I am trying to resolve a stalling problem combined with a no crank no start problem after the engine warms up. The engine is a 2.0 Liter four cylinder which will start up run/idle fine for about 15 minutes and then will stall. When trying to crank it over after it stalls the only thing that happens is the click coming from the solenoid and it will not turn over unless given a jump or putting a charge on the battery. It cranks over fine when given a jump and starts but will idle rough and stall again. The fuel filter has been replaced with a new one and the fuses check out OK. If anyone has encountered this type of symptom and solved the issue please provide what your problem turned out to be. I believe the regulator on the alternator is malfunctioning and is allowing the battery to discharge while the engine is running. The voltage will read from 12 to 15 volts when the regulator is slightly moved on a bench test. Can the alternator be causing the stall problem?

 

You didn't say anything about the battery. It is entirely possible the alternator is not putting out anything, but it is also possible the battery is no good.
Not sure I understand exactly what you mean about it being on a test bench. Do you mean the alternator? If the battery is weak and not being charged by the alternator , eventually you will get nothing. Once we know where we stand with the battery and alternator then we start looking for poor connections from the battery on up to the fuse panels etc. Ground connections are equally important and should be checked and cleaned.

 

Battery has a full charge and holds it. Alternator was removed to have it bench tested. Already checked battery prior to removing alternator. Cleaned both post and cable connections. Still in process of observing/looking at all wiring harness leads around engine compartment with nothing obviously loose or and bare wires. Engine does have a small exhaust leak close to O2 sensor. Have looked for leaky, loose and cracked vacuum lines. None obviously leaking or loose. Wondering if fuel pump is cutting out due to its age. Just odd how it runs fine, stalls, and then will not crank over when trying to restart and have to jump start it afterward.

 

You have a poor connection somewhere in the battery supply system and that is why it works with a jump. Looking at electrical connections does nothing ! You need to remove and clean them then reinstall them. Start at the battery and check and clean the connections on the battery positive side and the ground connections from the negative post of the battery to the engine block and the sheet metal. There is a connection that is putting high resistance in the circuit and additional voltage from a jump is required to overcome it. There are tests you could do with a voltmeter, but maybe since you may not have one the next best thing is to get at all the connections and you can do this. Remember connections can look good and still be poor as far as allowing current to pass.

 

I have already started the process of cleaning connections of corrosion and or scaling/grease on the top side. Both cables to the battery post and the post from the inside of the cable connection to the entire battery post with a battery post and cable cleaner. Also have cleaned connections to the alternator and will soon be doing the connections for the starter. The alternator needed some repair work and I will be picking it up and finding out what was in need of repair. Find it odd that the car would stall because of a possible starting circuit issue. Prior to registering to the Ford Forum I had done the cleaning of post and cables. Although, I do know a loss of current to and/or from the charging circuit will cause stalling because of a drop in the battery voltage. Thanks for the input. I do understand that what may look good can hide the initial cause of the problem. Will be working under the car in the morning to check and clean cables to the starter. I will also be reinstalling the alternator tomorrow and will update the results to readers. Just hope it's a positive outcome. Tired of working outside in the cold.

 

Finally resolved the stall and no start issue on daughters 2000 Escort. It turned out that the Alternator was the demon creating the problem of stalling. Alternator was suspected but not able to confirm because it would show it was putting out the proper voltage. However, after having it taken apart and inspected, the brushes were worn and the surface they rode had lost it's contact point surface for one brush and badly worn on the other. Vehicle is running much better with the rebuilt alternator and no longer stalls. Thanks for the comments and input on helping me solve the problem