Test A: Warning Indicator Is On With Engine Running, System Is Not Charging
WARNING: This page is about a different car, the 2003 Ford Pickup, 2003 Ford F550 Super Duty, 2003 Ford F450 Super Duty, and 2003 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
- Check The Fault Codes In The PCM
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. - Check "I" Circuit (Light Green/Red Wire)
Turn ignition switch to LOCK position. Disconnect NGS tester. Disconnect upper generator 3-pin connector. Turn ignition switch to RUN position. Measure voltage between ground and upper generator connector terminal No. 1 (Light Green/Red wire). See Figure. If battery voltage is not present, go to next step. If battery voltage is present, go to step 5. - Check "I" Circuit (White/Yellow Wire/Light Green/Red Wire) For An Open
Turn ignition switch to LOCK position. Disconnect PCM connector C175 or C1381c. PCM is located at left rear of engine compartment. Measure resistance between upper generator connector terminal No. 1 (Light Green/Red wire) and 7.3L PCM connector C175 terminal No. 35 (White/Yellow wire), or 6.0L PCM connector C1381c terminal No. 1 (White/Yellow Wire). See Figure or Figure . If resistance is less than 5 ohms, go to step 6. If resistance is 5 ohms or more, repair open in wire between upper generator and PCM. See WIRING DIAGRAMS . - Check The Voltage To The Lower Generator
Turn ignition switch to LOCK position. Disconnect lower generator connector. Turn ignition switch to RUN position. Measure the voltage between the lower generator connector terminal No. 1 (Yellow wire) and ground. See Figure or Figure . If the voltage is greater than 10 volts, go to step 6. If voltage is not greater than 10 volts, go to next step. - Check Lower Generator "I" Circuit (Yellow Wire) For An Open
Turn ignition switch to LOCK position. Connect upper generator connector. Disconnect lower generator connector. Disconnect PCM connector C175 or C1381c. PCM is located at left rear of engine compartment. Measure resistance between lower generator connector terminal No. 1 (Yellow wire) and 7.3L PCM connector C175 terminal No. 60, or 6.0L PCM connector C1381c terminal No. 4. See Figure or Figure and Figure or Figure . If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Yellow wire between lower generator and PCM. See WIRING DIAGRAMS . - Check The Upper Generator Output
Connect PCM harness connector. Start engine and let idle. Perform load test on upper generator. See GENERATOR LOAD TEST under ON-VEHICLE TESTING. If generator is okay, go to next step. If generator is not okay, replace generator. - Check The Lower Generator Output
Turn ignition switch to LOCK position. Connect lower generator harness connector. Disconnect upper generator harness connector. Start engine and let idle. Perform load test on lower generator. See GENERATOR LOAD TEST under ON-VEHICLE TESTING. If generator is okay, go to next step. If generator is not okay, replace generator. - Check For Correct PCM Operation
Turn ignition switch to LOCK position. Disconnect PCM harness connector. Inspect PCM harness connector for corrosion and pushed out pins. Connect PCM harness connector, ensuring it is connected properly. Connect all disconnected connectors. Operate system. If fault is still present, replace PCM. If fault is not present, system is operating properly at this time.