Test F: Warning Indicator Flickers Or Operates Intermittently

Check The Fault Codes In The PCM

Connect New Generation Star (NGS) tester to Data Link Connector (DLC). Turn ignition switch to RUN position. Using NGS tester, perform Powertrain Control Module (PCM) self-test. If no DTCs exist, go to next step. If any DTCs exist, perform appropriate test. See DIAGNOSTIC TROUBLE CODE DEFINITIONS in SELF-DIAGNOSTICS - CNG, FLEX-FUEL & GASOLINE in ENGINE PERFORMANCE.

Check For Loose Connections

Disconnect generator 3-pin connector. Check all generator, battery, and power distribution connections for looseness, corrosion, loose or bent terminals, or loose eyelets. Connect generator 3-pin connector. Are all connections clean and tight? If yes, go to next step. If no, repair as necessary. Test the system for normal operation.

Check Fuse Connection

Start engine. With the engine running, check central junction box fuse 9 (10A) in circuit 35 (Orange/Light Blue wire) for looseness by wiggling the fuse and noting the charging system warning indicator lamp operation. Does the charging system warning indicator lamp flicker? If yes, repair loose fuse connections as necessary. Test the system for normal operation. If no, go to next step.

Check The Battery Voltage

Start engine. With the engine running, and all accessories turned off, measure the voltage at the battery while varying the engine RPM. Is the voltage greater than 15.5 volts? If yes, go to TEST C: SYSTEM OVERCHARGES (GREATER THAN 15.5 VOLTS) . If no, go to next step.

Check The Warning System Indicator Operation

Turn ignition off. Disconnect generator 3-pin connector. Turn ignition on. Connect a fused jumper wire between generator connector terminal No. 1 (Brown/Pink wire) and ground. Does the charging system warning indicator illuminate? If yes, go to next step. If no, repair the circuit. Test the system for normal operation.

Check The PCM Operation

Turn ignition off. Connect generator 3-pin connector. Turn ignition on. Monitor the charging system warning indicator operation. Is the charging system warning indicator illuminated? If yes, the PCM is operating correctly. Recheck the generator circuits (including the generator) for intermittent shorts or opens. Test the system for normal operation. If no, go to next step.

Check For Correct PCM Operation

Check for corrosion and pushed-out pins. Connect any disconnected connectors. Make sure all other system connectors are fully seated. Operate the system and verify the concern is still present. Is the concern still present? If yes, install a new PCM. See COMPUTERIZED ENGINE CONTROLS in REMOVAL & INSTALLATION article in ENGINE PERFORMANCE. Repeat the PCM self-test. If no, the system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. Clear the DTCs. Repeat the self-test.