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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1184 (Charging System - General Information) >> Diagnosis And Testing >> Charging System >> Inspection and Verification

Inspection and Verification

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Batteries contain sulfuric acid. Avoid contact with skin, eyes, or clothing. Also, shield your eyes when working near batteries to protect against possible splashing of the acid solution. In case of acid contact with skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If acid is swallowed, call a physician immediately. Failure to follow these instructions may result in personal injury.
WARNING: Batteries normally produce explosive gases which may cause personal injury. Therefore, do not allow flames, sparks or lighted substances to come near the battery. When charging or working near a battery, always shield your face and protect your eyes. Always provide ventilation. Failure to follow these instructions may result in personal injury.
WARNING: When lifting a plastic-cased battery, excessive pressure on the end walls could cause acid to spew through the vent caps resulting in personal injury, damage to the vehicle or to the battery. Lift with a battery carrier or with your hands on opposite corners. Failure to follow these instructions may result in personal injury.
CAUTION: Do not make jumper connections except as directed. Incorrect connections may damage the voltage regulator test terminals, fuses, or fusible links.
CAUTION: Do not allow any metal object to come in contact with the generator housing and internal diode cooling fins. A short circuit may result and burn out the diodes.
NOTE: While carrying out any pinpoint test, disregard any diagnostic trouble codes (DTCs) set while following any specific pinpoint test. After the completion of any test, be sure to clear all codes in the PCM.
NOTE: All voltage measurements are referenced to the negative (-) battery post unless otherwise specified.
NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the PCM relearns its fuel trim. The vehicle may need to be driven to relearn the strategy.
  1. Verify the customer concern.
  2. Visually inspect for obvious signs of mechanical or electrical damage.
    VISUAL INSPECTION CHART

    Mechanical Electrical
    • Battery case, posts, hold-down clamp, cables and connections
    • Generator drive belt for condition and to make sure there is proper tension between the belt and the pulley. Refer to ACCESSORY DRIVE .
    • Generator/pulley
    • Fusible link 290A 12 ga (GY)
    • Fusible link 290B 12 ga (GY)
    • Fuse link 292C 18 ga (BN)
    • Battery charge
    • Circuitry
    • Charging system warning indicator
    • Cables
    • Generator
    • Powertrain control module (PCM)
  3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
  4. Verify the battery condition. Refer to BATTERY, MOUNTING AND CABLES .
  5. Check the operation of the charging system warning indicator (instrument cluster). Normal operation is as follows:
    • with the ignition switch OFF, the charging system warning indicator should be off.
    • with the ignition switch ON and the engine OFF, the charging system warning indicator should be on.
    • with the engine running, the charging system warning indicator should be off.
  6. Turn off the headlamps and the A/C system (if equipped). Turn the climate control blower to low/off. Check the battery voltage before and after starting the engine to determine if the battery voltage increases.
  7. If the cause is not visually evident, connect the diagnostic tool to the data link connector (DLC) and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle:
    • check that the diagnostic card is correctly installed.
    • check the connections to the vehicle.
    • check the ignition switch position.
  8. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool operating manual.
  9. Carry out the diagnostic tool data link test. If the diagnostic tool responds with:
    • CAN, UBP or ISO circuits fault; all electronic control units no response/not equipped, refer to MODULE COMMUNICATIONS NETWORK .
    • No response/not equipped for instrument cluster, refer to INSTRUMENT CLUSTER .
    • No response/not equipped for the PCM, See INTRODUCTION - GASOLINE article.
    • System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs, and carry out the self-test diagnostics for the PCM.
  10. If the DTCs retrieved are related to the concern, go to the POWERTRAIN CONTROL MODULE (PCM) DIAGNOSTIC TROUBLE CODE (DTC) INDEX  or the INSTRUMENT CLUSTER DIAGNOSTIC TROUBLE CODE (DTC) INDEX  to continue diagnosis.
  11. If no DTCs related to the charging system are retrieved, GO to SYMPTOM CHART  to continue diagnosis.
NOTE: DTC P0620 can be set by the loss of the I circuit 904 (LG/RD). The generator warning indicator then illuminates. If the engine is operated at greater than 2,000 rpm momentarily, the generator self-excites, the charging system warning indicator stays illuminated, and the generator operates in a default mode (approximately 13.5 volts) until the engine is turned off.
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