Pinpoint Test K: The Charging System Warning Indicator Is Never On

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, and 2005 Ford E450 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.

K1 CHECK THE CHARGING SYSTEM WARNING INDICATOR OPERATION
- Key in OFF position.
- Disconnect: Generator C102a (gasoline engines and diesel engines with single generator).
- Disconnect: Powertrain Control Module (PCM) C176c (diesel engines with dual generators).
- For vehicles equipped with gasoline engines and diesel engines equipped with a single generator, connect a fused (10A) jumper wire between the generator C102a-1, circuit 904 (LG/RD), harness side and ground.
  
  Fig 1: Checking Charging System Warning Indicator Operation (Single Generator)
  Courtesy of FORD MOTOR CO.
- On diesel engines equipped with dual generators, connect a fused (10A) jumper wire between the PCM C176a-30, circuit 904 (LG/RD), harness side and ground.
  
  Fig 2: Checking Charging System Warning Indicator Operation (Dual Generators)
  Courtesy of FORD MOTOR CO.
- Key in ON position.
- Does the charging system warning indicator illuminate?
- Yes : On gasoline and diesel engines with a single generator, INSTALL a new generator. REFER to GENERATOR AND REGULATOR . TEST the system for normal operation.
  On diesel engines equipped with dual generators, REMOVE the jumper wire, GO to K5.
- No : For gasoline and diesel engines equipped with a single generator, REMOVE the jumper wire, GO to K3.
For diesel engines equipped with dual generators, REMOVE the jumper wire, GO to K2.
K2 CHECK CIRCUIT 904 (LG/RD) FOR AN OPEN
- Key in OFF position.
- Disconnect: Instrument Cluster C220a.
- Measure the resistance between the instrument cluster C220a-14, circuit 904 (LG/RD), harness side and the PCM C176a-30, circuit 904 (LG/RD), harness side.
  
  Fig 3: Checking Circuit 904 (LG/RD) For An Open
  Courtesy of FORD MOTOR CO.
- Is the resistance less than 5 ohms?
- Yes : GO to K4.
- No : REPAIR the circuit. TEST the system for normal operation.
K3 CHECK CIRCUIT 904 (LG/RD) FOR AN OPEN
- Key in OFF position.
- Disconnect: Instrument Cluster C220a.
- Measure the resistance between the instrument cluster C220a-14, circuit 904 (LG/RD), harness side and the generator C102a-1, circuit 904 (LG/RD), harness side.
  
  Fig 4: Checking Circuit 904 (LG/RD) For An Open
  Courtesy of FORD MOTOR CO.
- Is the resistance less than 5 ohms?
- Yes : GO to K4.
- No : REPAIR the circuit. TEST the system for normal operation.
K4 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
- Disconnect all the instrument cluster connectors.
- Check for:
  - Corrosion
  - Pushed-out pins
- Connect all the instrument cluster connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
- Yes : INSTALL a new instrument cluster. REFER to INSTRUMENT CLUSTER . TEST the system for normal operation.
- No : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. TEST the system for normal operation.
K5 CHECK FOR CORRECT PCM OPERATION
- Disconnect all the PCM connectors.
- Check for:
  - Corrosion
  - Pushed-out pins
- Connect all the PCM connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
- Is the concern still present?
- Yes : INSTALL a new PCM. REFER to ELECTRONIC ENGINE CONTROLS - GASOLINE ENGINES (gasoline engines), ELECTRONIC ENGINE CONTROLS - DIESEL ENGINE (diesel engines). TEST the system for normal operation.
- No : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. TEST the system for normal operation.