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Home >> Ford >> 2006 >> Focus ZX5 SE, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 84 (Charging System - General Information -- F250-F550 Super Duty) >> Diagnosis And Testing >> Charging System - Dual Generators >> Inspection and Verification

Inspection and Verification

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. 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 can 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.
  1. Verify the customer concern by operating the engine to duplicate the concern.
  2. Inspect to determine if one of the following mechanical or electrical concerns apply.
    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. For additional information, refer to ACCESSORY DRIVE .
    • Battery condition
    • Generator pulley
    • Central junction box (CJB) fuse 45 (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 ignition switch in the ON position and the engine off.
    • The charging system warning indicator is off with the engine running.
    • The charging system warning indicator is off with the ignition switch in the off position.
    6. NOTE: The powertrain control module (PCM) requires 3 key cycles to 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 certain 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 CHART .
    NORMAL CHARGING SYSTEM VOLTAGES

    Ignition Switch Position A Circuit 35 (OG/LB) 1 Circuit 904 (LG/RD) Generator B+ Circuit 36 (YE/WH) Battery Engine to Battery Ground Charging System Warning Indicator Operation
    Key OFF 12V 0v 12V 12V 0V 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 communicate with the vehicle, refer to the diagnostic tool operating manual.
  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 -- 6.0L DIESEL article.
    • 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. 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. If no DTCs related to the concern are retrieved, go to the SYMPTOM CHART  to continue diagnosis.
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