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Test G: Warning Indicator Is On With Engine Running, System Is 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.
  1. 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 DIAGNOSTIC TROUBLE CODE DEFINITIONS  under SELF-DIAGNOSTIC SYSTEM.
  2. Turn ignition switch to LOCK position. Disconnect NGS tester. Start engine and let idle. Turn all accessories off. Measure voltage between battery terminals while varying engine speed. If voltage is less than 15 volts, go to next step. If voltage is 15 volts or more, perform TEST E: SYSTEM OVERCHARGES, BATTERY VOLTAGE IS GREATER THAN 15.5 VOLTS (2.0L ZETEC) .
  3. Turn ignition switch to LOCK position. Disconnect generator 3-pin harness connector. Turn ignition switch to RUN position. Measure voltage between ground and generator harness connector terminal No. 3 (Black/Yellow wire). See Figure. If voltage is equal to battery voltage, go to next step. If voltage is not equal to battery voltage, repair Black/Yellow wire between generator and battery junction box.
  4. Turn ignition switch to LOCK position. Disconnect PCM 104-pin harness connector. Measure resistance between ground and PCM harness connector terminal No. 59 (Gray/Orange wire). If resistance is 10 k/ohms or more, go to next step. If resistance is less than 10 k/ohms, repair short to ground in Gray/Orange wire between generator and PCM.
  5. Connect PCM harness connector and generator harness connector. Perform load and no-load tests on generator. See GENERATOR LOAD TEST  and GENERATOR NO-LOAD TEST  under ON-VEHICLE TESTING. If generator is okay, go to next step. If generator is defective, replace generator.
  6. Disconnect PCM harness connectors. 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.
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