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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 244 (Generators & Regulators - F250-F550 Super Duty (Diesel With Dual Generators)) >> System Tests >> Test C: Warning Indicator Is On With Engine Running, System Is Charging

Test C: Warning Indicator Is On With Engine Running, System Is 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 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. Are generator fault codes present? If yes, perform appropriate test. See DIAGNOSTIC TROUBLE CODE DEFINITIONS  under SELF-DIAGNOSTIC SYSTEM. If no, go to next step.

  2. Check System For Overcharging

    Turn ignition switch to LOCK position. Disconnect NGS tester. Start engine and let idle. Turn off all accessories. Measure voltage between primary battery terminals while varying engine speed. Is the voltage greater than 15.5 volts? If yes, go to TEST G: SYSTEM OVERCHARGES (BATTERY VOLTAGE GREATER THAN 15 VOLTS) . If no, go to next step.

  3. Check Charging System Warning Indicator Operation

    Turn ignition switch to LOCK position. Connect lower generator 3-pin connector. Disconnect PCM connector C1381c. PCM is located at left rear of engine compartment. Turn ignition switch to RUN position. Observe warning indicator. Is the indicator illuminated? If yes, go to next step. If no, go to step  5.

  4. Check Warning Indicator Circuit

    Turn ignition switch to LOCK position. Disconnect instrument cluster connector C220b. Instrument cluster connector C220b is located behind instrument cluster. Measure resistance between ground and PCM connector C1381c terminal No. 30 (Violet wire). See Figure. Is the resistance greater than 10,000 ohms? If yes, see appropriate ANALOG INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT for further diagnosis. If no, repair circuit. See WIRING DIAGRAMS . Test system for normal operation.

  5. Check Lower Generator "A" Circuit

    Turn ignition switch to LOCK position. Connect upper generator 3-pin connector. Disconnect lower generator 3-pin connector. Turn ignition switch to RUN position. Measure voltage between ground and lower generator harness connector terminal No. 3 (Orange/Light Blue wire). See Figure. Is the voltage equal to battery voltage? If yes, go to next step. If no, repair circuit between lower generator and Fusible Link "H". See WIRING DIAGRAMS .

  6. Check For Correct PCM Operation

    Disconnect PCM connectors. Inspect PCM connectors for corrosion and pushed out pins. Connect PCM connectors, 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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