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PINPOINT TEST D: DTCs P0625 AND P0626 - GENERATOR FIELD TERMINAL CIRCUIT STUCK LOW/HIGH

NOTE: Make sure battery voltage is greater than 12.2 volts prior to and during this pinpoint test.
NOTE: Do not have a battery charger attached during vehicle testing.
  1. D1 CHECK THE BATTERY CONDITION 
    • Carry out the Battery - Condition Test to determine if the battery can hold a charge and is OK for use. Refer to BATTERY, MOUNTING AND CABLES .
    • Does the battery pass the condition test? 
    • Yes  : GO to D2.
    • No  : INSTALL a new battery. REFER to BATTERY, MOUNTING AND CABLES . CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
  2. D2 CHECK THE GENERATOR B+ CONNECTION 
    • Ignition OFF.
    • Inspect generator C102B, circuit SDC14 (RD), harness side. Connection should be tight.
    • Measure the voltage between generator C102B, circuit SDC14 (RD) and ground.
      Fig 1: Checking Generator B+ Connection
      G06065172Courtesy of FORD MOTOR CO.
    • Is the generator C102B connection tight and does the generator B+ measure battery voltage? 
    • Yes  : GO to D3.
    • No  : REPAIR the generator B+ connection or circuit. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
  3. D3 CHECK THE A SENSE VOLTAGE 
    • Disconnect: Generator C102A.
    • Ignition ON.
    • Measure battery voltage and record.
      Fig 2: Checking Sense Voltage
      G06065179Courtesy of FORD MOTOR CO.
    • Measure the voltage between generator C102A-3, circuit SBB17 (RD), harness side and ground.
    • Is the voltage equal to battery voltage? 
    • Yes  : GO to D4.
    • No  : VERIFY Battery Junction Box (BJB) fuse 17 (10A) is OK. If OK, REPAIR circuit SBB17 (RD). If not OK, REFER to the appropriate Systems Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
  4. D4 MONITOR THE PCM PID GENERATOR MONITOR (GENMON) WITH IGNITION ON/ENGINE OFF 
    • Connect: Generator C102A.
      • NOTE: Many of the PCM PIDs selected will be monitored later in this pinpoint test.
    • Select and monitor the following PCM PIDs:
      • Generator Monitor (GENMON).
      • Generator Command (GENCMD).
      • Generator Voltage Desired (GENVDSD).
      • Engine Revolutions Per Minute (RPM).
      • Module Supply Voltage (VPWR).
    • Monitor the GENMON PID.
    • Does the GENMON PID read 0%? 
    • Yes  : GO to D5.
    • No  : GO to  D10.
  5. D5 MONITOR THE PCM PIDs GENERATOR MONITOR (GENMON) AND GENERATOR VOLTAGE DESIRED (GENVDSD) WITH ENGINE RUNNING AND NO LOADS 
    • Start the engine and turn all electrical accessories (lights, blower motor, etc.) off.
    • With the engine at idle, wait at least 15 seconds for the GENVDSD PID to increase to greater than 13 volts.
    • Monitor PID GENMON at idle.
      • NOTE: On some vehicles equipped with a manual transaxle/transmission, the parking brake must be applied and the clutch pedal depressed in order to use the output state control RPM.
    • Using output state control PID RPM, increase the engine rpm to 3,000 rpm.
    • Monitor PID GENMON at 3,000 rpm.
    • Does the GENMON PID read between 3% and 98% at engine idle speed and at 3,000 rpm? 
    • Yes  : GO to D6.
    • No  : GO to  D11.
  6. D6 MONITOR THE PCM PIDs GENERATOR MONITOR (GENMON), GENERATOR VOLTAGE DESIRED (GENVDSD) WITH THE ENGINE AT IDLE LOADS ON 
    • Decrease the engine speed to 500 rpm using active command PID RPM and monitor PIDs.
      • NOTE: On vehicles with low electrical loads, it is necessary to make sure that all of the vehicle's electrical loads are turned on to determine the maximum GENMON PID value. The GENMON PID value may not reach between the desired 95%-98% on a low load vehicle with minimal electrical accessories. As long as the GENMON PID increases significantly with all of the electrical loads on, answer YES to the question below.
    • Determine the maximum GENMON PID value by lowering engine idle rpm to 500 rpm or less using output state control PID RPM and turn on all electrical accessories until the module supply voltage (VPWR) PID is less than the GENVDSD PID by at least 0.7 volt. Under this condition the GENMON PID should read between 95% and 98%.
    • Does the GENMON PID read between 95% and 98%? 
    • Yes  : GO to D7.
    • No  : GO to  D11.
  7. D7 MONITOR THE PCM PIDs GENERATOR MONITOR (GENMON), MODULE SUPPLY VOLTAGE (VPWR) AND GENERATOR VOLTAGE DESIRED (GENVDSD) WITH THE ENGINE AT 3,000 RPM 
    • Increase the engine speed to 3,000 rpm using active command PID RPM and monitor PIDs.
      • NOTE: If GENMON PID does not remain below 85%, make sure that the battery is at an acceptable state of charge and that all electrical accessories are off.
    • Monitor PIDs VPWR, GENVDSD and GENMON.
    • Does the VPWR PID remain within ±0.5 volt of the GENVDSD PID when the GENMON PID is less than 85%? 
    • Yes  : GO to D8.
    • No  : GO to  D11.
  8. D8 CHECK THE GENERATOR B+ RESISTANCE 
    • Ignition OFF.
      • NOTE: Failure to disconnect the battery will result in false resistance readings.
    • Disconnect the battery. Refer to BATTERY, MOUNTING AND CABLES .
    • Disconnect: Generator C102B.
    • Measure the resistance between generator C102B, component side and the generator housing.
      Fig 3: Checking Generator B+ Resistance
      G06065180Courtesy of FORD MOTOR CO.
    • Is the resistance greater than 25K ohms? 
    • Yes  : GO to D9.
    • No  : INSTALL a new generator. REFER to GENERATOR . CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
  9. D9 CHECK THE RESISTANCE OF THE VOLTAGE REGULATOR INTERNAL CIRCUITS TO GROUND 
    • Disconnect: Generator C102A.
    • Measure the resistance between generator C102A, component side and ground. Refer to the following table.
      PIN RESISTANCE CHART

      Pin Expected Resistance
      1 Greater than 1M/1,000K ohms
      2 Greater than 125K ohms
      3 Greater than 125K ohms
    • Are the resistance values as indicated? 
    • Yes  : The fault is not present at this time. This may indicate an intermittent fault. CARRY OUT a Wiggle Test on the charging system circuits to try and RECREATE the concern. CHECK generator connections for corrosion, loose connections and/or bent terminals. REPAIR as necessary. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
    • No  : INSTALL a new generator. REFER to GENERATOR . CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
  10. D10 CHECK THE PCM PID GENERATOR MONITOR (GENMON) INPUT TO THE PCM 
    • Ignition OFF.
    • Disconnect: Generator C102A.
    • Connect a fused jumper wire between generator C102A-1, circuit CDC15 (VT), harness side and ground.
      Fig 4: Checking PCM PID Generator Monitor Input To PCM
      G06065181Courtesy of FORD MOTOR CO.
    • Ignition ON.
    • Monitor the GENMON PID while performing a Wiggle Test on the generator wiring harness.
    • Does the GENMON PID read 0%? 
    • Yes  : GO to  D14.
    • No  : GO to  D15.
  11. D11 A SENSE CIRCUIT LOAD TEST 
    NOTE: This step puts a load on the A sense circuit. If there are corroded or loose connections, loading the circuit may help show the fault. A glass bulb style test lamp is required for this step. This circuit will not be loaded properly using an LED-style test lamp.
    • Ignition OFF.
    • Disconnect: Generator C102A (if not previously disconnected).
    • Ignition ON.
    • Using a 12-volt test lamp connected to ground, check for voltage at C102A-3, circuit SBB17 (RD), harness side.
    • Does the test lamp illuminate? 
    • Yes  : GO to D12.
    • No  : VERIFY Battery Junction Box (BJB) fuse 17 (10A) is OK. If OK, REPAIR circuit SBB17 (RD). If not OK, REFER to the appropriate Systems Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
  12. D12 B+ CIRCUIT LOAD TEST 
    NOTE: This step puts a load on the B+ circuit. If there are corroded or loose connections, loading the circuit may help show the fault. A glass bulb style test lamp is required for this step. This circuit will not be loaded properly using an LED-style test lamp.
    • Ignition OFF.
    • Disconnect: Generator C102b.
    • Using a 12-volt test lamp connected to ground, check for voltage at C102B-1, circuit SDC14 (RD), harness side.
    • Does the test lamp illuminate? 
    • Yes  : GO to D13.
    • No  : REPAIR circuit SDC14 (RD) for high resistance. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
  13. D13 CHECK CIRCUIT CDC10 (BU/OG) FOR DAMAGE OR AN OPEN 
    • Ignition OFF.
    • Disconnect: PCM C175B.
    • Inspect the following harness connectors for damaged or pushed-out pins:
      • PCM C175B-22, circuit CDC10 (BU/OG).
      • Generator C102A-2, circuit CDC10 (BU/OG).
        Fig 5: Checking Circuit CDC10 (BU/OG) For Damage Or An Open
        G06065176Courtesy of FORD MOTOR CO.
    • Measure the resistance between PCM C175B-22, circuit CDC10 (BU/OG), harness side and generator C102A-2, circuit CDC10 (BU/OG), harness side.
    • Are the connectors and pins free of damage and is the resistance less than 0.5 ohm? 
    • Yes  : GO to D14.
    • No  : REPAIR circuit CDC10 (BU/OG). CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
  14. D14 COMPARE THE PCM PIDs GENERATOR MONITOR (GENMON) AND GENERATOR COMMAND (GENCMD) 
    • Connect: Generator C102B.
    • Connect: PCM C175B.
    • Connect a fused jumper wire between generator C102A-1, circuit CDC15 (VT), harness side and generator C102A-2, circuit CDC10 (BU/OG), harness side.
      Fig 6: Checking PCM PID Generator Monitor And Generator Command
      G06065167Courtesy of FORD MOTOR CO.
    • Start the engine.
    • Using output state control, set the GENVDSD PID to 14.0 volts.
    • Monitor the GENMON and GENCMD PIDs while performing a Wiggle Test on the generator wiring harness.
    • Does the GENMON PID read within 2% of the GENCMD PID? 
    • Yes  : INSTALL a new generator. REFER to GENERATOR . CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
    • No  : GO to  D16.
  15. D15 INSPECT GENERATOR CIRCUITS 
    • Ignition OFF.
    • Disconnect: PCM C175B.
    • Inspect the following connector pins for damage and/or corrosion, generator C102A-1, circuit CDC15 (VT) and PCM C175B-23.
    • Are the connectors OK? 
    • Yes  : INSTALL a new PCM. REFER to ELECTRONIC ENGINE CONTROLS . CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
    • No  : REPAIR the affected circuit(s). CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
  16. D16 INSPECT PCM CIRCUITS 
    • Ignition OFF.
    • Disconnect: PCM C175B.
    • Inspect the following connector pins for damage and/or corrosion, PCM C175B-22, circuit CDC10 (BU/OG) and PCM C175B-23, circuit CDC15 (VT) and the generator.
    • Are the connectors OK? 
    • Yes  : INSTALL a new PCM. REFER to ELECTRONIC ENGINE CONTROLS . CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
    • No  : REPAIR the affected circuit(s). CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
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