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Charge System Warning Never/Always On

  1. Check instrument cluster to determine if warning light is always on or never on. If warning is always on, go to next step. If warning is never on, go to step 8).
  2. Measure voltage at test point "A" on voltage regulator. See Fig 1 . If voltage at "A" is battery voltage, go to next step. If battery voltage is not present, repair open in circuit No. 30 (Red wire).
  3. Disconnect 3-pin generator regulator connector. Turn ignition switch to RUN position. If indicator light is on, repair short to ground in circuit No. 15 (Green/Black wire). If indicator light is off, go to next step.
  4. Connect generator regulator connector. Remove single-pin "S" connector. Using a jumper wire, connect wiring harness "S" terminal, circuit No. 63 (White wire) to positive battery terminal. If indicator light is on, remove jumper and go to next step. If indicator is off, remove jumper and go to step 6).
  5. Remove 3-pin generator regulator connector. Measure resistance between single-pin "S" connector and "S" (center) pin of generator regulator connector. See Fig 1 . If resistance is less than 5 ohms, check for loose or bent pin in regulator or regulator connector. If okay, replace voltage regulator. If resistance is more than 5 ohms, repair open, or cause of excessive resistance, in circuit No. 63 (White wire).
  6. Start engine. Measure voltage at "S" terminal on back of generator. See Fig 1 . If voltage is at least half of battery voltage, go to next step. If voltage is not at least half of battery voltage, test generator for low output. See GENERATOR article in ELECTRICAL section.
  7. Measure voltage at B + terminal on back of generator with engine running at 2000 RPM and all accessories off. See Fig 1 . If voltage is more than 15.5 volts, test generator for high output. See GENERATOR article in ELECTRICAL section. If voltage is less than 15.5 volts, replace voltage regulator.
  8. Remove 3-pin generator regulator connector. Turn ignition switch to RUN position. Measure voltage at wiring harness "I" terminal, circuit No. 15 (Green/Black wire). See Fig 1 . If voltage is less than 10 volts, repair open in circuit No. 15 (Green/Black wire). If voltage is more than 10 volts, go to next step.
  9. With a jumper wire, connect wiring harness "I" terminal, circuit No. 15 (Green/Black wire) to ground. If indicator light is on, remove jumper and go to next step. If indicator is off, replace light bulb or repair high resistance in light socket, or circuit No. 15 (Green/Black wire).
  10. Check for poor ground connections between voltage regulator and generator, generator and engine or engine and battery. If connections are clean and tight, go to next step. If not clean and tight, service connections as required.
  11. Remove single-pin "S" connector from generator. Refer to Fig. Fig 1 . Measure voltage at wiring harness "S" terminal, circuit No. 63 (White wire). If voltage is more than zero, repair circuit No. 63 (white wire). Voltage should only be present when engine is running. Check for swapped wires in generator voltage regulator connector. If voltage is zero, go to next step.
  12. Measure voltage at "S" terminal on back of generator. If voltage is more than one volt and signal light is on with single-pin "S" connector removed, replace generator. If voltage is less than one volt, replace voltage regulator.
Fig 1: Identifying Generator Terminals (Contour & Mystique)
G95J35427Courtesy of FORD MOTOR CO.
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