Test K: Warning Indicator Flickers Or Is Intermittent (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 DIAGNOSTIC TROUBLE CODE DEFINITIONS under SELF-DIAGNOSTIC SYSTEM.
- Disconnect generator 3-pin harness connector. Inspect all generator, battery, and power distribution connections for looseness, corrosion, loose or bent terminals, or loose eyelets. Connect generator connector. If problem does not exist, go to next step. If problem exists, repair connections as necessary.
- Start engine and let idle. Inspect battery junction box fuse No. 11 (15-amp) for looseness. Wiggling fuse and note warning indicator operation. If warning indicator does not flicker, go to next step. If warning indicator flickers, repair loose fuse connections as necessary.
- 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) .
- Turn ignition switch to LOCK position. Disconnect generator 3-pin harness connector. Turn ignition switch to RUN position. Connect a fused jumper wire between ground and generator harness connector terminal No. 1 (Gray/Orange wire). See Figure. If warning indicator illuminates, go to next step. If warning indicator does not illuminate, repair open in Gray/Orange wire between generator and PCM.
- Turn ignition switch to LOCK position. Remove jumper wire. Connect generator harness connector. Turn ignition switch to RUN position. Observe warning indicator operation. If warning indicator does not illuminate, go to next step. If warning indicator illuminates, PCM is operating properly. Recheck generator circuits for intermittent shorts or opens.
- 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.