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Inspection and Verification

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Batteries contain sulfuric acid. Avoid contact with skin, eyes, or clothing. Also, shield your eyes when working near batteries to protect against possible splashing of the acid solution. In case of acid contact with skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If acid is swallowed, call a physician immediately. Failure to follow these instructions may result in personal injury.
WARNING: Batteries normally produce explosive gases which may cause personal injury. Therefore, do not allow flames, sparks or lighted substances to come near the battery. When charging or working near a battery, always shield your face and protect your eyes. Always provide ventilation. Failure to follow these instructions may result in personal injury.
WARNING: When lifting a plastic-cased battery, excessive pressure on the end walls could cause acid to spew through the vent caps resulting in personal injury, damage to the vehicle or to the battery. Lift with a battery carrier or with your hands on opposite corners. Failure to follow these instructions may result in personal injury.
CAUTION: Do not make jumper connections except as directed. Incorrect connections may damage the voltage regulator test terminals, fuses, or fusible links.
CAUTION: Do not allow any metal object to come in contact with the generator housing and internal diode cooling fins. A short circuit may result and burn out the diodes.
NOTE: While carrying out any pinpoint test, disregard any DTCs set while following any specific pinpoint test. After the completion of any test, be sure to clear all codes in the PCM.
NOTE: All voltage measurements are referenced to the negative (-) battery post unless otherwise specified.
NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) relearns its fuel trim. The vehicle may need to be driven to relearn the strategy.
  1. Verify the customer concern.
  2. Visually inspect for obvious signs of mechanical or electrical damage.
    VISUAL INSPECTION CHART

    Mechanical Electrical
    • Battery case, posts, hold-down clamp, cables, and connections for damage
    • Generator drive (serpentine) belt for condition and tension to make sure there is no slip between the belt and the pulley. Refer to ACCESSORY DRIVE .
    • Battery condition
    • Generator pulley
    • Battery junction box (BJB) fuse 23 (10A)
    • Charging system warning indicator
    • Circuitry
    • Cables
  3. If the inspection reveals obvious concern(s) that can be readily identified, service as necessary.
  4. Verify the battery condition. Refer to BATTERY, MOUNTING AND CABLES .
  5. Observe the charging system warning indicator status under the following conditions:
    • The charging system warning indicator illuminates with the key in the ON position and with the engine OFF.
    • The charging system warning indicator is off with the engine running.
    • The charging system warning indicator is off with the key in the OFF position.
    6. NOTE: The PCM requires 3 key cycles re-learn the configuration.
    NOTE: On California vehicles, the malfunction indicator lamp (MIL) illuminates if the lower generator circuit has 12 volts (which the PCM has commanded off) for 2 consecutive drive cycles.
    NOTE: When testing the I circuit with the engine running, make sure to load the charging system by turning the blower motor to the HIGH position and the headlamps on high beam.
  6. Check the battery voltage before and after starting the engine to determine if the battery voltage increases. Refer to the NORMAL CHARGING SYSTEM VOLTAGES 
    NORMAL CHARGING SYSTEM VOLTAGES

    Key Position A Circuit 35 (OG/LB) I Circuit 904 (LG/RD) Generator B+ Circuit 1119 (RD) (Upper Generator), 2037 (RD) (Lower Generator) Battery Engine to Battery Ground Charging System Warning Indicator Operation
    Key OFF 12 0V 12V 12V OV Off
    Key ON -engine off 12V 1-3V (glow plugs off) 12V 12V 0V Illuminated
    Engine running 13-15V 8-9V 13-15V 13-15V 0V Off
  7. If the concern remains after the inspection, connect the diagnostic tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the vehicle selection cannot be entered:
    • Check that the program card is correctly installed.
    • Check the connections to the vehicle.
    • Check the ignition switch position.
  8. If the diagnostic tool still does not communicate with the vehicle, refer to diagnostic tool operating manual.
  9. 9. Carry out the diagnostic tool data link test. If the diagnostic tool responds with:
    • CAN or ISO circuits fault; all electronic control units no response/not equipped, refer to MODULE COMMUNICATIONS NETWORK .
    • No response/not equipped for powertrain control module (PCM), see INTRODUCTION - GASOLINE and/or INTRODUCTION -- 6.0L DIESEL articles.
    • System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs, and carry out the self-test diagnostics for the PCM.
  10. 10. If the DTCs retrieved are related to the concern, go to the Powertrain Control Module (PCM) Diagnostic Trouble Code (DTC) Index  or the INSTRUMENT CLUSTER DIAGNOSTIC TROUBLE CODE (DTC) INDEX .
  11. 11. If no DTCs related to the concern are retrieved, GO to SYMPTOM CHART  to continue diagnostics.
POWERTRAIN CONTROL MODULE (PCM) DIAGNOSTIC TROUBLE CODE (DTC) INDEX

DTC Description Action
P0620 Dual generator upper fault detected GO to PINPOINT TEST T .
P1148 Dual generator lower fault detected GO to PINPOINT TEST U .
P1149 Dual generator lower circuit fault detected GO to PINPOINT TEST V 
P0623 Dual generator battery lamp circuit fault detected GO to INSTRUMENT CLUSTER .
P1397 System voltage out of self-test range GO to PINPOINT TEST Q .
INSTRUMENT CLUSTER DIAGNOSTIC TROUBLE CODE (DTC) INDEX

DTC Description Action
B1317 Battery voltage high GO to PINPOINT TEST Q .
B1318 Battery voltage low GO to PINPOINT TEST Q .
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