Test C: Warning Indicator Is On With Engine Running, System Is Not Charging (2.0L ZETEC)
WARNING: This page is about a different car, the 2004 Ford Escape, 2003 Ford Escape, and 2002 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
- 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. If no DTCs exist, go to next step. If any DTCs exist, perform appropriate test. See POWERTRAIN CONTROL MODULE DIAGNOSTIC TROUBLE CODE INDEX under SELF-DIAGNOSTIC SYSTEM.
- Turn ignition switch to LOCK position. Disconnect NGS tester. Disconnect generator 3-pin harness connector. Turn ignition switch to RUN position. Measure voltage between ground and generator harness connector terminal No. 1 (Gray/Orange wire). See Figure. If voltage is zero volts, go to next step. If voltage is not zero volts, go to step 4.
- Turn ignition switch to LOCK position. Disconnect PCM 104-pin harness connector. Measure resistance in Gray/Orange wire between PCM harness connector terminal No. 59 and generator harness connector terminal No. 1. See Figure and Fig 1 . If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Gray/Orange wire between PCM and generator.
- Connect generator harness connector. Perform GENERATOR LOAD TEST under ON-VEHICLE TESTING. If generator is okay, go to next step. If generator is defective, replace generator.
- Turn ignition switch to LOCK position. Disconnect PCM harness connector. Inspect connector for corrosion and pushed out pins. Connect PCM harness connector. Ensure connector is seated properly. Operate system. If problem still exists, replace PCM. If system is operating properly, problem may have been caused by a loose or corroded connector. Clear DTCs. Repeat PCM self-test.