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Home >> Ford >> 2012 >> Explorer Limited, 3.5 8, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 36 (Charging System) >> Diagnosis And Testing >> Pinpoint Test >> Special Tool(s) >> Pinpoint Test I: DTCs P163C and P163D >> PINPOINT TEST I: DTCs P163C AND P163D

PINPOINT TEST I: DTCs P163C AND P163D

WARNING: This page is about a different car, the 2013 Ford F-550 Super Duty, 2013 Ford F-450 Super Duty, 2013 Ford F-350 Super Duty, and 2013 Ford F-250 Super Duty. 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. I1 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 I2.
    • 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. I2 CHECK THE GENERATOR B+ CONNECTION 
    • Ignition OFF.
    • Inspect generator C1251B, circuit SDC02 (RD), harness side. Connection should be tight.
    • Measure the voltage between generator C1251B, circuit SDC02 (RD) and ground.
      Fig 1: Measuring Voltage Between Generator C1251B, Circuit SDC02 (RD) And Ground
      G06065172Courtesy of FORD MOTOR CO.
    • Is the generator connection tight and does the generator B+ measure battery voltage? 
    • Yes  : GO to I3.
    • No  : REPAIR the generator B+ connection or circuit. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
  3. I3 CHECK THE "A" SENSE VOLTAGE 
    • Disconnect: Generator C1251A.
    • Measure battery voltage and record.
      Fig 2: Measuring Battery Voltage
      G06544266Courtesy of FORD MOTOR CO.
    • Measure the voltage between generator C1251A-3, circuit SDC02 (RD), harness side and ground.
      Fig 3: Measuring Voltage Between Generator C1251A-3, Circuit SDC02 (RD) And Ground
      G06098956Courtesy of FORD MOTOR CO.
    • Is the voltage equal to battery voltage? 
    • Yes  : GO to I4.
    • No  : VERIFY fusible links are OK. If OK, REPAIR circuit SDC02 (RD). If not OK, REFER to the SYSTEM 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. I4 MONITOR THE PCM PID GENERATOR MONITOR (GENMON) WITH IGNITION ON/ENGINE OFF 
    • Connect: Generator C1251A.
    • Ignition ON.
    • 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).
    • Does the GENMON PID read 0%? 
    • Yes  : GO to I5.
    • No  : GO to  I10.
  5. I5 MONITOR THE PCM PIDs GENERATOR MONITOR (GENMON) AND GENERATOR VOLTAGE DESIRED (GENVDSD) WITH ENGINE RUNNING AND NO LOADS 
    • Start and idle 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 vehicles equipped with a manual 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.
    • Does the GENMON PID read between 3% and 98% at engine idle speed and at 3, 000 RPM? 
    • Yes  : GO to I6.
    • No  : GO to  I11.
  6. I6 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 vehicles 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 I7.
    • No  : GO to  I11.
  7. I7 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 I8.
    • No  : GO to  I11.
  8. I8 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 C1251B.
    • Measure the resistance between generator C1251B, component side and the generator housing.
      Fig 4: Measuring Resistance Between Generator C1251B, Component Side And Generator Housing
      G06065180Courtesy of FORD MOTOR CO.
    • Is the resistance greater than 25K ohms? 
  9. I9 CHECK THE RESISTANCE OF THE VOLTAGE REGULATOR INTERNAL CIRCUITS TO GROUND 
    • Disconnect: Generator C1251A.
    • Measure the resistance between generator C1251A, component side and ground as follows:
      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 - 6.7L DIESEL, DUAL GENERATOR . CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
  10. I10 CHECK THE PCM PID GENERATOR MONITOR (GENMON) INPUT TO THE PCM 
    • Ignition OFF.
    • Disconnect: Generator C1251A.
    • Connect a fused jumper wire between generator C1251A-1, circuit CDC47 (WH), harness side and ground.
      Fig 5: Connecting Fused Jumper Wire Between Generator C1251A-1, Circuit CDC47 (WH) And Ground
      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  I14.
    • No  : GO to  I15.
  11. I11 "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 the 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 C1251A (if not previously disconnected).
    • Ignition ON.
    • Using a 12-volt test lamp connected to ground, check for voltage at C1251A-3, circuit SDC02 (RD), harness side.
      Fig 6: Checking Voltage At C1251A-3, Circuit SDC02 (RD) To Ground
      G06098957Courtesy of FORD MOTOR CO.
    • Does the test lamp illuminate? 
    • Yes  : GO to I12.
    • No  : VERIFY fusible links are OK. If OK, REPAIR circuit SDC02 (RD). If not OK, REFER to the SYSTEM 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. I12 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 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 C1251B.
    • Using a 12-volt test lamp connected to ground, check for voltage at C1251B-1, circuit SDC02 (RD), harness side.
      Fig 7: Checking Voltage At C1251B-1, Circuit SDC02 (RD) To Ground
      G07974102Courtesy of FORD MOTOR CO.
    • Does the test lamp illuminate? 
    • Yes  : GO to I13.
    • No  : REPAIR circuit SDC02 (RD) for high resistance. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
  13. I13 CHECK GENCOM CIRCUIT FOR DAMAGE OR AN OPEN 
    • Ignition OFF.
    • Disconnect: PCM C1232B.
    • Inspect the following harness connectors for damaged or pushed-out pins:
      • PCM C1232B-54, circuit CDC48 (YE/GN).
      • Generator C1251A-2, circuit CDC48 (YE/GN).
    • Measure the resistance between PCM C1232B-54, circuit CDC48 (YE/GN), harness side and generator C1251A-2, circuit CDC48 (YE/GN), harness side.
      Fig 8: Measuring Resistance Between PCM C1232B-54, Circuit CDC48 (YE/GN) And Generator C1251A-2, Circuit CDC48 (YE/GN)
      G07974112Courtesy of FORD MOTOR CO.
    • Are the connectors and pins free of damage and is the resistance less than 0.5 ohm? 
    • Yes  : GO to I14.
    • No  : REPAIR circuit CDC09 (YE) or CDC10 (BU/OG). CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
  14. I14 COMPARE THE PCM PIDs GENERATOR MONITOR 2 (GENMON) AND GENERATOR COMMAND 2 (GENCMD) 
    • Connect: Generator C1251B (if previously disconnected).
    • Connect: PCM C1232B (if previously disconnected).
    • Connect a fused jumper wire between generator C1251A-1, circuit CDC47 (WH), harness side and generator C1251A-2, circuit CDC48 (YE/GN), harness side.
      Fig 9: Connecting Fused Jumper Wire Between Generator C1251A-1, Circuit CDC47 (WH) And Generator C1251A-2, Circuit CDC48 (YE/GN)
      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? 
  15. I15 INSPECT GENERATOR CIRCUITS AND CONNECTORS 
    • Ignition OFF.
    • Disconnect: PCM C1232B.
    • Inspect the following connector pins for damage and/or corrosion:
      • generator C1251A-1, circuit CDC47 (WH)
      • PCM C1232B-15, circuit CDC47 (WH)
    • Are circuits and connectors OK? 
    • Yes  : INSTALL a new PCM. REFER to ELECTRONIC ENGINE CONTROLS - DIESEL ENGINES . CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
    • No  : REPAIR the circuit(s) and/or connector(s) as necessary. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
  16. I16 INSPECT PCM CIRCUITS 
    • Ignition OFF.
    • Disconnect: PCM C1232B.
    • Inspect the following connector pins for damage and/or corrosion:
      • PCM C1232B-15, circuit CDC47 (WH)
      • PCM C1232B-54, circuit CDC48 (YE/GN)
    • Are the connectors OK? 
    • Yes  : INSTALL a new PCM. REFER to ELECTRONIC ENGINE CONTROLS - DIESEL ENGINES . 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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