2003 Mustang Workshop Manual .

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SECTION 303-06: Starting System 2003 Mustang Workshop Manual

SPECIFICATIONS

General Specifications
Item Specification
Normal engine cranking speed rpm 100-140 rpm
Starter motor no load current draw amperes 60-80 amps
Starter motor normal load current draw 130 amps
Starter motor maximum load current draw amperes 400 amps
Maximum starting circuit voltage drop (engine at normal engine temperature) 0.5 volt

Torque Specifications
Description Nm lb-ft lb-in
Starter motor bolts 25 18 —
Starter motor ground cable nut 25 18 —
Starter motor solenoid S terminal nut 6 — 53
Starter motor solenoid B terminal nut 12 9 —

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SECTION 303-06: Starting System 2003 Mustang Workshop Manual

DESCRIPTION AND OPERATION

Starting System
Starter Motor

The starter motor is a 12-volt unit that has the starter solenoid mounted on the drive end housing and
functions as follows:

The current flows through the solenoid energizing coil until the solenoid plunger is at the end of
its travel.
The plunger closes a set of contacts that bypass the energizing coil, letting the holding coil keep
the starter drive engaged and passing starting current to the starter motor.
The motor is energized when the starter solenoid contacts are closed.
The starter drive engages the flywheel ring gear and starts the engine.
An overrunning clutch in the starter drive protects the starter motor from excessive speed when
the engine starts.

Starter Relay

The starter interrupt relay consists of:

pull in coil and contacts

When the ignition switch is in the START position:

the pull-in coil is activated and pulls the contacts together.

current passes through the starter relay from the engine compartment power distribution box to
the starter solenoid.

Clutch Pedal Position (CPP) Switch

The CPP switch for:

a manual transmission closes when the clutch pedal is depressed, completing the starting
circuit.
an automatic transmission is a jumper inserted in place of the CPP switch to complete the
circuit.

Starter System — Operation

When the ignition switch is turned to the START position the starter relay switches power to the starter
solenoid causing the starter motor to engage as long as:

the clutch pedal is depressed (manual transmission only).

the digital transmission range (TR) sensor is in PARK or NEUTRAL (automatic transmission
only).

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SECTION 303-06: Starting System 2003 Mustang Workshop Manual

DIAGNOSIS AND TESTING

Starting System
Refer to Wiring Diagrams Cell 20 , Starting System for schematic and connector information.

Special Tool(s)
Digital Multimeter
105-R0051 or equivalent

Inspection and Verification

WARNING: When servicing starter motor or carrying out other underhood work in the
vicinity of the starter motor, be aware that the heavy gauge battery input lead at the starter
solenoid is "electrically hot" at all times. A protective cap or boot is provided over this terminal
that must be installed after servicing. Be sure to disconnect the battery negative cable before
servicing the starter. Failure to follow these instructions may result in personal injury.

WARNING: When working in area of the starter motor, be careful to avoid touching hot
exhaust components. Failure to follow these instructions may result in personal injury.

WARNING: When using a remote starter switch or jumper wire, be sure the ignition switch
is in the OFF position and the transmission is in PARK (A/T) or Neutral (M/T) with the parking
brake control fully applied.

1. Verify the customers concern by operating the starting system to duplicate the conditions.

2. Inspect to determine if any of the following mechanical or electrical concerns apply.

Visual Inspection Chart

Mechanical Electrical
Starter motor Battery
Brackets Battery junction box (BJB) fuse ignition switch (40A)
Central junction box (CJB) Fuse 6 (20A)
Fuse 24 (10A)
Damaged wiring harness
Starter Relay
Loose or corroded connections

3. If the inspection reveals an obvious concern that can be readily identified, repair as necessary.

4. If the concern remains after the inspection, determine the symptom. GO to Symptom Chart .

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Symptom Chart

SYMPTOM CHART
Condition Possible Sources Action
The engine does Battery. Go To Pinpoint Test A .
not crank and the Fuse.
relay does click Starter
motor/solenoid.
Ignition switch.
Circuit.
The engine does Fuse. Go To Pinpoint Test B .
not crank and the Battery.
relay does not Starter relay.
click Ignition switch.
Digital transmission
range (TR) sensor.
Starter solenoid.
Clutch pedal
position (CPP)
switch.
Circuit.
The engine Battery. Go To Pinpoint Test C .
cranks slowly Starter
motor/solenoid.
Circuit.
Unusual starter Starter motor Go To Pinpoint Test D .
noise mounting.
Starter motor.
Incorrect starter
drive engagement.
The starter spins Starter Motor INSPECT the starter motor
but the engine mounting and engagement.
does not crank REPAIR as necessary.
Damaged INSPECT the flywheel/ring
flywheel/ring gear gear for damaged, missing or
teeth. worn teeth. REPAIR as
necessary.

Pinpoint Tests

PINPOINT TEST A: THE ENGINE DOES NOT CRANK AND THE

RELAY DOES CLICK

Test Step Result / Action to Take

A1 CHECK THE VOLTAGE TO THE STARTER RELAY
Measure the voltage between the starter relay pin 30, Yes
circuit 1050 (LG/VT) and ground. GO to A2 .

No
REPAIR circuit 1050 (LG/VT)

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for an open. TEST the

system for normal operation.

Is the voltage greater than 12.5 volts?

A2 CHECK THE VOLTAGE TO THE STARTER MOTOR
SOLENOID
Measure the voltage between the starter motor solenoid Yes
positive terminal and ground. GO to A3 .

No
REPAIR circuit 2037 (RD) for
an open. TEST the system
for normal operation.

Is the voltage 12.5 volts or greater?

A3 MANUALLY JUMP THE STARTER MOTOR
Connect one end of a fused (15A) jumper wire to the Yes
positive terminal of the battery and touch the other end to GO to A4 .
the starter solenoid S-terminal.
No
INSTALL a new starter
motor. REFER to Starter
Motor—3.8L or Starter
Motor—4.6L . TEST the
system for normal operation.

Does the starter solenoid engage?

A4 TEST THE STARTER MOTOR RELAY
Carry out the relay component test on the starter motor Yes
relay. Refer to the relay component test in this section. REPAIR circuit 33
Does the starter motor relay test good? (WH/PK)/262 (BN/PK) for an
open. TEST the system for
normal operation.

No
INSTALL a new starter motor
relay. TEST the system for
normal operation.

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PINPOINT TEST B: THE ENGINE DOES NOT CRANK AND THE

RELAY DOES NOT CLICK

Test Step Result / Action to Take

B1 CHECK CIRCUIT 33 (WH/PK) FOR VOLTAGE
Disconnect: Starter Motor Relay. Yes
Key in START position. GO to B10 .
Measure the voltage between the starter motor relay pin 85,
circuit 33 (WH/PK) and ground while holding the key in the No
START position. For automatic
transmissions, GO to
B2 . For manual
transmissions, GO to
B5 .

Is the voltage greater than 10 volts?

B2 CHECK CIRCUIT 32 (RD/LB) FOR VOLTAGE AT THE DIGITAL
TR SENSOR
Key in OFF position. Yes
Disconnect: Digital TR Sensor C110. GO to B3 .
Key in START position.
Measure the voltage between the digital TR sensor C110 pin No
10, circuit 32 (RD/LB) and ground while holding the key in the GO to B7 .
START position.

Is the voltage greater than 10 volts?

B3 CHECK CIRCUIT 33 (WH/PK) FOR OPEN
Key in OFF position. Yes
GO to B4 .

No
REPAIR circuit 33
(WH/PK). TEST the
system for normal
operation.

Measure the resistance between the digital TR sensor C110 pin

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12, circuit 33 (WH/PK) and the starter motor relay pin 86, circuit
33 (WH/PK).
Is the resistance less than 5 ohms?
B4 CHECK DIGITAL TRANSMISSION RANGE (TR) SENSOR
ADJUSTMENT
Carry out the digital TR sensor adjustment. Refer to Section Yes
307-01 . INSTALL a new digital
Is the digital TR sensor adjusted correctly? TR sensor. TEST the
system for normal
operation.

No
ADJUST the digital TR
as necessary. TEST the
system for normal
operation.
B5 CHECK CIRCUIT 32 (RD/LB) FOR VOLTAGE AT THE CLUTCH
SWITCH OR JUMPER
Key in OFF position. Yes
Disconnect: Clutch Pedal Switch C255. GO to B6 .
Key in START position.
Measure the voltage between the clutch pedal switch C255 pin No
2, circuit 32 (RD/LB) and ground while holding the key in the GO to B7 .
START position.

Is the voltage greater than 10 volts?

B6 CHECK CIRCUIT 33 (WH/PK)/32 (RD/LB) FOR OPEN
Key in OFF position. Yes
Measure the resistance between the clutch pedal switch C255 INSTALL a new clutch
pin 1, circuit 33 (WH/PK)/32 (RD/LB) and the starter motor relay pedal switch. TEST the
pin 86, circuit 33 (WH/PK)/32 (RD/LB). system for normal
operation.

No
REPAIR circuit 33
(WH/PK)/32 (RD/LB).
TEST the system for
normal operation.

Is the resistance less than 5 ohms?

B7 CHECK FOR VOLTAGE AT FUSE 6
Key in OFF position. Yes
Disconnect: Fuse #6. REPAIR circuit 32
Key in START position. (RD/LB). TEST the

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Measure the voltage between the central junction box fuse 6, system for normal
circuit 33 (WH/PK) and ground while holding the key in the operation.
START position.
No
GO to B8 .

Is the voltage greater than 10 volts?

B8 CHECK CIRCUIT 1050 (LG/VT) FOR VOLTAGE
Key in OFF position. Yes
Disconnect: Ignition Switch C209. GO to B9 .
Key in ON position.
Measure the voltage between the ignition switch connector No
C209 pin B4, circuit 1050 (LG/VT) and ground. REPAIR circuit 1050
(LG/VT). TEST the
system for normal
operation.

Is the voltage greater than 10 volts?

B9 CHECK THE IGNITION SWITCH
Carry out the ignition switch component test. Refer to Yes
REPAIR circuit 33
Refer to Wiring Diagrams Cell 149 for schematic and connector (WH/PK). TEST the
information. system for normal
operation.
. No
Does the ignition switch test good? INSTALL a new ignition
switch. TEST the
system for normal
operation.
B10 CHECK CIRCUIT 1205 (BK) FOR OPEN
Key in OFF position. Yes
INSTALL a new starter
motor relay. TEST the
system for normal
operation.

No
REPAIR circuit 1205
(BK). TEST the system
for normal operation.

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Measure the resistance between the starter motor relay pin 86,
circuit 1205 (BK) and ground.
Is the resistance less than 5 ohms?

PINPOINT TEST C: THE ENGINE CRANKS SLOWLY

Test Step Result / Action to Take

NOTE: Before beginning this test, be sure that the battery is tested and fully charged.
C1 CHECK THE VOLTAGE TO THE STARTER
Key in OFF position. Yes
Measure the voltage between the starter motor GO to C2 .
solenoid positive terminal and ground.
No
REPAIR the circuit between the
battery and the starter solenoid.
CLEAN and TIGHTEN the
connections at the battery terminals.
TEST the system for normal
operation.

Is the voltage 12.5 volts or greater?

C2 CHECK MOTOR GROUND CIRCUIT
Carry out the Motor Ground Circuit test; refer to Yes
Component Tests in this section. INSTALL a new starter motor.
Is the ground OK? REFER to Starter Motor—3.8L or
Starter Motor—4.6L . TEST the
system for normal operation.

No
REPAIR the ground circuit as
necessary. TEST the system for
normal operation.

PINPOINT TEST D: UNUSUAL STARTER NOISE

Test Step Result / Action to Take

D1 CHECK THE STARTER MOTOR
MOUNTING
Inspect the starter motor mounting Yes

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brackets for cracks. GO to D2 .

Check the starter motor mounting
bolts for looseness. No
Is the starter motor mounted REINSTALL the starter motor correctly. REFER to
correctly? Starter Motor—3.8L or Starter Motor—4.6L in this
section.
D2 INSPECT THE STARTER MOTOR
Remove the starter motor; refer to Yes
Starter Motor—3.8L or Starter INSTALL a new starter motor. REFER to Starter
Motor—4.6L in this section. Motor—3.8L or Starter Motor—4.6L in this section.
Inspect the starter motor for TEST the system for normal operation.
damage.
Is the starter motor damaged? No
CHECK the starter drive. REFER to Component
Tests, Starter Drive Test in this section. INSTALL a
new starter motor. TEST the system for normal
operation.

Component Tests

Starter Motor —Voltage Drop Test

WARNING: When servicing starter motor or carrying out other underhood work in the
vicinity of the starter motor, be aware that the heavy gauge battery input lead at the starter
solenoid is "electrically hot" at all times. A protective cap or boot is provided over this terminal
that must be installed after servicing. Be sure to disconnect the battery negative cable before
servicing the starter. Failure to follow these instructions may result in personal injury.

WARNING: When using a remote starter switch or jumper wire, be sure the ignition switch
is in the OFF position and the transmission is in PARK (A/T) or Neutral (M/T) with the parking
brake control fully applied.

Always make the Digital Multimeter connections at the component terminal rather than at the wiring
end connector. Making a connection at the wiring end connector could result in false readings because
the meter will not pick up a high resistance between the wiring connector and the component.

Starter Motor—Motor Feed Circuit

1. Make sure the battery is fully charged. Perform a battery load test. For additional information,
refer to Section 414-00 .

2. Disconnect the inertia fuel shut off (IFS) switch.

3. Connect a remote starter switch between the starter solenoid S-terminal and the battery positive
(+) terminal.

4. Connect the Digital Multimeter positive lead to the battery positive (+) post. Connect negative
lead to the starter solenoid M-terminal.

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Item Part Number Description

1 — S-terminal
2 — Remote starter switch
3 10653 Battery
4 — Digital multimeter
5 — B-terminal
6 — M-terminal

5. Engage the remote starter switch. Read and record the voltage. The voltage reading should be
0.5 volt or less.

6. If the voltage reading is less than 0.5 volts, go to the Starter Motor-Ground Circuit Component
Test.

7. If the voltage reading is greater than 0.5 volts, this an indication of excessive resistance in the
connections, the positive battery cable or in the starter solenoid. Move the Digital Multimeter
negative lead to the starter solenoid B-terminal and repeat the test. If the voltage reading at the
B-terminal is less than 0.5 volts, the concern is either in the connections at the starter solenoid
or in the solenoid contacts. Go to Step 8. If the voltage reading is greater than 0.5 volts at the B-
terminal, the concern is either the positive battery cable or connections. Go to Step 9.

Item Part Number Description

1 — S-terminal
2 — Remote starter switch
3 10653 Battery
4 — Digital multimeter
5 — B-terminal
6 — M-terminal

8. Remove the cables from solenoid B-, S- and M-terminals. Clean the cables and connections
and reinstall the cables to the correct terminals. Repeat Steps 3 through 6. If the voltage drop

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reading is still greater than 0.5 volts when checked at the M-terminal and less than 0.5 volts
when checked at the B-terminal, the concern is in the solenoid contacts. Install a new starter
motor. Refer to Starter Motor—3.8L or Starter Motor—4.6L .

9. Clean the positive (+) battery cable connections. Repeat the test at the starter solenoid B
terminal. If the voltage is greater than 0.5 volts, install a new positive battery cable.

Starter Motor—Ground Circuit

A slow cranking condition can be caused by resistance in the ground or return portion of the cranking
circuit. Check the voltage drop in the ground circuit as follows:

1. Connect the Digital Multimeter positive lead to the starter motor housing (the connection must
be clean and free of rust or grease). Connect the negative lead to the negative (-) battery
terminal.

Item Part Number Description

1 105-R0057 Digital multimeter
2 10653 Battery
3 — S-terminal
4 — M-terminal
5 — B-terminal
6 — Remote starter switch

2. Engage the remote starter switch. Read and record the voltage. The voltage reading should be
less than 0.3 volts.

3. If the voltage is greater than 0.3 volts, clean the negative cable connections at the battery, body
ground connections, and the starter ground connections. Retest.

4. If the voltage is greater than 0.3 volts, install a new cable. If the voltage reading is less than 0.2
volts and the engine still cranks slowly, install a new starter motor. Refer to Starter Motor—3.8L
or Starter Motor—4.6L .

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SECTION 303-06: Starting System 2003 Mustang Workshop Manual

GENERAL PROCEDURES

Starter Drive and Flywheel Ring Gear Inspection

1. Remove the starter motor. For additional information, refer to Starter Motor—3.8L or Starter
Motor—4.6L in this section.

2. Check the wear patterns on the starter drive gear and the flywheel ring gear . If the wear pattern
is normal, install the starter motor. For additional information, refer to Starter Motor—3.8L or
Starter Motor—4.6L in this section.

3. If the starter drive gear and the flywheel ring gear are not fully meshing and both of the gears
are scored or damaged, install a new starter motor. For additional information refer to Starter
Motor—3.8L or Starter Motor—4.6L in this section.
If necessary, install a new flywheel. For additional information, refer to Section 303-01A or
section Section 303-01B .

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SECTION 303-06: Starting System 2003 Mustang Workshop Manual

REMOVAL AND INSTALLATION

Relay Switch
1. Disconnect the battery ground cable. For additional information, refer to Section 414-01 .

2. Remove the power distribution box cover.

3. Remove the starter relay from the power distribution box.

Installation

1. To install, reverse the removal procedure.

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SECTION 303-06: Starting System 2003 Mustang Workshop Manual

REMOVAL AND INSTALLATION

Starter Motor —3.8L

Removal

WARNING: When servicing starter motor (11002) or carrying out other underhood work in
the vicinity of the starter motor, be aware that the heavy gauge battery input lead at the starter
solenoid (11390) is "electrically hot" at all times. A protective cap or boot is provided over this
terminal that must be installed after servicing. Be sure to disconnect the battery negative cable
before servicing the starter. Failure to follow these instructions may result in personal injury.

WARNING: When working in area of the starter motor, be careful to avoid touching hot
exhaust components. Failure to follow these instructions may result in personal injury.

NOTE: When working on the starter system, make sure the anti-theft system is deactivated (if
equipped.)

1. Disconnect the battery ground cable. For additional information, refer to Section 414-01 .

2. Raise and support the vehicle. For additional information, refer to Section 100-02 .

3. Remove the ground cable nut.

4. Remove the cap.

5. Remove the nuts and position aside the wires.

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6. Remove the bolts and the starter motor.

Installation

1. To install, reverse the removal procedure.

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SECTION 303-06: Starting System 2003 Mustang Workshop Manual

REMOVAL AND INSTALLATION

Starter Motor —4.6L

Removal

WARNING: When servicing starter motor (11002) or carrying out other underhood work in
the vicinity of the starter motor, be aware that the heavy gauge battery input lead at the starter
solenoid (11390) is "electrically hot" at all times. A protective cap or boot is provided over this
terminal that must be installed after servicing. Be sure to disconnect the battery negative cable
before servicing the starter. Failure to follow these instructions can result in personal injury.

WARNING: When working in area of the starter motor, be careful to avoid touching hot
exhaust components. Failure to follow these instructions can result in personal injury.

NOTE: When working on the starter system, make sure the anti-theft system is deactivated (if
equipped.)

1. Disconnect the battery ground cable. For additional information, refer to Section 414-01 .

2. Raise and support the vehicle. For additional information, refer to Section 100-02 .

3. Remove the red starter solenoid safety cap.

4. Remove the starter solenoid nuts and position aside the wires.

5. NOTE: To ease removal, remove the upper, concealed bolt first.

Remove the three starter motor bolts.

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6. Remove the starter motor.

Installation

1. Position the starter motor to the engine.

2. NOTE: To ease installation, first install the two lower bolts finger tight, then install the upper,
concealed bolt. Tighten all three bolts to specification.

Install the three starter motor bolts.

3. Connect the starter motor solenoid and starter motor cable connections.

4. Install the red starter solenoid safety cap.

5. Lower the vehicle.

6. Connect the battery ground cable.

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