No Crank - No Start on New Engine Swap First Startup

[TXCrownline225]

Hello. I have a 2004 Crownline 225 with a Volvo Penta 5.7GI-D. I have replaced the engine after suffering a cracked block. Everything is back together but experiencing a no crank/no start situation on initial startup Has new starter, solenoid and starter relay. Installed a remote starter and from battery positive to small “S” stud and starter bumps engine over. Removed the wire (yellow with red stripe) and connected a multimeter. No voltage detected when turning the key to the start position. Replaced the ignition switch. No improvement. Hard to believe it’s the neutral safety switch but that is the next check. Will also pull and check the new relay and test the receptacles it plugs into. Has anyone else experienced this situation or can help in troubleshooting?

Engine details from tag:
5.7GI-D
3869220
4012102935

 

[alldodge]

Welcome aboard
Your motor has a start assist relay and start solenoid.

Key yel/red small wire goes to assist relay via neutral safety

Assist relay has larger yel/red which goes to starter solenoid S terminal

Check fuse item 6

 

[TXCrownline225]

The right edge of the diagram (ignition & neutral safety) are cut off. ive checked the relay in the fuse panel and the fuse. Both are good. Researching this site I found an electrical troubleshooting guide (attached). I followed it to the letter. everything passed until I got to number 6 which indicates a bad relay ground. I will need to trace the ground wire down and check the connection. Any idea where this would be grounded to? I am guessing to the main ground stud on either side of the bellhousing.

 

[alldodge]

Any idea where this would be grounded to?

Figure it goes to the block somewhere, if all else fails or even just make it easier, run another to the block or Bat

 

[TXCrownline225]

Figure it goes to the block somewhere, if all else fails or even just make it easier, run another to the block or Bat

Do you recommend splicing into the relay ground wire (#86 pin) to run a new one?

 

[Scott Danforth]

make sure the controls are in neutral and you dont have a MOB switch tripped

 

[alldodge]

Do you recommend splicing into the relay ground wire (#86 pin) to run a new one?

Yes, if its the ground and 85 has the red/yel

 

[TXCrownline225]

I ran a new temporary ground wire from the engine main ground terminal into the 86 pin receptacle. Tested it and was getting a good ground test now. Re-inserted the relay and tried to start the engine. This time when turning the key to start, I can hear the relay click but still no start. Completed the remaining steps in the troubleshooting guide. The last item on #12 was to jumper and connect the 2 leads on the neutral safety. I ran out of daylight and will try this tomorrow.

 

[TXCrownline225]

make sure the controls are in neutral and you dont have a MOB switch tripped

Yes sir, double checked these items. Without the clip installed on the kill switch (dead man switch) the fuel pumps don’t energize. Installed the clip back on and they activated so I believe it’s working properly. Will splice the 2 leads and bypass the neutral safety switch and try again tomorrow.

 

[dubs283]

Your troubleshooting by passed a few steps. You started investigating at the starter and starter realy, got it to turn over. Then you completely skipped all other components of the starter circuit and went to the exact opposite end and replaced the key switch to no avail

Broad strokes I'm understanding thus far:

Engine turns over jumping the starter solenoid. After repairing the ground for the slave relay the relay now clicks but still no crank/turn over. The issue is between the slave and starter relay/solenoid.

Either faulty output from the slave relay itself or an issue with the relay harness connection/wire to the starter solenoid

 

[TXCrownline225]

Your troubleshooting by passed a few steps. You started investigating at the starter and starter realy, got it to turn over. Then you completely skipped all other components of the starter circuit and went to the exact opposite end and replaced the key switch to no avail

Broad strokes I'm understanding thus far:

Engine turns over jumping the starter solenoid. After repairing the ground for the slave relay the relay now clicks but still no crank/turn over. The issue is between the slave and starter relay/solenoid.

Either faulty output from the slave relay itself or an issue with the relay harness connection/wire to the starter solenoid

i was following the Volvo troubleshooting guide (attached in post #3). Your assessment makes sense and will be something I investigate.