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Inspection and Verification

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. 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. 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 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 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 the diagnostic trouble codes (DTCs) set while following the specific pinpoint test. After the completion of any test, be sure to clear all DTCs in the PCM.
NOTE: All voltage measurements are referenced to the negative (-) battery post unless otherwise specified.
NOTE: The dual generator I circuit/bulb circuit 4-way connector MUST be connected before disconnecting or connecting the battery. The PCM relearns its parameters every time it is disconnected and connected to power. Failure to follow this procedure causes the PCM to misinterpret the charging system as a single generator system, causing loss of DTC capability and control.
  1. Verify the customer concern.
  2. Visually inspect for obvious signs of mechanical or electrical damage.
    VISUAL INSPECTION CHART

    Mechanical Electrical
    • Battery
    • Generator drive belt
    • Generator pulley
    • Charging system warning indicator
    • Circuitry
    • Cables
  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 article.
  5. Check the operation of the charging system warning indicator in the instrument cluster (IC) as follows:
    • With the key in the OFF position, the charging system warning indicator should be off.
    • With the key in the ON position 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. NOTE: The PCM requires 3 key cycles to re-learn the configuration.
    NOTE: On California vehicles, the malfunction indicator lamp (MIL) illuminates if the lower generator circuit has 12 volts (which the PCM has commanded off) for 2 consecutive drive cycles.
    NOTE: When testing the I circuit with the engine running, make certain to load the charging system by turning the blower motor to the HIGH position and the headlamps on high beam.
  6. Check the battery voltage before and after starting the engine to determine if the battery voltage increases. Refer to the Normal Charging System Voltages chart.
    NORMAL CHARGING SYSTEM VOLTAGES

    Ignition Key Position A Circuit 35 (OG/LB) I Circuit 904 (LG/RD) (Upper), Circuit 1185 (YE) (Lower) Generator B+ Circuit 1119 (RD) (Upper), Circuit 36 (YE/WH) (Lower) Battery Engine to Battery Ground Charging System Warning Indicator Operation
    Key OFF 12V 0V 12V 12V 0V Off
    Key ON - engine off 12V 1-3V (glow plugs off) 12V 12V 0V Illuminated
    Engine running 13-15V 8-9V 13-15V 13-15V 0V Off
    7. NOTE: Make sure to use the latest scan tool software release.
  7. If the cause is not visually evident, connect the scan tool to the data link connector (DLC).
    8. NOTE: The vehicle communication module (VCM) LED prove out confirms power and ground from the DLC are provided to the VCM.
  8. If the scan tool does not communicate with the VCM:
    • check the VCM connection to the vehicle.
    • check the scan tool connection to the VCM.
  9. If the scan tool does not communicate with the vehicle:
    • verify the ignition key is in the ON position.
  10. Carry out the network test.
    • If the network test passes, retrieve and record continuous memory diagnostic trouble codes (DTCs).
  11. Clear the continuous DTCs and carry out the self-test diagnostics for the PCM.
  12. If the DTCs retrieved are related to the concern, go to Powertrain Control Module (PCM) Diagnostic Trouble Code (DTC) Index or the Instrument Cluster (IC) Diagnostic Trouble Code (DTC) Index. For all other DTCs, refer to MULTIFUNCTION ELECTRONIC MODULES article.
  13. If no DTCs related to the concern are retrieved, go to Symptom Chart .
POWERTRAIN CONTROL MODULE (PCM) DIAGNOSTIC TROUBLE CODE (DTC) INDEX

DTC Description Action
P0620 Dual generator upper fault detected Go to Pinpoint Test T .
P0623 Dual generator battery lamp circuit fault detected REFER to INSTRUMENT CLUSTER article.
P1148 Dual generator lower fault detected Go to Pinpoint Test U .
P1149 Dual generator lower circuit fault detected Go to Pinpoint Test V .
P1397 System voltage out of self-test range Go to Pinpoint Test Q .
All Other DTCs - REFER to the INTRODUCTION - GASOLINE ENGINES article.
INSTRUMENT CLUSTER (IC) DIAGNOSTIC TROUBLE CODE (DTC) INDEX

DTC Description Action
B1317 Battery voltage high Go to Pinpoint Test Q .
B1318 Battery voltage low Go to Pinpoint Test Q .
All Other DTCs - REFER to MULTIFUNCTION ELECTRONIC MODULES article.
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