LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2009 >> Flex Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1676 (Charging System) >> Diagnosis And Testing >> Pinpoint Test >> Pinpoint Test C: DTC P0620 >> Pinpoint Test C: DTC P0620

Pinpoint Test C: DTC P0620

WARNING: This page is about a different car, the 2010 Mercury Milan, 2010 Lincoln MKZ, and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
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. C1 CHECK THE BATTERY CONDITION 
    • Yes:  GO to  C2.
    • No:  INSTALL a new battery. REFER to REMOVAL AND INSTALLATION . CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
  2. C2 CHECK THE GENERATOR CONNECTIONS 
    • Ignition OFF.
    • Inspect generator C102A connection. Connector should be installed correctly and tight.
    • Disconnect: Generator C102A.
    • Inspect generator C102A for bent and/or pushed-out pins.
    • Inspect generator C102B, B+ circuit SDC14 (RD) and radial arm connection(s). Connection should be tight.
    • Measure the battery voltage.
      Fig 1: Measuring Battery Voltage
      G06063926Courtesy of FORD MOTOR CO.
    • Measure the voltage between generator C102B, B+ circuit SDC14 (RD) and ground.
      Fig 2: Measuring Voltage Between Generator B+ C102B & Ground
      G06271228Courtesy of FORD MOTOR CO.
    • Are the generator C102B and radial arm adapter connections tight and does the generator B+ measure battery voltage? 
    • Yes:  GO to  C3.
    • No:  TIGHTEN or INSTALL a new C102B (B+ nut) and/or radial arm adapter as needed. REFER to SPECIFICATIONS . VERIFY the fusible link is OK. If the fusible link is OK, REPAIR circuit SDC14 (RD). If not OK, REFER to the appropriate SYSTEM WIRING DIAGRAMS article to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
  3. C3 CHECK THE VOLTAGE DROP IN THE B+ CIRCUIT 
    • Connect: Generator C102A.
    • Start the engine.
    • With the engine running at idle, headlamps on and blower on high, measure the voltage drop between generator B+ C102B, circuit SDC14 (RD) and the positive battery terminal.
      Fig 3: Measuring Voltage Drop Between Generator B+ C102B & Positive Battery Terminal
      G06271229Courtesy of FORD MOTOR CO.
    • Carry out a wiggle test of the generator wiring and connections while measuring voltage drop.
    • Is the voltage drop less than 0.5 volt? 
    • Yes:  GO to  C4.
    • No:  INSPECT circuit SDC14 (RD), radial arm adapter and the positive battery cable for loose connections, physical damage or wire corrosion. REPAIR as necessary. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
  4. C4 A SENSE CIRCUIT LOAD TEST 
    NOTE: The following step uses a test light to simulate normal circuit loads. Use only the test light recommended in Special Tools table at the beginning of this article. To avoid connector terminal damage, use the Flex Probe Kit for the test light probe connection to the vehicle. Do not use the test light probe directly on any connector.
    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 250-350 mA incandescent 12-volt 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.
    • Ignition ON.
    • Using a 12-volt test lamp connected to ground, check for voltage at generator C102A-3, circuit SBB17 (RD), harness side.
      Fig 4: Checking Resistance On Circuit SBB17
      G06098957Courtesy of FORD MOTOR CO.
    • Does the test lamp illuminate? 
    • Yes:  GO to  C5.
    • No:  VERIFY Battery Junction Box (BJB) fuse 17 (10A) is OK. If OK, REPAIR circuit SBB17 (RD). If not OK, REFER to the appropriate SYSTEM WIRING DIAGRAMS article to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
  5. C5 CHECK THE GENERATOR COMMAND LINE FAULT (GENCMD_LF) PID 
    • Ignition OFF.
    • Connect: Generator C102A.
    • Start the engine.
    • Select and monitor the following PCM PIDs:
      • Generator Monitor (GENMON)
      • Generator Command (GENCMD)
      • Generator Command Line Fault (GENCMD_LF)
      NOTE: Many of the PCM PIDs selected will be monitored later in this pinpoint test.
    • With the engine running at idle, monitor the GENCMD_LF PID.
    • Does the GENMON_LF PID indicate FAULT? 
    • Yes:  GO to  C6.
    • No:  GO to  C9.
  6. C6 CHECK THE GENERATOR COMMAND CIRCUIT FOR A SHORT TO POWER 
    • Ignition OFF.
    • Disconnect: Generator C102A.
    • Ignition ON.
    • Measure the voltage between generator C102A-2, circuit CDC10 (BU/OG), harness side and ground.
      Fig 5: Measuring Voltage Between Generator C102A-2 & Ground
      G06065174Courtesy of FORD MOTOR CO.
    • Does voltage read 1 volt or less? 
    • Yes:  GO to  C7.
    • No:  GO to  C11.
  7. C7 COMPARE THE PCM PIDs GENERATOR MONITOR (GENMON) AND GENERATOR COMMAND (GENCMD) 
    • Ignition OFF.
    • 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: Connecting Fused Jumper Wire Between Generator C102A-1 & C102A-2
      G06065167Courtesy of FORD MOTOR CO.
    • Start the engine.
    • Monitor the GENMON and GENCMD PIDs while performing a wiggle test on the generator harness.
    • Does the GENMON PID read within 5% of the GENCMD PID? 
    • Yes:  GO to  C8.
    • No:  GO to  C12.
  8. C8 CHECK THE GENERATOR COMMAND CIRCUIT FOR DAMAGE OR AN OPEN 
    • Ignition OFF.
    • Disconnect: Fused Jumper Wire.
    • Disconnect: PCM C175B (2.5L or 3.0L).
    • Disconnect: PCM C175E (3.5L).
    • Inspect the following harness connectors for damaged or pushed-out pins:
      • PCM C175B-53, circuit CDC10 (BU/OG) (2.5L or 3.0L)
      • PCM C175E-13, circuit CDC10 (BU/OG) (3.5L)
      • Generator C102B-2, circuit CDC10 (BU/OG)
    • For 2.5L or 3.0L engines, measure the resistance between PCM C175B-53, circuit CDC10 (BU/OG), harness side and generator C102A- 2, circuit CDC10 (BU/OG, harness side.
      Fig 7: Measuring Resistance Between PCM C175B-53 & Generator C102A- 2
      G06271233Courtesy of FORD MOTOR CO.
    • For 3.5L engines, measure the resistance between PCM C175E-13, circuit CDC10 (BU/OG), harness side and generator C102A-2, circuit CDC10 (BU/OG) harness side.
      Fig 8: Measuring Resistance Between PCM C175E-13 & Generator C102A-2
      G06271234Courtesy of FORD MOTOR CO.
    • Are the connectors and pins free of damage and is the resistance less than 5 ohms? 
    • Yes:  GO to  C9.
    • No:  REPAIR circuit CDC10 (BU/OG). CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
  9. C9 CHECK THE GENERATOR COMMAND CIRCUIT FOR A SHORT TO GROUND 
    • Ignition OFF.
    • Disconnect: Generator C102A (if not previously disconnected).
    • Disconnect: PCM C175B (2.5L or 3.0L).
    • Disconnect: PCM C175E (3.5L).
    • Measure the resistance between the generator C102A-2, circuit CDC10 (BU/OG), harness side and ground.
      Fig 9: Measuring Resistance Between Generator C102A-2 & Ground
      G06098975Courtesy of FORD MOTOR CO.
    • Is the resistance greater than 10,000 ohms? 
    • Yes:  GO to  C10.
    • No:  REPAIR circuit CDC10 (BU/OG). CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
  10. C10 CHECK THE CHARGING SYSTEM CIRCUITS FOR INTERMITTENT FAULTS 
    • Connect: Generator C102A.
    • Connect: PCM C175B (2.5L or 3.0L).
    • Connect: PCM C175E (3.5L).
    • Ignition ON.
    • Clear all DTCs.
    • Start the engine and let the engine run for 5 minutes.
    • Retrieve Continuous Memory Diagnostic Trouble Codes (CMDTCs) from all modules.
    • Did any charging system DTC get stored into memory? 
    • Yes:  INSTALL a new generator. REFER to Installation  (2.5L), Removal and Installation  (3.0L) or Removal and Installation  (3.5L). CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
    • No:  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.
  11. C11 CHECK THE GENERATOR COMMAND AND PCM FOR A SHORT TO VOLTAGE 
    • Ignition OFF.
    • Disconnect: PCM C175B (2.5L or 3.0L).
    • Disconnect: PCM C175E (3.5L).
    • Ignition ON.
    • Measure the voltage between generator C102A-2, circuit CDC10 (BU/OG), harness side and ground.
      Fig 10: Measuring Voltage Between Generator C102A-2 & Ground
      G06065174Courtesy of FORD MOTOR CO.
    • Does voltage read 0 volt? 
    • Yes:  INSTALL a new PCM. REFER to INSTALLATION for 2.5L engines , INSTALLATION for 3.0L engines or INSTALLATION for 3.5L engines . CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
    • No:  REPAIR circuit CDC10 (BU/OG). CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
  12. C12 INSPECT GENERATOR CONNECTORS AND CIRCUITS 
    • Ignition OFF.
    • Disconnect: PCM C175B.
    • Inspect the following connector pins for damage and/or corrosion:
      • PCM C175B-66, circuit GD113 (BK/YE)
      • Generator C102A-1, circuit CDC15 (VT)
      • Generator C102A-2, circuit CDC10 (BU/OG)
    • Are the connectors and circuits OK? 
    • Yes:  INSTALL a new PCM. REFER to INSTALLATION for 2.5L engines , INSTALLATION for 3.0L engines or INSTALLATION for 3.5L engines . CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
    • No:  REPAIR high resistance or loose connections in the affected circuit(s). CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
scientia non olet · About LEMON Manuals