Test B: Warning Indicator On, System Is Not Charging

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 appropriate SELF-DIAGNOSTICS in ENGINE PERFORMANCE.

Check The Generator B+ (Black/Orange Wire)

Turn ignition off. Disconnect the NGS tester. Measure the voltage between the generator C102b (Black/Orange wire), harness side and ground. Is the voltage equal to battery voltage? If yes, go to next step. If no, repair the circuit. Test the system for normal operation.

Check The Generator Integrity

Disconnect: generator connector C102a or C102c. Start engine. If the generator communication lines are disconnected, the generator will self-excite if it is operated at approximately 2,000 engine RPM for a momentary period of time. It will then operate in a default mode at 13.5 volts until the engine is turned off. With the engine running at approximately 2,000 RPM, measure the battery voltage. Is the battery voltage approximately 13.5 volts? If yes, go to next step. If no, install a new generator. See GENERATOR under REMOVAL & INSTALLATION. Test the system for normal operation.

Check Circuit 904 (Light Green/Orange Wire) For An Open

Turn the ignition off. Disconnect the PCM connector C175. Measure the resistance between the generator connector C102a or C102c terminal No. 2 (Light Green/Orange wire), harness side and the PCM connector C175 terminal No. 45, harness side and between the generator connector C102a or C102c terminal No. 2 (Light Green/Red wire) and ground. See Fig 1 -Fig 3 . Is the resistance less than 5 ohms between the generator and the PCM and greater than 10,000 ohms between the generator and ground? If yes, go to next step. If no, repair the circuit. Test the system for normal operation.

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 appropriate REMOVAL & INSTALLATION 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.

Fig 1: Identifying Generator 3-Pin Connector C102a Terminals (4G Generator)

Courtesy of FORD MOTOR CO.

Fig 2: Identifying Generator 3-Pin Connector C102c Terminals (6G Generator)

Courtesy of FORD MOTOR CO.

Fig 3: Identifying PCM Connector C175 Terminals

Courtesy of FORD MOTOR CO.