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Test F: Charge Warning Indicator Flickers Or Is Intermittent

WARNING: This page is about a different car, the 2003 Mercury Sable, 2003 Ford Taurus, 2002 Mercury Sable, and 2002 Ford Taurus. 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 on. Using NGS tester, perform Powertrain Control Module (PCM) self-test. If no DTCs are retrieved, go to next step. If any Diagnostic Trouble Codes (DTC) are retrieved, perform appropriate test in accordance with DTC retrieved. See appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.
  2. Inspect battery, Battery Junction Box (BJB), Central Junction Box (CJB) and generator connectors for loose, corroded or damaged connections. Repair as necessary and retest system operation. If all connections are okay, go to next step.
  3. Start engine. Wiggle fuse No. 26 (10-amp) in BJB while observing charge warning indicator. If charge warning indicator does not flicker, go to next step. If charge warning indicator flickers, repair appropriate loose connection and retest system operation.
  4. With engine running and all accessories turned off, measure voltage between battery terminals. If battery voltage is less than 15 volts, go to next step. If battery voltage is greater than 15 volts, perform TEST C: SYSTEM OVERCHARGES (MORE THAN 15 VOLTS) .
  5. Turn ignition off. Disconnect generator 3-pin harness connector. Connect a fused (15-amp) jumper wire between generator harness connector terminal No. 2 (Light Blue/Red wire) and ground. Turn ignition on and observe warning indicator. If warning indicator illuminates, go to next step. If warning indicator does not illuminate, go to step  7.
  6. Turn ignition off. Reconnect generator 3-pin connector. Turn ignition on. Monitor the charging system warning indicator operation. If charging system warning indicator is illuminated, PCM is operating correctly. Recheck the generator circuits (including the generator) for intermittent shorts or opens. Test the system for normal operation. If charging system warning indicator is not illuminated, install a new generator. See GENERATOR  under REMOVAL & INSTALLATION. Clear DTCs and TEST system for normal operation.
  7. Turn ignition off. Disconnect PCM connector C175. Measure resistance between the PCM connector C175 terminal No. 45 and Light Blue wire terminal in generator connector. If resistance less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Light Blue/Red wire. Test system for normal operation.
  8. Disconnect PCM harness connector C175. Inspect harness connector for pushed out pins, corrosion or bent terminals. Repair as necessary. If harness connector is okay, reconnect and retest system operation. If fault is still present, replace PCM. Clear DTCs and repeat PCM self-test. If fault is still not present, system is operating correctly at this time.
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