Mees, Removal an ntl) No [Thess epsang coral tis ra, The concon ris ave tao cased by ose comers ADDRESS et caicecot ay comecir on sues ‘Component Tests) Starter Motor -Poive Cre Tst [NOTE: Aivays mate the matter connection athe compart tema rather than a th wn endo he conto: Making a cormecen a the wing end (Ofte cornactor cou est fase ratings because fe mee Wil a DOK ep a igh rasstsnce btuee the wing corner and comoarent 1 Make sso to at is tty charges REFER to fate (414.01 Bate, Moutbng and Cables, Dagnsis and Testing) 2 Porta a ater antes.2 Connac ramet stair itch between state solani 'S"femial and bate postive trina 4 connect tn mutmotr posite lad tothe batery postive post, Connect th negate lad fhe Stat cna“ termina eae 5 Place ger selector leverin Park or Nut 68 Emage theres starter svtch, Read and ec the vole. The vane easng shouldbe 05 vt ess 7 tne votage eadng is 05 vo oss, pelo Stator Moor - round Citcut Test ins section, £8 vatagereacng geste than 05 vt san cation of excesive sistance inthe connctons the postive ater cate onthe ster sole Remove to cates fom he sdlenad"E""S and'N teminals. Clean the cae and comactons and ens he Cals fo the cone tsmanae. Repel Steps 3 hough © © the votape reasngis til gtr than 05 vot when checked th Meinl move the mimes natives a to the stata cleo" tinal 10 With he gsr selector ver n Pasko Net, ennaye the emote state wich, Read and rect vlogs 1 Ihe votage retinas the" tominais toner than 05 vat the cance inthe conection athe starter soena rin the sole cntt, Install ‘anew ste mer REFER fo Site to (03.06 Staring System 26L Dursec HE (122KW/155PS) M4, Remove andstalaten). 121 votag eacing taken athe seenld “tomas rater than 05 vel ae cleaning the catlos and conactns a the sland the cance a ‘he postve batty cate comecton rn te postive bat catle fsa Clean tno posave Day abe cornocten Is dos Nt esave He ‘congo rela s Now posvebaltay cae Starter Motor -Groune Cite Tet ‘Aso cra conan can be casey resstnce te rnd or tim pron the cana ct. This sce checks thevtage pin the 1. Connect eta star switch beween state soko "S"temina a th atany postive termina 2 Connect th mutimstr paste led tothe star ctr reusing the cennacton must be closn and te of nist or ress). Comec he negative lead to te nate bate tern 3 Place ger selector leven Park o Nutra «4 Ema the remaster switch ae cra he engine, Read an rca the vlog reading. The rating shouldbe 05 vat ores 9 te ytan edna eserthan Sac Menegeve cee comers te te, ie bay ee aes nd eS 6 Ifthe votape easing is grater than 0.5 vol ital anew negate bata cable, 7 tthe votape rang is es than 05 vt andthe engine sl cranks sony instal an stat reer. PREFER to Se ina (20308n Stag System 26L Dutaee HE (IZAKW 1259) Nia, Removed nStalaten).woos'ubelpieo303-068 Starting System = 2.5L Duratec-HE (122kW//165PS) - Mt 2015 2016 Ranger ICA General Procedures Procedure evson date 097282014 Starter Motor Drive Gear and Flywheel Ring Gear Inspection Activation + A\warnine: Before beginning any service procedure inthis section, refer to Safety Warnings in Section 100.00 General information. Feilire to follow this instruction may result in serious personal injury. Refer to: Heath and Safety Procautions (100-00 General information, Description and Operation) 2. Refer to: Statter Motor (303-06A Starting System - 2.5L Duratec-HE (122kW/165PS) - M4, Removal and Installation). 3. Check the wear patterns on the starter dive gear and the flywheel or flexplate ring gear. If the wear pattem is normal, install the starter motor. Refer to: Statler Motor (303-06A Starting System - 2.5L Duratec-HE (122kW/165PS) - Md, Removal and Installation). Lie 148835 e 4. If the starter drive gear and the flywheel or flexplate ring gear are not fully meshing and the gears are scored or ‘damaged, install a new starter motor. Refer to: Starter Motor (303-06A Starting System - 2.5 Duratec-HE (122kW/165PS) - M4, Removal and Installation). 5. If necessary, install a new flywheel or flexpiate. Cenriahe $2016 Ford Mor Comearywoos'ubelpieo303-068 Starting System - 2.5L Duratec-HE (122kW//165PS) - Ml 2015+ 2016 Ranger ICA Removal and Installation Procedure ewson date: 04/6/2011 ‘Starter Motor Base Part Number. 11000 Removal NOTE: Removal steps in this procedure may contain installation details. 1, Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 2. Remove Front LH wheel only. Refer to: Wheel and Tie (204-044 Wheels and Tires, Removal and Installation). 3. Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Descristion and Operation) 4 4. Torque: 10. Nm 2. Torque: 10 Nm 3. Torque: 10 Nm131929 Installation 1. To install, reverse the removal procedure. yr © 2016 For Motor Company2015 2016 Ranger ICA 303-068 Starting System - 2.5L Duratec-HE (122kW//165PS) - Ml Procedure reson date 05/12/2015 Removal and Installation Start Inhibit Switeh Removal NOTICE: Make sure that the clutch pedal remains in the rest position. 1 Installation 1. NOTICE: Make sure that the clutch pedal remains in the rest position. To install, reverse the removal procedure. Cepyrahe 2016 Fort Matar Companywoos'ubelpieo303-068 Starting System - 2.21. Duratorg-TDCi (88KW/120PS) - Puma/2.2L. Duratorg-TDCI 2015 - 2016 (96kW//130PS) - Puma/2 2L Duratorg-TDCI (110kW//150PS) - Puma Ranger ICA Procedure revise Description and Operation a ee ‘Starting System - Overview Starting System The stating system conto the cranking ofthe engine, The starter motor is enabled by the starter relay when the relay i activated by the ECM. The PCM receives inputs from the ignition switch, ICM automatic transmission, CPP ‘manual transmission and the BOM before activating the starter relay to initiate cranking of the engine. Starting System-with Auto-Start-Stop ‘The Auto-Start-Stop system helps reduce fuel consumption by automatically shutting off the vehicle's engine while the vehicle is at a complete stop and resterting the engine when the clutch pedal is pressed. The Auto-Start-Stop system Is automatically enabled whenever the ignition is tumed on, The vehicle may restart automatically in order to ‘maintain interior comfort or to recharge the battery. Refer to the Owner's Literature for additional information, conyrone «2018 Fra Meter Company303-068 Starting System - 2.21. Duratorg-TDCi (88KW/120PS) - Puma/2.2L. Duratorg-TDCI 2015 - 2016 (96kW//130PS) - Puma/2 2L Duratorg-TDCI (110kW//150PS) - Puma Ranger ICA Procedure revise Description and Operation dbte 027152016 Starting System - System Operation and Component Description ‘System Operation ‘System Diagram fin! Network Message Chart Module Network Input Messages Powertrain Control Module (PCM) Broadcast Message Originating Module Message Purpose ignition status BOM Provides the BOM with ignition mode Starting System‘The starting system controls the cranking of the engine. Under normal operation, when the ignition is tumed t0 START, the PEM receives the following inputs: Request to crank engine message from the BCM \Voltage signal on the crank detect circuit from the ignition switch, PATS enable message from the BCM Correct transmission park or neutral input from the automatic transmission Correct bottom of travel input from the CPP switch (manual transmission), When the PCM receives the correct inputs, voltage and ground is supplied to the starter relay coil. When the starter relay coil is energized, it provides voltage to the starter solenoid, allowing the starter motor fo crank the engine, ‘The POM disengages the starter once an engine Revolutions Per Minute (RPM) threshold is reached, a set crank time is exceeded or the ignition is tured OFF. Auto-Start-Stop System ‘The Auto-start-stop system helps reduce fuel consumption by automatically shutting off the vehicle's engine while the vehicle is idling at a complete stop, and restarting the engine when the clutch pedal is pressed. The system can be disabled through the auto-start-stop contral switch. The Auto-start-stop system is automatically enabled whenever the ignition is tumed on. Tho engine automatically stops when: * the vehicle is stopped, and + the transmission is in neutral, and + the clutch pedal and accelerator pedals are released. The engine automatically restarts when: the clutch pedal is pressed. the Auto-star-stop system is cisabled through the auto-start-stop control switch the battery has a low state of charge. itis necessary to maintain interior comfort. the blower fan speed is increased or the climate contral temperature is changed. lan electrical accsssory is turned on or plugged in, there is low brake vacuum. ‘The Auto-statt-stop system may not tum the engine off under these conditions the HVAC system is in A/C, heat or defrost modes. the rear defroster is on, the battery has a low state of charge. the battery temperature is below 5°C (41°F) or above 60°C (140°F). the engine temperature is balow 46°C (115°F). the engine temperature is below 60°C (140°F) and the HVAC system is in heat mode, the steering wheel is turned rapidly or is at a sharp angle. Vehicle speed of greater than 4 kmh (2,5 mh) for more than 2 seconds has not occurred. the vehicle is on a stoop road grade. elevation is approximately above 3,048 meters (10,000 feet) If the system detects a malfunction, it tums off and the OFF lamp on the auto-start-stop control switch illuminates continuously. If the OFF lamp remains on after an ignition cycle, a malfunction is indicated, Refer to the Owners Literature for additional information. Passive Anti-theft System (PATS) This vehicle may be equipped with PATS. PATS disables the engine from starting if an unprogrammed PATS key is Used or an invalid PCM ID is received. The PATS is controled by the BCM. If there is a PATS concem that disaties, the IBC displays a corresponding message in the message center. the engi Refer to s . ‘Theft System (PATS), Description and Operation). (419-018 Passive Anti ‘Component Description Body Control Module (BCM) Refer to: Modu‘e Controlled Functions - Component Location (419-10 Multifunction Electronic Modules, Description ‘and Operation).Passive Anti-Theft Transceiver I equipped with PATS, Refer to: Passive Anti-Theft System (PATS) - System Operation and Component Description (419.01B Passive Anti- ‘Theft System (PATS), Description and Oparation). Integrated Keyhead Transmitter (KT) If equipped with PATS, Refer to: P ft Syst : ‘Theft System (PATS), Description and Operation). on (419-018 Passive Anti- Ignition Switch Refer to: Steering Wheel and Column Electrical Components (211-05 Steering Column Switches, Diagnosis and Testing). Powertrain Control Module (PCM) ‘The PCM provides power and ground to the starter relay to initiate cranking of the engine. Coppa 2016 Fora water Company308.068 Stats 5ystom -2 21 DuratrTDCi (SRW 120") - Pana’ A. Det TOC GEKWSYSOPS)- Puna? 2. Durston TO 2015-2046 Ranger ICA (rowwrrsces) Pane Dasgnoee aa Testy Pcxde orgen ‘Starting System Ingpecton and Verfation 4. Vent the cust cncem by aperbg the stating system 2 Before agresing ops te staring system inspect he flowing tens 1+ Chock he ate fr nse, damaged or coma connectors. 1 Check ie gente or ode, darian or coed cornectens 1 Chock engne ana tat genes fo lose, damaged ot ceded comectos, {Cheek high eure BU8 fr eoue of cones comectons 1 ey tses ores irks 1 Insp! wna fea and connectors 8 Ghote bate canton ad site of hare REFER to let) C1401 Satay, Moxon and Cables, Dagnesis ard Testing) 4 Check for abnormal nen cet css), Refer to secon 41401 Bary Drsin Chak 5. Remove te acossoy deve bot REFER to Accesso Dive Bat 08050 Accessory Drve-3.2L Dusters TDCi (4KW/200PS)-Puna, Remvel an Instalation ‘eat ho crarksft and cach ofthe compos aren Oy the accessor Give el lato ad a ot Sazod Caged. 6 ary alternate accecsones hae ben ait the vice, mak see they sr pent rec 7 an avis cause for an cbseved or rept cone is eure conect the cause (if possible) belorepecesra, 8 Using tte gros scan oo, rte a Diagrestc Towle Cass (DTCs) Ree toe appeal DTC Chart nhs secon Te charts Diagnostics inthis manual assur a cetain sil evl ant knaede of For specie Sagat rats REFER to Dasnosic ethos (10000 Gone roman, bescfpien an Operate) emote chat ore ‘escen "ion Fen |Erare Sar Parerance | tw ee oa, Raerio Paver Cer Eres rs Dnaios PCED) nana GOs ema oso [Panta Scnno | Somaenmnar ars lator = Bree REFER w Coc Eno Conta (02-14 Electanc Erg Coos - aL Dust TOC: [Gis Sac Pings 27 “ “ ‘em ore cnet ore Dascipion Baio Sides 1 [Ravana Sint Cre See | Cota a rand lator —[— oe REFER te Ao ons Nan CAD (ODM econ Neves, Dar a sro) symptom Charts) Sympiom Char: Stating Siem Diagnoses ints manual secure a cetansillevl art knowledge of Fors epecc sti rates REFER fo: Disqrosic Meth 10000 Geer rfomaton, Description ant Operate ‘Symptom Chart. Condition Pesible Sourers ‘eons ie enanecoes nto [Refer tote Proont | GOI PHmNTLA [est [Tie ergneciaks siwy [RetertothePapant [CARRY OUT ihe laa system capone lal Ralero Sire ar Posie Gra Testi ths [est secon The engine cranks ba wil [lotion faut ‘Rola to Powerran GawiclEmissons Dignass (POIED) manual rt statamar sarornase ero be Papont | Goan fhe sae sonsbane — [Starer motor INSPECT te sate: nota raurtng ed oaapeNeTe REPAIR 6s neces franecees cot cerk’ [pamagod texpato [INSPECT tw Roxie er damagod, sig f Wom Tet. REPAIR as necossay Te tar does ret ~ Sister ay | REMOVE te starr ray the ene stops canara, INSTALL anew lay. he Sais cas Jasenpaze tomo toxotto | + wring fo crank REAR crcut COC2SAB (ONGN) fox ashe vag cence, Pinpoint Tests Engine Does Not crank Refer to Wing Disrams Col 20 fr schematc and comectorinfaatin. ‘Normal Operation and Fault Condtions For mere feat, REFER i Slag Syston System Opeaion and Conon Desciion (0.008 Stating Sytem 2.2L Out TDC S8KW/120S) Pura? 2. ‘usta TOC (ea 10S) - Punal2 a. Oaaioe- TDC (CRW TaGPS)- Pura, Descipon afd Coon. DTC Fault Tigger Conations OTe. Besaripon Fault Tigger Conditions Pose9 | Enare Star Petemance [is DIG sets nthe POM when io gies Glected Gunna cank evenL Possible Sources State mot BID state fay ‘Visual Inspection and Diagnostic Pre-checks + ety the BUR fuse 4 na) 1 Ne Se Bh comet Si ie 1 708) 1 Very the BED se 3 (88 + Baty 4 Baty cates PINPOINT TESTA : ENGINE DOES NOT CRANK. [Ai_ PERFORM INSPECTION AND VERIFICATION NOTE: tok swe Dat vaage is ester than 122 vas rir to ae dua Ps oe Tes NOTE: 1s necossry tov bat tod argos 2 9 eave on KS NOM as Sing. The Nes eta can exces 16 ot essa ft ute an aetna cf rrsre Tone Cazes OTC Fe specton and Varian proce nhs scion | wae en obvious cause for an observed o reported conesen found? eu [Corec th ene a racesaany No [Coe [aa RETRIEVE DIAGNOSTIC TROUBLE CODES TCS) ignition ON Ung a agnostic santo, pom sel tests for pei 2 Bg |are any agnostic Trouble Codes (OTCs) present? Yes [Feral Ton Demoste Trouble Cones (OTC) REFER o Digna Toate Sade Goats G07-01 Aartic Transmssion -6-Spoed Auomatc Tarenisson REO, agnois ard Festina). For at CM Diagnostic Tobie Ces (TCS), GOt0 A For at CM Diagnostic Tous Codes (TCs), REFER to tho BCM DTC Chatin hs secon [AS_CHECK THE PCM POWERTRAIN CONTROL MODULE) ENGINE CRANKING (ENG_CRANK PIO PARAMETER IDENTIFICATION) Using a dagrostic sar fo, view tha PCM Parameter ations (PI) Mat sus the tanemisson ism PARK or NEUTRAL Using a agnostic sear ta, vi tha BOM BID ENG CRANK. with the ky inthe START poston‘Does the PCM PID ENG_CRANK change from Insctve to Active? Yes [orem No _[cowas [Ad CHECK THE CRANK DETECT CIRCUIT FOR VOLTAGE AT THE PCM (POWERTRAIN CONTROL NODULE) igntion OFF Discomect BoM 012504 ‘ith te key nthe START postion, mere Positive Lead Measurement? Acton Negative Lad cma ne Gans Ite voltage grestr than 1 volts? Yeo [wa ino [cores [AS_ CHECK THE IGNITION SWITCH Ignscn OFF Cary et te lpn Switch Compenent Test Refer io Weng Disrams Cal a for senamatic an connecter inferntion Dic the ignition etch pase the component test? Yee REPAIR creat COCSSOA BUH) aan open, [No INSTALL anon ton swan, PREFER fo lanton Sch 21-05 Stewing Colurn Swiches, Removal end ists [AG_ CHECK THE TOM (TRANSMISSION CONTROL MODULE) TR_GRANK PID (PARAMETER IDENTIFICATION) ‘Using a dagrostic san fo, wie vig the-TGM EID TR_CRANK, place ie goa Seleciorn PARK and then NEUTRAL Does the ToM PID TR_CRANK read YES in both postions? Yes [Oem No [DIAGNOSE th TR sons REFER inst Te Cota chats 20701 Aura Tansssen 6 Speed Ademate Tarsmston GRE, Daas and sir [AT_CHECK THE PCM POWERTRAIN CONTROL MODULE) IN_GEAR PID (PARAMETER IDENTIFICATION) Using a diagnostic scan ot, vow tho ECM Pareto Iorticatons Ds) ‘ine cosevg the PCM ID IN_GEAR, pace te gear selector in PARK an hen NEUTRAL [Dove the PIO read Non both positions? ves [Soom No |Dapese Oe sae a Dizvesi Tbe Code Chars (07-01 Atamatic Tansmission -6 Speed Automatic Transmission -6RA0,Diagnests ard [estr [Ri_ CHECK THE STARTER RELAY CONTROL OPERATION NOTICE: The following sep uses a et ight to simulate normal crcl loads. Use only he test ght recommended in the Special Tool able at he boginning of hs secon. To avoid connecter erminal Gamage, use the Flex Probe Ki forthe tas light probe connection tthe vehicle Do mat uc the test ligt probe avec on any connector Remove te BB siater ay Messe Posiive Lead essurement) Wepstive Leed "actionessa?) — 155067 1 — 8 startet in 18 stat roy pn 2 ako sro te ansmission i in PARK oF NEUTRAL, With tho kay inthe START postin, obsave the ett Dove the et ight illuminate when the kay ie in the START position? ves [oom INo_[cowais [AB CHECK THE VOLTAGE TO THE STARTER RELAY Tessie Positive Lead Measurement 7 Acton | Negative Load essa?) —_ aus stoner ray ons ls the voltage oester than 11 vols? res [Sowa INo [VERIFY BiB tse 84 Gon)is OX TOK REPAIR To crcul fr ancpan ret OK, REFER tothe Weng Dagar Maral to Gey [be posto causes of he cc short. [AYo_ CHECK THE STARTER MOTOR OPERATION AT THE STARTER RELAY ignton OFF ‘ith te tansmission n PARK oc NEUTRAL, momeniely comect fase ump wire Posive Lead Wesgaenent? Wogstve Leadessa?) 8 stare rear in’ 155067 1 518 stato ry pn Dic the starter engage and the engine errk? INSTALL anon ate ay No [Sova [aw CHECK THE BATTERY GROUND CABLE Tanase Positve Lead ‘Measurement? Aion | _ Negative Lend 148040 +) cura C1100 re the yltages oreater than 1 volts? Yee [eowanz Ne [CLEAN oc NSTALL are nageivebaley cable as necessary) lat? CHECK THE STARTER MOTOR GROUND Tease Positive Lead essurement "aation ave e14an10 Eien Starter motor casethe voltage aester than 11 volte? ves [was [No [OLEAN te stator rete mowing tango ard MAKE SURE ts sary meters covery ours [AYS_ CHECK THE VOLTAGE TO THE STARTER MOTOR wears Postive Lead Measurement Acton Negative Leed Gone ste voltage greater than 1 vots? Yes [Owais [No [CLEAN re igh corer BIR conncion toh bation post CLEAN cr REPAIR a pesitve ball cole asTecessay [ats CHECK THE STARTER MOTOR FOR CORRECT OPERATION Ignten OFF ® a @) Is Die the starter engage andthe engine crank? ‘th te tnsmission in PARK ee NEUTRAL, momealy engage the start (Eee! src starter switch between the state solenoid C17054-1 ("tmina) and 7158-1 Stein ves [owas No INSTALL a nen sate, REFER io. Sates Ide QOSO0C Stag Syston 321 Duran: TOG:(HBKZO0PS) - Puma, Remora nds) [AiG CHECK FOR START INPUT AT THE STARTER Conect Bu stately Discomect Sater slensd C197 With tikoy nthe START postin, measur Pontive Lead ‘Measurement Acton Negative Loa ciara mo Gone ste voltage greater tan 1 vols? Vee rete comecion [No [REPAIR th creat foranepon [GLEAN ester sold "© emral and saver sence connecor GHIEGK te wing ands stax malar fra ase [AT6_ CHECK THE PCM POWERTRAIN CONTROL MODULE) STARTER RELAY CIRCUITS FOR A SHORT TO POWER ight OFF Biscorect POM C1252A Messe Positive Lead Measurement? Acton Negative Load cae noe Ganeorn ! sary voltage resent? es [REPAIR te afacad crea No_[GOvwaur [AGT CHECK THE PCM (POWERTRAIN CONTROL MODULE] STARTER RELAY CIRCUITS FOR A SHORT TO GROUND Tgnton OFF Messe Potive Lead ‘Measurement? Acton Negative eed Cra o Gone Crees o ‘Gount Are the resistance greater tan 10,000 chm? Yee [SOA No [REPAIR te atacad re [At@_ CHECK THE PCM (POWERTRAIN CONTROL MODULE) STARTER RELAY CIRCUITS FOR AN OPEN ease Positive Lead oasurement Acton Negative Lnad CRRA 2 [BIB stat ray pint Crm 2 [U8 stan ray pn2 Are the resitances ees than 3 ohm? Ves [was No [REPAIR the wacled creat [At@_CHECK FOR CORRECT POM (POWERTRAIN CONTROL MODULE) OPERATION igntn OFF Discorect and inspect all BAM connector Rena * conesion insta naw conoctrs otamnas- ean modo pins) 1 amon orb prs nstal non tomas. 1 [Link] pn ntl om pr a paces, Recon! be PUM comectos, Make Sue ey seal an atch conecty, (pert the Systm ad detemnne he concen ssl present Is the concern stil present? ves ORECK OASIS fo ay appicane Techical Sovico Bulins TSBs) 11a ESR ists Yrs Copry, DISCONTINUE ts tst and FOLLOW the 738 rabucirs ‘no Teena Senics Bula (TS3s) avers ts corcam, INSTALL 2 ow BCL REFER to Bowed Cont Node (PCM) GOS140 Electric Engne Cows 82. Duree-TDGi (12/2000) - Pura, Removal an retaliation) | No hesystems opting corecty a his tre Te concen may have ben calsed by Waale comectons ADDRESS hevoa cause | ot ry conectt op sss ‘Unusual Starter Nolse ‘Normal Operation and Fault nations Corec tare operon ries on corct maring fhe stare the engine algnert of the stare rng gear tothe expt and cone functioning othe States essembiy neal gets, beans) Posable Sources + Enane 1 Sttermter 1 Staer meter mauVisual Inspection and Diagnostic Pre-checks + Inept ne stax motor 1 Ineget he Starter meter mounting PINPOINT TEST! UNUSUAL STARTER NOISE. [Bi_ CHECK THE STARTER MOUNTING TnSpect to ler meutng LORS To ose. ls the starter motor mounted securiy? free [oto InSTALL star rete, [REFER to Sa te (28060 String Syste 3 2. Duratr TO (482008) Pre, Remo nan) [Ba CHECK FOR ENGINE NOE Igntn OFF Connect arco starr switch btwean the starter solos CAS7C ("toma and C10TC-1 CS" termina). ewes? Engage the starter nd vey the noses et start portion the noi duet the starter engagement? Frew REFER to. stave Mote Dive Gear ant Flue! Ring Gear inspection (8068 Staring System - 22 Date TDCI ese 20Ps) - Pana? a Our TOC (Soci 130PS)- Puna’? A Durty TOC (HOKW/1200S) Puma, ener Preceaues) oe ———— Ino REFER Enace 20.00 Ene Syne - Gene ion, Des at Testa) to canrue aagress, HOES Ht -Roferto Wing Degas Cll 2 fe schematic nd comet itomaton ‘Norma Operation ana Fault Conctions “The wakoup contol cxcut wakes up the POM porto ene clanking to lw tea rake. The wake-up cont ccs acvaedty te BM when {ho dior dirs opened, aay insetodirothe giben, or when the nen sin tho ON er START poston DTC Fault Tigger Conations oT Description Feult Taper Conditions [510e5 1 [PCI Wako Sat Crcut Shotto Gourd [Ths DIC ses nto BGM when a set fo ound s stcted one wakeup conte creat Possible Sources + sce ECM 1 Wa tominls or comectors PINPOINT TEST C= 2106611 [C1 CHECK THE PEM POWERTRAIN CONTROL MODULE) FOR A SHORT TO GROUND Tandon OFF Discomect BoM C12504 Igntien ON Using aagnoste scan to, clear ne BGM Cortiuous Diagnose Tcube Codes (OTCS} Using adagroste sean leo perfor CM sltest.Is CM DTC BIOES-1 present? [Yes [oor Ino [oowas [C2 CHECK THE PEM POWERTRAIN CONTROL MODULE) WAKEWP SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE igntion OFF Discomect BoM 022800, Ignscn ON Mosse Posiive Lead Measurement? Action Negative lad Cr ave Gos Is any voltage present? [res [REPAIR he creat Ino [estos [63_ CHECK THE PCM POWERTRAIN CONTROL MODULE) WAKEWP SIGNAL CIRCUITFOR A SHORT TO GROUND Ignien OFF Messire Postive Lead | Measurement? Aeon Negative Lad a CA sth resistance greater than 10,000 ohms? fvee [ooo [No |REPAIR he creat (CA_ CHECK THE PCW POWERTRAIN CONTROL MODULE) WAKEUP SIGNAL CIRCUIT FOR AN OPEN Tgnton OFF Mose CE Postve Lead assurement/ Acton Negative lad a CTE othe resatance ess han 3 ohme? free [oomos Ino [REPAIR te creat (GS CHEGK FOR CORRECT BCM (BODY CONTROL MODULE) OPERATION ignton OFF Discoroct and inspect al BGM ceerctors Repair cones stat naw conociss or tarinas- lan mode prs) 1 raged ober pine nstal ne terials 1 pustedout pn ntl te as neces Recon! the BGM comectos. Make Sue they sea andlatch corety (parte he Systm ar tami he cancer is stl peso I the concern stil present? [Yes [CHECK OASIS fo any sepicatle Tetnce Sopice Buen (TSGe) Fa TRH exats fe tig concen, DISCONTINUE tis et ang FOLLOM tho TSE notte po TSR asesses ths concem INSTALL aw BOM REFER to Red Cano Roale Gc -AHD t6-0 muniurcten Eletone Mecues. Removal aa instalation), REFER to. Boas Coa Nooo (SCL (10-10 Mulfuctonelecvonc Moses, ReMoval ad nation. Jno Tne systam sopra corecy at ths ime, The concer may have bast Cased by made Comarians ADDRESS the oa cause ot ary comect’ on suesIC6_CHECK FOR CORRECTPCM (POWERTRAIN CONTROL MODULE) OPERATION. Tgnton OFF Discomect and inspect ll BGM connectors Repar cones stat new conacirs rtrinas- lean module prs) 1 raged orber pre nstal now tomas 1 pusnetea petal non ps as necessary Reconect te PCM comects. Nake sue they seat anh conecty ‘perth system a toma i he concerns Sl peso the concern stil present? [Yes [GHECK OASIS o-ary sppcaut Toanca Sovice Bulsrs (TS65) Ta TSB cuss x Wie ence DISCONTINUE tie test ang FOLLOW to TS nstuciens, no Texted Sevice Bult (TS) addees ths conc, INSTALL 2 ou POM. REFER to Povey Canta Mahle [OCI (Rts44C Elecvonc Engne Cots 8 2 Dust} TDCi 1 40KW 2000S) ums, Rerevel en raion JR [onsyten coy cracy ati ve Tn cca nny Tv cad ose comeio ADDRESS we | eatse of ay comes’ o bn sues. ‘Component Tests) Starter Moor - Positive Citclt Test NOTE: Aivays make the mutnete cometon athe compare tema ater thane th wig ed othe comet Making @ common a the wing end (ort connector cou es fase reacngsOecause To meer WM Dat DEK ep a ig resco between fh Wing Cornero and Component 1 Make swe te bat is uy chaged. Retert 14.01 2 Pasta a bata din test, Refer to 41401 {3 enn fenet stan atch betwoen ster Sleao 'S tema and be bate posite tama 4 Connect the mutimetrpstve lead tothe batley postive post. Connect he aaatve led tothe stata sclenad "Mtl 5 Place ger selector lever in Pato Nut 6. Engage terme stator sven, Read and ecu te votage. Te voape ead staid be 0.5 va eres 7 the votage easing is 05 vo oless, pom Starter Moor Grou Citcut Test ints section 1 vttape rong goer than 05 vot isan caton of wxcesive resistance inthe conactons the postive ater cable onthe str scent Reeve te cates fom he slanod"E""S an"N Teminas Clan hs cables an comachon® an onsite Cabs the core Lamia Repeal Steps 3 hough © | © I the yotape reading is til peter than 05 vot when checked th Meinl, move the mimes naga a to the sata cleo" terinal 10- With he ose selector ver Pace Neutra, engage te rect stat wth, Rea and racer ine vatags 111th votage rang at the "5" tariralis toner than 05 vat, the Conca sin he commen atthe star Scena rin he soleil contats. rsa ‘anon str mar PREFER fo. Sur tor (205080 Staring System -321 Duar: TDG! (14K/200PS) - Puna, Removal and ist). 12 Ifthe vatage acing taken atthe sce teminal is rater than 05 vl fir Clearing the cables and conection a the sla the cence in {ne postve tatty calle comecton on the postive balay catlo tsa? Clean (ho posi Day cable cmectors. is does Meso Te caneory Petal aw postive balay abl, 41-01 Storer Moot - Positive Citelt Test 1 Conect he multimeter postve lea tothe tay pose pst, Connect te nagsve les othe stare sclennd MeiE1osar 2 Place ger selector leven Park or Neutra 23. Engage terme stators, Read and eco te votage, Te voape earn staid be 05 vers 4 the voto easing is 05 voto less, fom Starter Moor Ground Citcut Test ints section 5 A vlan eadna sete than 05 vols an indication of excessive resistance inthe conection the sostve battery cae onthe ster sled Remove te cates frm Ie slenod "6" "S anN teins Clan hs cables a Conchons and onsale CabWs 1 the Cone imal FRepet Steps 3 hcush © 6 {the votone reading is sl rete than 0S vot when rocked et the Merial, move te mutimeter negative lad tthe state sole trminal ‘rdropen Stop 7h votape ean ate “Serials ower han 05 va th conc ine Comets a he Sater Slanad rin he Soleo oma. sta REFER fo Sate Motor (208080 Staring System -9 21 Durstor-TDC: (12KMZNUPS) - Puma, Removal end istic) 8 11 vetape eating taken ate solnod4"S omnis foster tan 05 vol ater ccang the cates and connections fo sena, te cence sn {he postive balety calle comection on the postive bait cate fsa Cleon theposinvebaty cable Comectors ths does Mt ese the concer reals Now postive ally C2 Starter Motor -Ground Creu Tet ‘sow cranking crit can be caused by resistance inthe gre o tum pron cf the cranky circuit. This procedure checks the vallags dep inthe ond creat 1 Conact arate starter svten betwee sate solnot "Stamina athe batiery postive termina 2 enn th timer psive lato the Sate ctr housing he canneton must be cles en eof rus or ras), Comet the regav esd to ‘hermatve bt tena 3 Place gor selector leverin Park o Neue 4 Emaze the rece starter svt and crank the engine: Read an recor the vole readeg. The eating shoud Be 05 voto ess 5 Ifthe votage ratings eter than 05 vt, clos he negtve cable conectons tthe bate the body ground canectons andthe starter gn comectons Retest 6 tthe votone eating is reser than 5 va instal enw nave bate cable 7 Ine votage aang is es than 03 vat and to eng sti carks only, si a nw statrmec PREFER to Sater Ilr (09000 Staring Systam 32. Duaorg TOC. (HHUGH/Z00PS) Pury. Removal and ister).woos'ubelpieo303-068 Starting System - 2.21. Duratorg-TDCi (88KW/120PS) - Puma/2.2L. Duratorg-TDCI 2015 - 2016 (@6kWW/130PS) - Puma/2. 2L Duratorg-TDCi (110kWW/150PS) - Puma Ranger ICA Procedure revista General Procedures naira eet Starter Motor Drive Gear and Flywheel Ring Gear Inspection Inspection 41, Remove the starter motor Refer to: Starter Motor (303-06C Starting System - 3.2L. Duratorg-TDCi (148kW/200PS) - Puma, Removal and Installation). 2. Check the wear patterns on the starter drive gear and the flywheel or flexplate ring gear. If the wear pattem is, ‘normal, then instal the starter motor. Refer to: Starter Motor (303-06C Starting System - 3.2L Duratorg-TDCI (148kWW/200PS) - Puma, Removal and Installation). [oe] evra e 3. If the starter motor drive gear and the flywheel or flexplate ring gear are not fully engaging and the starter motor ive gear is scored or damaged, then instal a new starter motor Refor to: Starter Motor (303-06C Starting System - 3.2L Duratorq-TDCi (148kWW/200PS) - Puma, Removal and Installation). 4. If the teeth on the flywheel or flexplate ring gear are scored or damaged, then install a news flywheel or lexpiate. Ccopyrane © 2018 Ford Mor Companywoos'ubelpieo303-068 Starting System - 2.21. Duratorg-TDCi (88KW/120PS) - Puma/2.2L. Duratorg-TDCI 2015-2016 (96kW//130PS) - Puma/2 2L Duratorg-TDCI (110kW//150PS) - Puma Ranger ICA Procedure revista Removal and Installation date 057122019 Starter Motor Base Part Number: 11000 Removal NOTE: Removal stops in this procedure may contain instalation details. 1 Refer to: Batery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 2, Remove Front LH Wheel only. Refer to: Wheel and Tire (204.044 Wheels and Tires, Removal and Installation). 3, Refer to: Jacking and Lifting - Overviow (100-02 Jacking and Lifting, Descristion and Operation) £210270 4. Torque: 10. Nm 2. Torque: 10 Nm 3. Torque: 10 Nm7. Inspect the starter motor drive gear and flywheel ring gear Refer to: Starter Motor Drive Gear and Flywheel Ring Gear Inspection (303-068 Starting System - 2.2L Duratorg-TDCi (@8kW/120PS) - Pumal2.2L Duratorg-TDCi (96KW/T30PS) - Pumal2.2L Duratore-TOCi (110kW/150PS) - Puma, General Procedures). Installation 1. To Install, reverse the removal procedure. Cora © 2016 Fer Mor Companywoos'ubelpieo303-068Btarting System - 2.2L DuratoreDCi (8 8 kW/120PS) - Puma/2.2L DuratordDCi 2015 - 2016 (8 8k\/130PS) - Puma/2 2L DuratorgDCi (110kW/150RS) - Puma Ranger ICA Procedure revista Removal and Installation pong el Start Inhibit Switeh Removal NOTICE: Make sure that the clutch pedal remains in the rest position. 1 Installation 1. NOTICE: Make sure that the clutch pedal remains in the rest position. To install, reverse the removal procedure, Cepyrghe © 2016 Fort Metor Companywoos'ubelpieo303-06C Starting System = 3.2L Duratore-TDCi (148KW/200PS) - Puma 2015 2016 Ranger ICA Description and Operation Procedure reson date 02/15/2016 Starting System - Overview Starting System ‘The starting system controls the cranking of the engine. The starter motor is enabled by the starter relay when the relay is activated by the PCM, The ECM receives inputs from the ignition switch, TCM automatic transmission, CPP. ‘manual transmission and the BCM before activating the starter relay to initiate cranking of the engine, Starting System-with Auto-StartStop ‘The Auto-Start-Stop system helps reduce fuel consumption by automatically shutting off the vehicle's engine whila the vehicle is at a complete stop and restarting the engine when the clutch padal is prassed. The Auto-Start-Stop system Is automatically enabled whenever the ignition is tumed on. The vehicle may restart automatically in order to ‘maintain interior comfort or to recharge the bettery. Refer to the Oviner’s Literature for additional information, Cena © 2016 Fors ator Company303-06C Starting System = 3.2L Duratore-TDCi (148KW/200PS) - Puma 2015 2016 Ranger ICA Description and Operation Procedure reson date 02/15/2016 Starting System - System Operation and Component Description ‘System Diagram ‘System Operation Network Message Chart Module Network Input Messages Powertrain Control Module (PCM) Broadcast Message Originating Module Message Purpose Ignition status BCM Provides the PCM with ignition mode, Starting System ‘The starting system controls the cranking of the engine, Under normal operation, when the ignition is tumed toSTART, the PCM receives the following inputs: + Request to ctank engine message from the BCM * Voltage signal on the crank detect circuit from the Ignition switeh. + PATS enable message from the BCM + Correct transmission park or neutral input from the automatic transmission * Correct bottom of travel input from the GPP witch (manus transmission). When the PCM receives the correct inputs, voltage and ground is supplied to the starter relay coil. When the starter relay coil is energized, It provides voltage to the starter solenoid, allowing the starter motor to crank the engine, ‘The PCM disengages the starter once an engine Revolutions Per Minute (RPM) threshold is reached, a set crank time is exceeded or the ignition is tumed OFF. Auto-Start-Stop System ‘The Auto-start-stop system helps reduce fuel consumption by automatically shutting off the vehicle's engine while the vehicle is idling at a complete stop, and restarting the engine when the clutch pedal is pressed. The system can be disabled through the auto-start-stop contral switch. The Auto-start-stop system is automatically enabled whenever the ignition is tumed on, ‘The engine automatically stops when: * the vehicle is stopped, and * the transmission is in neutral, and * the clutch pedal and accelerator pedals are released. ‘The engine automatically restarts when: the clutch pedal is pressed. the Auto-star-stop system is disabled through the auto-start-stop control switch, the battery has a low state of charge. itis necessary to maintain interior comfort. the blower fan speed is increased or the climate contral temperature is changed. fan electrical accessory is turned on or plugged in. there is low brake vacuum. ‘The Auto-start-stop system may not tum the engine off under these conditions the HVAC system is in A/C, heat or defrost modes. the rear defroster is on, the batteny has a low state of charge. the battery temperature is below 5°C (41°F) or above 60°C (140°F). the engine temperatura is below 46°C (115°F). the engine temperature is below 60°C (140°F) and the HVAC system is in heat mode, the steering wheel is tuned rapidly or is at a sharp angle. vehicle speed of greater than 4 knvh (2.5 moh) for more then 2 seconds has not occurred. the vehice is on a steep road grade. ‘lovation is approximately above 3,048 meters (10,000 feet) If the system detects a malfunction, it tums off and the OFF lamp on the auto-start-stop control switch illuminates continuously. If the OFF lamp remains on after an ignition cycle, a malfunction is indicated, Refer to the Owners Literature for additional information. Passive Anticheft System (PATS) This vehicle may be equipped with PATS. PATS disables the engine from starting if en unprogremmed PATS key is used or an invalid POM ID is received. The PATS is controled by the BCM. If there is a PATS concem that disaties tha engine, the IPG depays a covesponcing message inthe message cee. Refer to: Bas Theft System (PATS), Descipion and Operation. (419-018 Passive Anti ‘Component Description Body Control Module (CM) Refer to: Modu‘e Controlled Functions - Component Location (419-10 Multifunction Electronic Modules, Description ‘and Operation).Passive Anti-Theft Transceiver I equipped with PATS, Refer to: Passive Anti-Theft System (PATS) - System Operation and Component Description (419.01B Passive Anti- ‘Theft System (PATS), Description and Oparation). Integrated Keyhead Transmitter (KT) If equipped with PATS, Refer to: P ft Syst : ‘Theft System (PATS), Description and Operation). on (419-018 Passive Anti- Ignition Switch Refer to: Steering Wheel and Column Electrical Components (211-05 Steering Column Switches, Diagnosis and Testing). Powertrain Control Module (PCM) ‘The PCM provides power and ground to the starter relay to initiate cranking of the engine. Coppa 2016 Fora water Company308.060 Stating System 3.2L Dust TOO (148KN/200FS)- Pra 2015-2046 Ranger ICA Disgosis ar Testing Pree vse dle ORS201S ‘starting System Inspection and Verifeaion 1. Vest he custom cncem by darating the staring system 2 Bolo aagresingoepareg to staring system inspect ho along tas: + Shock te bates for lose, damsned or conan comets. 1 Chock he generator te, dag ot coed corrects. Sack engne ae tater graunas for oo, camoge or coveded cormecions, ‘Sk nigh cure gs Tose of conooed conection enty uses or fest irks Inspec wing temas encom 3 Shock to bateryconton and state ot cage REFER fo Stl (C1401 Satay, Mourn and Cables, Dugnass ard Testing) 4 Check for abo ntentcurent cars). Refer to secon 4140 Baty Dian Check 5 Remove he acessoy dive bet REFER to Access Dive Ral GOBOSC Accessor Drve-3.2L Duong TDCI (148kW200PS) -Puna, Removal and Insta), ‘eaty io cfaresft and each lho compres aver bythe accessor Give el ao and a et Sazod or caraned 0 ary aftermarket acessories have ben aed tothe vice, make sige they ar ety ed 7 an avis cause for an cbseved or rept concer seu cone the cause (possible) betore proces, 8. Using tho ogres scan too, tive al Dagrestc Trouble Cades (DTCs) Refer tothe aprepae DTC Chartin ths secon Te Charts Diagnoses ins manual secure a cetan sil evl ans knavedge of For specie dag rates REFER to Dragos Methods 10000 Gane eematen, GesctBvon and Operabo PeMoTe char OTe ‘Beseipton ‘Raion sce | Eee Strex Pstomance |i ie enare ranks, Rete To Poveran ConicrEmssions Dapieas POIED) mana) GO io PASGAL TSIA| Foeso [Fak Nowa Swen ext SO Pont TL eu ice — |= pres REFER to Electric Engne Contes (203-14 Ekcronc Engine Cori 321 Duraterg TDCi sex) - Puma) BoM OTE chert ore Deception eon BES |EaMVikow Sonal Grats | SOMAmeR ao ours lat omer |= orcs REFER to: Body Cons Node (CH (1840 Mutton Electionic Noles, Diagwss en esto) Symptom Char) Symptom Chart Starting System Diagnostics in ts manual sume a cri sil va ana kngnlede of Fors-spectic donc practoes REPER lo Duagnsic Mets (10000 Gener rématen,Descrpien an Opec) ‘Symptom Chart Condition Possible Sources ‘aione Theeranesoes etc [RatriomePepont | GMD ies Tieeronecrmia sony [Reeriotie Pant [AREY GUT ata sstan congener Sta Hae Posie Cra Ts [iis exgecreks ba wil ignon fat ‘Relate Powatian ConiclEmissons Dighaais PCED) manual stat [Unsua'sanornase — [Reterotwerrpont | GoivPrmont Tatest estan sens bathe [Str mctar | NSPECT te ater maar marr and egagerirt REPAIR a naceasan erane ors rt cerk [Demnagedtexpste [INSPECT he Rex for dananed. msn of won teh. REPAIR a5 necessary The sat does ret ~ Star ay — | REMOVE the ster ly he ene sees caning. NETALL anew the ge cones serge fomthe texste | * ima ocak REPAIR creat COGZEAB (ONGN) ora shot to atone ten o Pinpoint Tots Engine Does Net Crank ‘lero Ving Dagar Cl 20 fo schematic comet information [Normal Operation and Fault Conations Former erento, REFER to. Saray Sis. System Oneatia and Gamponant Desc (03-008 Stating System -2 21 Duslerg TDCi (SKVW/20PS) -Puma22L rst T0 (Sak 120PS)-Punal2 at Daaiou-TOC (He TPS). Pune, Descipon afd pean). DIC Fault Tigger Contons oT ‘Deseripton Fault Tigger Conaltons Paseo [Engi Ste Petemance Fas EG seis ne BGM when ro gine raion elcid rg Gah we Possible Sources + Baty Baty cafes Sater mat Bui sano ‘Views Ingpection and Diagnose Pre-checks 1 Mey the BUR ose 4 nay ent ho ig carer JB se #708, ‘eet ho BEM fuse 324) PINPOINT TESTA: ENGINE DOES NOT CRANK. [Ai_ PERFORM INSPECTION AND VERIFICATION NOTE: Nake suo bay vatago is grat han 122 vats porto adding Bis iret Tos NOTE: recess fo lave the bate chams comet cing testing, ot laa on its het bons setig. Te ighest stings can exceed 16 vats, resutng nfo fest ests ad stig of Brayostic Mole Cogs (TCS). Paroen ispecton ana Vericaton procedure in ths sacton |was on obvious cause for an observed or reported concern found? Vee. [Corec he came a rcesaary INo_[so0m [AZ_RETRIEVE DIAGNOSTIC TROUBLE CODES (TCH) igntn ON. Using adiagrostic sro, pero seltest for vec Tou eau |are any Diagnostic Trouble Coes (OTCs) present? es [For al Tan Dapioric Taubl Codes (OTC, REFER wo Dingle rouse Cade Chas (007.01 Rulers Tansmssen -6-Spood Aulamatc Warsmisson- RED, Dayne and For at BM Diagnostic Taube Codes (TOS), S010 83 For al ECM Dianostis Tove Codes (DTCs) REFER tothe BOM DTC Chartin hs secton [aS CHECK THE PCW (POWERTRAIN CONTROL MODULE) ENGINE CRANKING (ENG _CRANK) PID (PARAMETER IDENTIFICATION) Usiny a dagrostc canto, view the POM ParaneseISeiicatons PDs) Matsa to ransmsson in PARK of NEUTRAL Using adagrostic scant, vi tha BOM BID ENG CRANK. with the key inthe START postonows the PCM BID ENG_CRANK change fom Inactive to Active Yeo [Oem INo_[cowas [Ra CHECK THE GRANK DETECT CIRCUIT FOR VOLTAGE AT THE PCM (POWERTRAIN CONTROL MODULE) Tgnton OFF, Discanacr Bom ca2%20, ‘tht kay ithe START poston, measur Postive Lead TMesaurement/ Acton Negative Lesa Gane Cra ste voltage pester than 1 vols? Ye [wan No [sows IAE_ CHECK THE IGNITION SWITCH ignton OFF Cary et te Inton Sutch Component Test. Refer fo Wing Dagars Cal 9 fr schematic aed comectr inert Dic the ignition switch pass the component test? [Yea [REPAIR creat COCHOA BUH) a a cpen [No INSTALL a nom gn swich [REFER o Igor Such 21-05 Stoing Colurn Swiches, Removal and insta [Aé_ CHECK THE TOM (TRANSMISSION CONTROL MODULE) TR_GRANK PIO (PARAMETER IDENTIFICATION) Using a dagrostic scan fo whie vier the TOM EID TR_CRANK lace the gear sectorin PARK and then NEUTRAL Does the TCM PID TR_CRANK read YES in both positions? ives [ooo No [DIAGNOSE the TR senso REFER io. Liars Tice Code Chars (907.01 uteri Tansmssen -6Spood Autaatc Tarsmisson - RED, Dayna ad [estno. [AT_CHECK THE PCM POWERTRAIN CONTROL MODULE) IN_GEAR PID (PARAMETER IDENTIFICATION) sing a dagrostc scan fe, viow the BGM Prana rifiatons Ds) ‘wns cosewing te BGM BD IN. GEAR, pace he goa stecerim PARK and hen NEUTRAL, [ows the BID rea No in both positions? Yee [Se No [Disgose he TR serece REFER Diane ma Caia Chas 0701 Aart Tessson-6 Speed aac: Tarsmsson-ORED, Daas ant est) [Ra CHECK THE STARTER RELAY CONTROL OPERATION NOTICE: The following sep uses a tet ight to simulate normal crcultloads. Use only Ue test ght recommended in the Special Tool able at he Beginning ofthe seca. To aveld connecter terminal damage, use the Flex Probe Kit forthe tee light probe connection tthe vehicle Da nat Use the test Iight probe dec on any connector Remove he BB stars ay Mouse Positive Lead TWeasurement) Wegatve ad “actionessa?) — 155067 1 — 8 startet in 18 state roy pn 2 ako sro te ansmission i in PARK oF NEUTRAL, With tho kay inthe START postin, obsave the ett Dove the et ight illuminate when the kay ie in the START position? ves [oes INo_[cowais [AS_CHECK THE VOLTAGE TO THE STARTER RELAY Wass Positive Lead ‘Measurement? Acton | _ Negative Lead e1ssseT ia stoner rr on’ the vltge greater than 1 vols? Yes [SOA No] VERIEY Bu se GDN) OC TOK REPAIR ciclo an open na OR REFER Toe Weg Dnyans na TO Uy possEle causes fe cur sh. [Aid_ CHECK THE STARTER WOTOR OPERATION AT THE STARTER RELAY Igntcn OFF ‘With tte tansmission in PARK or NEUTRAL, merely connect fused ps wire Positive Lead Wessarement) Wepatve Lead "aconessa?) 8 stare rear in’ 155067 1 518 stato ry pn Dic the starter engage and the engine errk? INSTALL ana ate ay No [Sova [aH CHECK THE BATTERY GROUND CABLE Tanase Positve Lead ‘Measurement? Aion | _ Negative Lend 148040 +) cura C1100 re the yltages oreater than 1 volts? Yee [sowanz Ne [CLEAN or NSTALL are nageivebaley cable ws ecessan) lat? CHECK THE STARTER MOTOR GROUND Tease Positive Lead essurement "aation ave e14an10 Eien Starter motor casethe voltage aester than 11 volte? ves [was [No [OLEAN te stator rete mowing tango ard MAKE SURE ts sary meters covery ours [AS CHECK THE VOLTAGE TO THE STARTER WOTOR easue Pontive Lead ‘Meeaurement/ Acton negative Lasd e1mre Going the votge greater han 1 vols? es [oowas [No [OLEAN re igh carer BIB conscton foie tatty past CLEAN REPAIR a pose balay Ca [AYE CHECK THE STARTER MOTOR FOR CORRECT OPERATION Tgnton OFF Cormac 2 femote state sich between ta star Seno C17S5A1 ("amin and C17IS6-1 (torn). ®) 5 Z @ eves ‘ith te tansmisionn PARK oc NEUTRAL, momertelyenaape he starr Dic the starter engage and the engine crank? ves [Owais No INSTALL anon sate, REFER io. Sater lite @OS00C Staring System 321 Durer TDG (BKNIZOOPS) - Pura, Removal nd nstalaten) [até CHECK FOR STARTINPUTAT THE STARTER Connect BB sae ly Discomect Stata slonid C197 ithe key nthe START poston, measure Poative Lead Messurement/ Acton egaive Lasd ewe ste votage pester han 1 vols? Yea [CLEAN esate Sosiaa "Saal and Sara Soma connector: CHECK towing anda Wat mala Tor alone ementcomecton [No [REPAIR ie crcutforonpen [Aié_ CHECK THE PCH (POWERTRAIN CONTROL WODULE) STARTER RELAY CIRCUITS FOR A SHORT TO POWER Tanto OFF DBiscamact Pom Cx2200. ease Postive lead Tessurement/ Acton Negative bese CRT me Goincrewns | =e cond any voltage resent? [Yea [REPAIR te ated creat INo_[sowair [AiT_CHECK THE PCM (POWERTRAIN CONTROL MODULE) STARTER RELAY CIRCUITS FOR A SHORT TO GROUND Ignton OFF Measee Potive Lead Messurement/ Acton Negative Lesa CRT a Gand Cras 0 ‘Goind lar the resistances greater than 10,000 ohms? Yes [was No [REPAIR tho acted creat [At@_ CHECK THE PCM (POWERTRAIN CONTROL MODULE) STARTER RELAY CIRCUITS FOR AN OPEN Tosasue Poslive Lend Measurements Aion Negative Lead Cre 2 [aun stan ray pn Crea 2 [518 stat ray pn? ate the resistances les than 3 ohms? yes [wa [No [REPAIR to ated cron [Af@_ CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION igntn OFF Biscoect and inspect ll BGM ceenectos Repar cones nts new conacto or tama - lan mode prs) 1 drugged erbore pre metal now tora 1 putt penta en pn as acsmry Reconnact ne Deh eamactn eau tay seek ante const (pert the Systm ard deterie ihe concer is stl presen athe concern stil present? [Vea [GHECK OASIS fay appcabie Tecnica Sowics Bins (TSES) [1a TSB ics fa The cars DISCONTINUE Tastes ord FOLLOW be TSa istuctors. no Tecnica! Seco Bulrs (Tse) ales tne corcet, INSTALL aN ECM REFER to Bavarian Cant Nadie (POM GS 40 Elector Engne Cones 3 2. Dualorg TDCi (@KNV/200PS) - Pura, Removal stalin) Fine system is opsratng covery et is tne Ts Concern hay hav bash Causedby Meals Conpeclons ADDRESS thou cause [ota conactr opin seine ‘Unusual Starter Noise [Normal Operation and Fault Conations Corea starter epson res on corect moutiea ofthese othe engine, alonmert ofthe starring get the lexplte and core fucioning othe ‘Statr assembly (eal gers, bears) Possible Sour + Enane 1 Star mater 1 Sister meter maunting Vieual Inepection and Diagnostic Pre-checks4 Inspect the star meter Inspec te stare motor moun, PINPOINT TESTS : UNUSUAL STARTER NOISE, [Bi_ CHECK THE STARTER MOUNTING Tnepec The Sle wen Los oRTaRS ste starter motor mounted securely? i, [REFER to Saar Ms (909.000 Stating System -3 21 Duatr: TOC: (+4KN200°S) Puma, Removal istic). [B2_ CHECK FOR ENGINE NOSE, ignton OFF Connect remote ster snitch between th state solenoid CAE7C (8 temin) and C197C-1 CS" trina) ees? Engage the stor ar vont tne nose oe to tae portion. le the noine dus to the starter engagement? free REFER to. Stace ito Dive Ges ant ah! Ring Gea nspcton 02008 Stating System -22L Dari TDCi anv n2ies) = Pura 2 Durr TOC (SOGH 19S) Pune’? ZL Duley TOC (FHOKW 06S) Puma, Soe Proceaues) REFER to. Enane (90060 Eng Syston - Gael Inomaton, Diagresis and Testing) to cantrue dagress Brves:tt ter to ving Diagrams Cll 23 er schema ara comet intamaton, [Normal Operation ane Fault Conations ‘The wake contol cxcut wakes ub the PGA porto enae snk a lw tea raze The wake cont ccs acne the BCM when ‘he dierdiropons, sey © ReetediaDthe giben, wen fhe gens nthe ON er START poston DTC Fault Tiager Conditions Die Description Fault Tigger Condions BI0E5 11 [EGRI Waker Sat: Oreut Shot te Gard | This DTC sets nthe BOM wan a set fo gurls celled on he wakeup cone crea Posable Sources + BoM + Ea {Wing tomas of comectos PINPOINT TESTC : B10E6:11 [C1_ CHECK THE PCM POWERTRAIN CONTROL MODULE) FOR A SHORT TO GROUND Igntion OF. Discomect BoM C1252 Ignun ON: Using aiagrostic scan to, cla the BGM Cantrunis Diagnostic Teuble Codes (OTC) Using a dagroste scan feo, perm ECM sltest. Is CM DTC BIOES-1 present?free [estos Ino [eotoas [C2_CHECK THE PCN POWERTRAIN CONTROL MODULE) WAKEWP SIGNAL CIRCUITFOR A SHORT TO VOLIAGE: igaten OFF Discomect BoM C22000, Inti ON: Messe Positive Lead Measurement? Adon Negative Lad Cae ne word any vattage present? [Yee [REPAIR he creat Ino [oom [E3_ CHECK THE PCM POWERTRAIN CONTROL MODULE) WAKEUP SIGNAL CIRCUITFOR A SHORT TO GROUND Ignscn OFF Mosse Pesive Lead Measurement? Aeon Negative lad CR a Gord lathe resotance grester than 10,000 che? [yee [Sowa [No [REPAIR the creat [C4 CHECK THE PCM POWERTRAIN CONTROL MODULE) WAKEUP SIGNAL CIRCUIT FOR AN OPEN ignition OFF Mose PootveLeed asourement/ Acton Negative Lead — _ Sa sth resatance lees han 3 ohms? [vee [Sow [no_[REPAR he crear [CE_CHECK FOR CORRECTBCM (BODY CONTROL MODULE) OPERATION Tgnten OFF Biscomect and inspect al ACM cconectos era + cones insta ne conects or teminas - ean moa rns) {mage bere prensa now tominalepes 1 pesneut pr ntl ta ps a neessry Reconoc! the BGM comectos, Make Sue Tey sea and atch comety (pert he Systm ad tome he concern is stl present the concern ail present? [Yee [OHECK OASIS fo ary appcatleToohnew Sorice Busine (TSG0) Ta TSB oxaa fxTs cance, DISCONTINUE Tie stand FOLLOW to Tse nstuctors no Tam adaeeses sconce, INSTALL 3 OW BC REFER fo Body Cana Rlaaue (SCM AHD (418.0 Musiuncion Elecione Mecules, Removal an stalin), REFER to. Bod Can Nose G@CMI-LHD (416-0 Mulfncton Electonc Modes, Removal ad Instat No | Syn epsang coral tis i. Te conzon a av ben awed Ro Comecbrs ADDRESS Oo ea caise ot ny comect ob sues, [E&_ CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATIONIgnten OFF Discoect and inspect al BGM cee Repair conosen stat na conectrs tama - lan moo prs) {mane ober pre nstal now tomas 1 pxstedout pn nial not ps a nest, Recon! he Bol comecto, Make sue ey seat and lth corey (perth Systm ard detain he concer is St present the concern sil present? [Yes [GHECK OASIS any sppicatle Technca Savice Gules [TS65) Fa TSB aust fis concen DISCONTINUE fis est and FOLLOW tn TSE ntetors no Technical Sewice Buti (TSS) ads ths concen INSTALL 3 new POM IREFER to Postman Nhte PCM CAS 4c Eectrone Engne Corte 3.21 Duar TDC (48K 2003) uns, Reraval an raion [No [izesasiem eps corey ths be Te concen may hve Oem caed by meade cones ADDRESS We Reh eaice ot ay comect’ en ues ‘Component Tests) Starter Motor -Posiive Circuit Test NOTE: vay make the mutter connection athe compare teil ahr than the wg enc he connactor Making a conmscen a the wing end (ihe carter cau est fase racrgsbecasce to meri be BOK Up gh rasa etvee tbe Wing corner ad Carparert 4. Ne re tne ately enames Retr ta 4801 2 Pasar a bata dain test. Reto 41401 3. Connect a romct stata ten botwoen starter solenoid 'S"femial and be batty poste trina 4 Connect the mtinstr posite lead to the battery postive post. Connect the native led tthe stare sclenad "Mt termina Ol) Euosar 5 Place ger selector leven Park o Neutra 6, Engage te remce stator ste Read and eco tne votage. Te voape ead staid be 05 vate 7 I the vatage easing is 05 vo oss, em Starter Moor Ground Circ Test ints section A can ey ps imine maga cca bo i isin A cg ei eh of hen cts ier bere Smee 191 yatage ean is Sl grater ian 05 vo when checked the Mein, eve te miner nove la tothe State Soleo’ tmina 10 With he ose selector leven Parc Neutral engage the ramet starter switch Rea and racer the vlogs 1.11 vonage rena st he "S" tern ster then 05 va, the concen sin he comets ate star Scena rahe Sole Cont. rsa PREFER fo. Safe tor (03080 Staring System - 321 Duar: TDC:(14KH200PS) - Puna, Removal and instar). 12 Ite votage aang taken these "toma i rater han 05 ve ir Cente cables and conoctns a he sland the concen {he postive satey cae comecton rh the pstave balay calle ta can thoposahe batay cable cnmactors itis doesnt esa the aneery Petal a Yow postive balay able 401 Starter Motor - Positive Citeult Test 1. Comect tre multimo postve ead tothe balay pose pst. Connect to nogatve ead othe stator slenaé "emiaE1osar 2 Place ger selector leven Park or Neutra 23. Engage terme stators, Read and eco te votage, Te voape earn staid be 05 vers 4 the voto easing is 05 voto less, fom Starter Moor Ground Citcut Test ints section 5 A vlan eadna sete than 05 vols an indication of excessive resistance inthe conection the sostve battery cae onthe ster sled Remove te cates frm Ie slenod "6" "S anN teins Clan hs cables a Conchons and onsale CabWs 1 the Cone imal FRepet Steps 3 hcush © 6 {the votone reading is sl rete than 0S vot when rocked et the Merial, move te mutimeter negative lad tthe state sole trminal ‘rdropen Stop 7h votape ean ate “Serials ower han 05 va th conc ine Comets a he Sater Slanad rin he Soleo oma. sta REFER fo Sate Motor (208080 Staring System -9 21 Durstor-TDC: (12KMZNUPS) - Puma, Removal end istic) 8 11 vetape eating taken ate solnod4"S omnis foster tan 05 vol ater ccang the cates and connections fo sena, te cence sn {he postive balety calle comection on the postive bait cate fsa Cleon theposinvebaty cable Comectors ths does Mt ese the concer reals Now postive ally C2 Starter Motor -Ground Creu Tet ‘sow cranking crit can be caused by resistance inthe gre o tum pron cf the cranky circuit. This procedure checks the vallags dep inthe ond creat 1 Conact arate starter svten betwee sate solnot "Stamina athe batiery postive termina 2 enn th timer psive lato the Sate ctr housing he canneton must be cles en eof rus or ras), Comet the regav esd to ‘hermatve bt tena 3 Place gor selector leverin Park o Neue 4 Emaze the rece starter svt and crank the engine: Read an recor the vole readeg. The eating shoud Be 05 voto ess 5 Ifthe votage ratings eter than 05 vt, clos he negtve cable conectons tthe bate the body ground canectons andthe starter gn comectons Retest 6 tthe votone eating is reser than 5 va instal enw nave bate cable 7 Ine votage aang is es than 03 vat and to eng sti carks only, si a nw statrmec PREFER to Sater Ilr (09000 Staring Systam 32. Duaorg TOC. (HHUGH/Z00PS) Pury. Removal and ister).woos'ubelpieo303-06C Starting System - 3.2L Duratora-TDCi (148KW/200PS) - Puma 2015 2016 Ranger ICA General Procedures Procedure reson date: 087292014 Starter Motor Drive Gear and Flywheel Ring Gear Inspection - 3.2L Duratorq-TDCi (149kW/200PS) - Puma Inspection 41. Remove the starter motor. Refer to: Statter Motor (303-06 Starting System - 3.2L Duratorg-TDCi (148kWW/200PS) - Puma, Removal and Installation) 2. Check the wear pattems on the starter drive gear and the flywheel or flexplate ring gear. Ifthe wear pattem is ‘normal, then install the starter motor, Refer to: Starter Motor (303-06C Starting System - 3.2L Duratorg:-TDCi (148kW/200PS) - Puma, Removal and Installation). e358 eo 3. If the starter motor drive gear and the flywheel or flaxplate ring gear are nat fully engaging and the starter motor ive gear is scored or damaged, then install a new starter motor. Refer to: Starter Motor (303-06C Starting System - 3.2L Duratorg-TDCI (148kW/200PS) - Puma, Removal and Installation). 4. If the teeth on the flywheel or flexplate ring gear are scored or damaged, then install a new flywheel or floxpiate, Copy © 2016 Ferd Matar Companywoos'ubelpieo308-060 Sterting System - 3.2L Duratore-TDCi (148KW/200PS) - Puma 2015 2016 Ranger ICA Removal and instalation Procedure revo date: 05/1272015 Starter Motor Base Part Numbex 11000 Removal NOTE: Removal steps in this procedure may contain instalation details 1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 2. Remove Front LH Wheel only Refer to: Wheel and Tire (204.044 Wheels and Tires, Removel and Installation). 8, Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Descriction and Operation), 5, Refer to: Cooling System Draining, Filling and Bleeding (303-03C Engine Cooling - 3.2L Duratore-TDCi (148W/200PS) - Puma, General Procedures).4. Torque: 10. Nm 2. Torque: 10 Nm 3. Torque: 10 Nm8. Inspect the starter motor drive gear and flywheel ring gear Refer to: Starter Motor Drive Gear and Flywheel Ring Gear Inspection (303-068 Starting System - 2.2L Duratorg-TDCi (88kW/20PS) - Pumal2.2L. Duratorg-TDCi (96KVV/130PS) - Pumal2.2L Duratorg-TDCi (110k\W/150PS) - Puma, General Procedures). Installation 1. To instal, reverse the removal procedure. Copyrare 2018 Fora eter Company2015 2016 Ranger ICA 303-06C Starting System - 3.2L DuratorCi (148 kW/200PS) - Puma Procedure reson date 05/12/2015 Removal and Installation Start Inhibit Switeh Removal NOTICE: Make sure that the clutch pedal remains in the rest position. 1 Installation 1. NOTICE: Make sure that the clutch pedal remains in the rest position. To install, reverse the removal procedure. Cepyrahe 2016 Fort Matar Companywoos'ubelpieo