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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 244 (Generators & Regulators - F250-F550 Super Duty (Diesel With Dual Generators)) >> System Tests >> Test A: Warning Indicator Is On With Engine Running, System Is Not Charging

Test A: Warning Indicator Is On With Engine Running, System Is Not Charging

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

  1. Check For Fault Codes In 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. Do generator fault codes exist? If yes, perform appropriate test. See DIAGNOSTIC TROUBLE CODE DEFINITIONS  under SELF-DIAGNOSTIC SYSTEM. If no, go to next step.

  2. Check "I" Circuit (Light Green/Red Wire)

    Turn ignition switch to LOCK position. Disconnect NGS tester. Disconnect upper generator 3-pin connector. Turn ignition switch to RUN position. Measure voltage between ground and upper generator connector terminal No. 1 (Light Green/Red wire). See Figure. Is the voltage greater than 10 volts? If no, go to next step. If yes, go to step  4.

  3. Check "I" Circuit (White/Yellow Wire/Light Green/Red Wire) For An Open

    Turn ignition switch to LOCK position. Disconnect PCM connector C1381c. PCM is located at left rear of engine compartment. Measure resistance between upper generator connector terminal No. 1 (Light Green/Red wire) and PCM connector C1381c terminal No. 1 (White/Yellow Wire). See Figure and Figure . Is the resistance less than 5 ohms? If yes, go to step  6. If no, repair open in wire between upper generator and PCM. See WIRING DIAGRAMS .

  4. Check Voltage To Lower Generator

    Turn ignition switch to LOCK position. Disconnect lower generator 3-pin connector. Turn ignition switch to RUN position. Measure the voltage between the lower generator connector terminal No. 1 (Yellow wire) and ground. See Figure. Is the voltage greater than 10 volts? If yes, go to step  6. If no, go to next step.

  5. Check Lower Generator "I" Circuit (Yellow Wire) For An Open

    Turn ignition switch to LOCK position. Connect upper generator 3-pin connector. Disconnect lower generator 3-pin connector. Disconnect PCM connector C1381c. PCM is located at left rear of engine compartment. Measure resistance between lower generator connector terminal No. 1 (Yellow wire) and PCM connector C1381c terminal No. 4. See Figure and Figure . Is the resistance less than 5 ohms? If yes, go to next step. If no, repair open in Yellow wire between lower generator and PCM. See WIRING DIAGRAMS .

  6. Check Upper Generator Output

    Connect PCM connector. Start engine and let idle. Perform load test on upper generator. See GENERATOR LOAD TEST  under ON-VEHICLE TESTING. Is the upper generator okay? If yes, go to next step. If no, replace generator.

  7. Check Lower Generator Output

    Turn ignition switch to LOCK position. Connect lower generator 3-pin connector. Disconnect upper generator 3-pin connector. Start engine and let idle. Perform load test on lower generator. See GENERATOR LOAD TEST  under ON-VEHICLE TESTING. Is the lower generator okay? If yes, go to next step. If no, replace generator.

  8. Check For Correct PCM Operation

    Turn ignition switch to LOCK position. Disconnect PCM connector. Inspect PCM connector for corrosion and pushed out pins. Connect PCM connector, ensuring it is connected properly. Connect all disconnected connectors. Operate system. Is the concern still present? If yes, replace PCM. If no, system is operating properly at this time.
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