Lincoln Nautilus: Charging System - General Information / Charging System - 2.0L EcoBoost (184kW/250PS) – MI4. Diagnosis and Testing

Inspection and Verification

1. Verify the customer concern by operating the charging system.
   

1. Before diagnosing or repairing the charging system inspect the following items:
   

• Check the battery for loose, damaged or corroded connections.
• Check the generator for loose, damaged or corroded connections.
• Check engine and battery grounds for loose, damaged or corroded connections.
• Check high current BJB for loose or corroded connections.
• Verify fuses or fusible links.
• Inspect wiring, terminals and connectors.

1. Inspect the FEAD system. REFER to 303-05.
   

1. Check the battery condition and state of charge.
   REFER to: Battery (414-01 Battery, Mounting and Cables, Diagnosis and Testing).

1. Check for abnormal ignition-off current drain(s).
   REFER to: Battery Drain Check (414-01 Battery, Mounting and Cables, General Procedures).

1. If an obvious cause for an observed or reported concern is found, repair as necessary (if possible) before proceeding.
   

1. Using the diagnostic scan tool, retrieve all Diagnostic Trouble Codes (DTCs). Refer to the appropriate DTC Chart in this section.
   

DTC Charts

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. For information about these practices,
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).

  BCM DTC Chart

NOTE: Diagnose all PCM DTCs first.

  PCM DTC Chart

Symptom Chart(s)

Symptom Chart: Charging System

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. For information about these practices,
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).

  Symptom Chart

Pinpoint Tests

System Voltage High

Refer to Wiring Diagrams Cell 12 for schematic and connector information.

NOTE: Diagnostic Trouble Code (DTC ) P0563 can be set if the vehicle has been recently jump started or the battery has been recently charged. The battery may become discharged due to excessive load(s) on the charging system from aftermarket accessories or if vehicle accessories have been operating for an extended period of time without the engine running.

Normal Operation and Fault Conditions

With the engine running, the charging system supplies voltage to the battery and the vehicle electrical system through the high current BJB and battery B+ cable. The voltage that is supplied to the vehicle electrical system is used for the operation of the various vehicle systems and modules. Many modules monitor this voltage and if it rises above or below their calibrated setpoints, a DTC sets.

  Diagnostic Trouble Code (DTC) Fault Trigger Conditions

Possible Sources

• Battery
• Generator
• Engine, generator or battery ground
• PCM
• Wiring, terminals or connectors

Visual Inspection and Diagnostic Pre-checks

• Inspect grounds G105 and G106 for loose, damaged or corroded connections.
• Inspect the high current BJB for loose, damaged or corroded connections.

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.

A1 PERFORM INSPECTION AND VERIFICATION

Perform Inspection and Verification procedure in this section. Was an obvious cause for an observed or reported concern found? Yes CORRECT the cause as necessary. No GO to A2

A2 MONITOR THE GENERATOR VOLTAGE DESIRED (GENVDSD) PID (PARAMETER IDENTIFICATION)

Start the engine. Using a diagnostic scan tool, view the PCM Parameter Identifications (PIDs). Monitor the PCM GENVDSD PID . Does the PID indicate 15.9 volts or less? Yes GO to A3 No GO to A9

A3 COMPARE THE GENERATOR VOLTAGE DESIRED (GENVDSD) PID (PARAMETER IDENTIFICATION) WITH BATTERY VOLTAGE

With the engine still running at idle, measure and record: Positive Lead Measurement / Action Negative Lead Using a diagnostic scan tool, view the PCM PID GENVDSD. Is the recorded battery voltage within ±0.5 volt of the PID ? Yes The system is operating correctly at this time. The concern may have been caused by an intermittently loose or corroded connector. ADDRESS the root cause of any connector or pin issues. No GO to A4

A4 CHECK THE VOLTAGE DROP IN THE VEHICLE GROUNDS

With the engine still running at idle, headlamps on and heater blower on high, measure the voltage drop between generator case and the battery negative terminal Measure and record: Positive Lead Measurement / Action Negative Lead Generator case Is the voltage drop less than 0.5 volt? Yes GO to A5 No INSPECT and REPAIR the engine ground, generator ground or the battery ground for corrosion.

A5 MONITOR THE GENERATOR VOLTAGE DESIRED (GENVDSD) PID (PARAMETER IDENTIFICATION) WHILE COMMANDED

Using a diagnostic scan tool, view the PCM GENVDSD PID . Using a diagnostic scan tool active command, set the PCM PID GENVDSD to 14 volts. With the engine still running at idle, measure battery and record: Positive Lead Measurement / Action Negative Lead Is the recorded battery voltage within ±0.5 volt of the PID ? Yes GO to A6 No INSTALL a new generator. REFER to: Generator - 2.7L EcoBoost (238kW/324PS) (414-02 Generator and Regulator, Removal and Installation).

A6 CHECK THE GENERATOR OUTPUT

Increase the engine rpm until the generator starts to generate output. With the engine running, measure and record: Positive Lead Measurement / Action Negative Lead   Ground Is the voltage above 15.2 volts? Yes INSTALL a new generator. REFER to: Generator - 2.7L EcoBoost (238kW/324PS) (414-02 Generator and Regulator, Removal and Installation). No GO to A7

A7 COMPARE THE SUPPLY VOLTAGE (VPWR) PID (PARAMETER IDENTIFICATION) TO BATTERY VOLTAGE

With the engine running at idle, measure and record: Positive Lead Measurement / Action Negative Lead Using a diagnostic scan tool, view PCM Parameter Identifications (PIDs). Monitor the PCM PID VPWR. Does the PID accurately display battery voltage within ±0.5 volt of the recorded battery voltage? Yes INSTALL a new generator. REFER to: Generator - 2.7L EcoBoost (238kW/324PS) (414-02 Generator and Regulator, Removal and Installation). No GO to A8

A8 CHECK PCM (POWERTRAIN CONTROL MODULE) SUPPLY VOLTAGE CIRCUITS

Turn the headlamps and heater blower off. Ignition OFF. Disconnect BJB PCM power relay. Disconnect PCM C1381B . Ignition ON. Measure: Click to display connectors Positive Lead Measurement / Action Negative Lead   C1381B-100   Ground   C1381B-101   Ground   C1381B-102   Ground Are the voltages within 0.5 volt of the recorded battery voltage? Yes GO to A9 No REPAIR the affected circuit(s).

A9 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION

Ignition OFF. Disconnect and inspect all PCM connectors. Repair: corrosion (install new connector or terminals – clean module pins) damaged or bent pins – install new terminals/pins pushed-out pins – install new pins as necessary Reconnect the PCM connectors. Make sure they seat and latch correctly. Operate the system and determine if the concern is still present. Is the concern still present? Yes CHECK OASIS for any applicable Technical Service Bulletins (TSBs). If a TSB exists for this concern, DISCONTINUE this test and FOLLOW the TSB instructions. If no Technical Service Bulletins (TSBs) address this concern,    Click here to access Guided Routine (PCM). No The system is operating correctly at this time. The concern may have been caused by module connections. ADDRESS the root cause of any connector or pin issues.

System Voltage Low or Battery is Discharged

Refer to Wiring Diagrams Cell 12 for schematic and connector information.

Normal Operation and Fault Conditions

With the engine running, the charging system supplies voltage to the battery and the vehicle electrical system through the high current BJB and battery B+ cable. The PCM monitors this B+ voltage through PCM VPWR or INJPWM circuits. If the charging system voltage drops 1.5 volts or more below the generator voltage desired (GENVDSD), the DTC sets and the charging system MIL illuminates after 30 seconds.

  Diagnostic Trouble Code (DTC) Fault Trigger Conditions

Possible Sources

• Battery
• Fuses or fusible links
• Generator
• PCM
• Wiring, terminals or connectors

Visual Inspection and Diagnostic Pre-checks

• Inspect the FEAD system. REFER to 303-05.
• Inspect for abnormal ignition-off current drain(s).
• Inspect the battery.
• Inspect the high current BJB for loose, damaged or corroded connections.

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.

B1 PERFORM INSPECTION AND VERIFICATION

Perform Inspection and Verification procedure in this section. Was an obvious cause for an observed or reported concern found? Yes CORRECT the cause as necessary. No GO to B2

B2 RETRIEVE DIAGNOSTIC TROUBLE CODES (DTCS)

Using a diagnostic scan tool, perform the PCM self-test. Is DTC P065B, P065C, U012D or U042E present? Yes If P065B and P065C are present, GO to Pinpoint Test C If P065B is present without P065C, INSTALL a new generator. REFER to: Generator - 2.7L EcoBoost (238kW/324PS) (414-02 Generator and Regulator, Removal and Installation). If U012D or U042E is present, GO to Pinpoint Test F No GO to B3

B3 CHECK THE GENERATOR CONNECTIONS

Ignition OFF. Disconnect all of the generator connectors and inspect for: corrosion (install new connector or terminals – clean module pins) damaged or bent pins – install new terminals/pins pushed-out pins – install new pins as necessary Reconnect the generator connectors. Make sure they seat and latch correctly. Measure and record: Positive Lead Measurement / Action Negative Lead Measure: Click to display connectors Positive Lead Measurement / Action Negative Lead   C102C-1   Ground Is the voltage within 0.5 volt of the recorded battery voltage? Yes GO to B4 No TIGHTEN or INSTALL a new generator B+ nut as needed. REFER to: Generator - 2.7L EcoBoost (238kW/324PS) (414-02 Generator and Regulator, Removal and Installation). VERIFY high current BJB fuse 5 (275A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams manual to identify the possible causes of the circuit short.

B4 CHECK THE VOLTAGE DROP IN THE GENERATOR B+ CIRCUIT

Start the engine. With the engine running at idle, headlamps on and blower on high, measure: Click to display connectors Positive Lead Measurement / Action Negative Lead   C102C-1 Perform 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 B5 No INSPECT and REPAIR any corrosion in the generator B+ circuit or positive battery cable connections.

B5 CHECK THE VOLTAGE DROP IN THE VEHICLE GROUNDS

With the engine still running at idle, headlamps on and heater blower on high, measure: Positive Lead Measurement / Action Negative Lead Generator case Is the voltage drop less than 0.5 volt? Yes GO to B6 No INSPECT and REPAIR the engine ground, generator ground or the battery ground for corrosion.

B6 MONITOR THE GENERATOR VOLTAGE DESIRED (GENVDSD) PID (PARAMETER IDENTIFICATION) WHILE COMMANDED

Using a diagnostic scan tool, view the PCM GENVDSD PID . Using a diagnostic scan tool active command, set the PCM PID GENVDSD to 14 volts. With the engine still running at idle, measure battery and record: Positive Lead Measurement / Action Negative Lead Is the recorded battery voltage within ±0.5 volt of the PID ? Yes GO to B7 No GO to B11

B7 COMPARE THE SUPPLY VOLTAGE (VPWR) PID (PARAMETER IDENTIFICATION) TO BATTERY VOLTAGE

With the engine still running at idle, headlamps on and blower on high, measure and record: Positive Lead Measurement / Action Negative Lead Using a diagnostic scan tool, view the PCM PID VPWR. Does the PID accurately display battery voltage within ±0.5 volt of the recorded battery voltage? Yes GO to B8 No REPAIR high resistance or loose connections in the affected PCM power circuit(s).

B8 CHECK PCM (POWERTRAIN CONTROL MODULE) VOLTAGE SUPPLY CIRCUITS

Ignition OFF. Disconnect BJB PCM power relay. Disconnect PCM C1381B . Connect a fused jumper wire: Positive Lead Measurement / Action Negative Lead BJB PCM Relay pin 3 BJB PCM Relay pin 5 NOTE: The following step will load test the circuit. A headlamp bulb would be an effective load. To avoid connector terminal damage, use the Flex Probe Kit for connector connections. Connect the load to a suitable ground connection. Measure and record: Positive Lead Measurement / Action Negative Lead Ignition ON. Measure and record: Click to display connectors Positive Lead Measurement / Action Negative Lead   C1381B-100   Ground   C1381B-101   Ground   C1381B-102   Ground Are the voltages within 0.5 volt of the recorded battery voltage? Yes REMOVE the fused jumper wire. GO to B9 No REPAIR the affected circuit(s).

B9 CHECK PCM (POWERTRAIN CONTROL MODULE) GROUND FOR HIGH RESISTANCE

NOTE: Measure battery voltage at the battery. With the engine still running at idle, turn off all accessory loads, measure and record: Positive Lead Measurement / Action Negative Lead Using a diagnostic scan tool, view PCM PID VPWR and record. With the engine still running at idle, turn headlamps ON and blower on HIGH. Measure and record: Positive Lead Measurement / Action Negative Lead Using a diagnostic scan tool, view PCM PID VPWR and record. Does the PID read within ±0.5 volt of battery voltage with accessory loads on and off? Yes GO to B10 No REPAIR the affected PCM ground circuit(s).

B10 MONITOR THE SUPPLY VOLTAGE (VPWR) PID (PARAMETER IDENTIFICATION)

NOTE: Measure battery voltage at the battery. With the engine still running at idle, turn off all accessory loads. Measure and record: Positive Lead Measurement / Action Negative Lead Using a diagnostic scan tool, view PCM PID VPWR and record. Momentarily accelerate the engine to Wide Open Throttle (WOT) and release. Repeat this step 4-5 times while continuing to monitor the PID . Does the PID stay within 0.5 volt of the recorded battery voltage when the engine Revolutions Per Minute (RPM) are increased? Yes The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. INSPECT and REPAIR any connector or pin issues found. If no connector or pin issues are found, PERFORM the battery drain test. REFER to: Battery Drain Check (414-01 Battery, Mounting and Cables, General Procedures). No GO to B12

B11 CHECK GENERATOR CLUTCH OPERATION

Ignition OFF. Perform the generator clutch component test. GO to Pinpoint Test H Is the generator clutch OK? Yes INSTALL a new generator. REFER to: Generator - 2.7L EcoBoost (238kW/324PS) (414-02 Generator and Regulator, Removal and Installation). No INSTALL a new generator clutch. REFER to: Generator Pulley (414-02 Generator and Regulator, Removal and Installation).

B12 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION

Ignition OFF. Disconnect and inspect all PCM connectors. Repair: corrosion (install new connector or terminals – clean module pins) damaged or bent pins – install new terminals/pins pushed-out pins – install new pins as necessary Reconnect the PCM connectors. Make sure they seat and latch correctly. Operate the system and determine if the concern is still present. Is the concern still present? Yes CHECK OASIS for any applicable Technical Service Bulletins (TSBs). If a TSB exists for this concern, DISCONTINUE this test and FOLLOW the TSB instructions. If no Technical Service Bulletins (TSBs) address this concern,    Click here to access Guided Routine (PCM). No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. ADDRESS the root cause of any connector or pin issues.

Generator Noise or Mechanical Performance

Normal Operation and Fault Conditions

The generator is belt-driven by the engine FEAD system. There are several sources of generator noise which include bearing noise, electrical fault noise, generator or belt pulley misalignment. A generator with certain types of diode or stator failures can also produce an audible noise.

  DTC Fault Trigger Conditions

Possible Sources

• FEAD belt
• Loose bolts/brackets
• Generator/pulleys

Visual Inspection and Diagnostic Pre-checks

• Inspect the FEAD belt.
• Inspect for loose bolts/brackets.
• Inspect the generator/pulley.

Radio Interference

Refer to Wiring Diagrams Cell 12 for schematic and connector information.

Normal Operation and Fault Conditions

The generator radio suppression equipment reduces interference transmitted through the speakers by the vehicle electrical system.

NOTE: If the Original Equipment Manufacturer (OEM) Audio Control Module (ACM) has been replaced with an aftermarket unit, the vehicle may not pass this test. Return the vehicle to Original Equipment Manufacturer (OEM) condition before following this pinpoint test.

NOTE: If the engine is operated at greater than 2,000 Revolutions Per Minute (RPM) momentarily, the generator self-excites. Make sure when the generator is disconnected the engine rpm stays below 2,000 Revolutions Per Minute (RPM). If it rises above 2,000 Revolutions Per Minute (RPM), turn the ignition to the OFF position and start the test over again.

NOTE: Inspect for any aftermarket accessories that have been added to the vehicle. Check the wiring for these accessories and be sure they have not been attached to the generator circuits and are positioned away from the generator wiring.

Possible Sources

• Generator
• In-vehicle entertainment system
• Wiring, terminals or connectors

Visual Inspection and Diagnostic Pre-checks

• Inspect the generator.
• Inspect the in-vehicle entertainment system.

Battery Monitoring Sensor Faults

Refer to Wiring Diagrams Cell 12 for schematic and connector information.

Normal Operation and Fault Conditions

The BCM monitors the battery state of charge using the battery monitoring sensor attached to the negative battery cable. Battery voltage is hardwired to the battery monitoring sensor and data is transferred from the battery monitoring sensor to the BCM via a LIN circuit.

  Diagnostic Trouble Code (DTC) Fault Trigger Conditions

Possible Sources

• Battery monitoring sensor
• BCM
• Wiring, terminals or connectors

Visual Inspection and Diagnostic Pre-checks

• Inspect the battery monitoring sensor.
• Inspect the battery monitoring sensor connector.
• Inspect the BJB fuse 5 (275A).

DTC U012D, U042E

Refer to Wiring Diagrams Cell 12 for schematic and connector information.

Normal Operation and Fault Conditions

The charging system supplies voltage to the battery and the vehicle electrical system through the battery B+ cable. The PCM monitors the generator output through a LIN communication circuit shared with the automatic grill shutters (AGS). The PCM uses this LIN circuit to communicate the desired voltage setpoint to the generator internal voltage regulator. The generator also uses this to communicate the generator load and error conditions to the PCM .

  Diagnostic Trouble Code (DTC) Fault Trigger Conditions

Possible Sources

• Active grille shutters
• Generator
• PCM
• Wiring, terminals or connectors

Visual Inspection and Diagnostic Pre-checks

• Inspect high current BJB for loose, damaged or corroded connections.
• Inspect the BJB fuse 5 (275A).
• Inspect the FEAD belt.

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.

F1 CHECK VEHICLE FOR PRESENCE OF GRILLE SHUTTERS

While looking through the grille opening, inspect the vehicle for the presence of grille shutters. REFER to: Active Grille Shutter (501-02 Front End Body Panels, Removal and Installation). Is the vehicle equipped with grille shutters? Yes GO to F2 No GO to F3

F2 RETRIEVE PCM (POWERTRAIN CONTROL MODULE) DIAGNOSTIC TROUBLE CODES (DTCS) WITH GRILLE SHUTTER ACTUATOR DISCONNECTED

Ignition OFF. Disconnect the connector C140 . KOER . Allow the engine to idle for at least one minute. Using a diagnostic scan tool, perform the PCM self-test. Is DTC U012D or U042E present? Yes GO to F3 No DIAGNOSE the grille shutter system. REFER to: Active Grille Shutter (501-02 Front End Body Panels, Diagnosis and Testing).

F3 COMPARE THE GENERATOR B+ CIRCUIT TO BATTERY VOLTAGE

Measure and record: Positive Lead Measurement / Action Negative Lead Measure: Click to display connectors Positive Lead Measurement / Action Negative Lead   C102C-1   Ground Is the voltage within 0.5 volt of the recorded battery voltage? Yes GO to F4 No TIGHTEN or INSTALL a new generator B+ nut as needed. REFER to: Generator - 2.7L EcoBoost (238kW/324PS) (414-02 Generator and Regulator, Removal and Installation). VERIFY high current BJB fuse 5 (275A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams manual to identify the possible causes of the circuit short.

F4 CHECK THE GENERATOR LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR A SHORT TO VOLTAGE

Ignition OFF. Disconnect Generator C102A . Disconnect PCM C1381B . Measure: Click to display connectors Positive Lead Measurement / Action Negative Lead   C102A-1   Ground Is any voltage present? Yes REPAIR the circuit. No GO to F5

F5 CHECK THE GENERATOR LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR A SHORT TO GROUND

Ignition OFF. Measure: Click to display connectors Positive Lead Measurement / Action Negative Lead   C102A-1   Ground Is the resistance greater than 10,000 ohms? Yes GO to F6 No REPAIR the circuit.

F6 CHECK THE GENERATOR LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR AN OPEN

Measure: Click to display connectors Positive Lead Measurement / Action Negative Lead   C102A-1   C1381B-47   C102A-1   C1651-2 Is the resistance less than 3 ohms? Yes INSTALL a new generator. REFER to: Generator - 2.7L EcoBoost (238kW/324PS) (414-02 Generator and Regulator, Removal and Installation). REPEAT the PCM self-test. If DTC U012D is retrieved again, GO to F7 No REPAIR the affected circuit.

F7 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION

Ignition OFF. Disconnect and inspect all PCM connectors. Repair: corrosion (install new connector or terminals – clean module pins) damaged or bent pins – install new terminals/pins pushed-out pins – install new pins as necessary Reconnect the PCM connectors. Make sure they seat and latch correctly. Operate the system and determine if the concern is still present. Is the concern still present? Yes CHECK OASIS for any applicable Technical Service Bulletins (TSBs). If a TSB exists for this concern, DISCONTINUE this test and FOLLOW the TSB instructions. If no Technical Service Bulletins (TSBs) address this concern,    Click here to access Guided Routine (PCM). No The system is operating correctly at this time. The concern may have been caused by module connections. ADDRESS the root cause of any connector or pin issues.

Generator Current Sensor Faults

Refer to Wiring Diagrams Cell 13 for schematic and connector information.

Normal Operation and Fault Conditions

The generator current sensor is a Hall-effect sensor attached to the generator B+ cable. It is supplied a 5 volt reference and ground from the PCM . The PCM reads the generator current sensor feedback voltage to determine how much current is flowing through the generator B+ cable.

  Diagnostic Trouble Code (DTC) Fault Trigger Conditions

Possible Sources

• Generator current sensor
• Generator clutch
• PCM
• Wiring, terminals or connectors

Visual Inspection and Diagnostic Pre-checks

• Inspect the generator current sensor.
• Inspect the generator current sensor connector.

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.

G1 RETRIEVE DIAGNOSTIC TROUBLE CODES (DTCS)

Ignition ON. Using a diagnostic scan tool, perform the PCM self-test Is DTC P0562 present? Yes GO to Pinpoint Test B No For DTC P0A5A, GO to G2 For DTC P0A5B, GO to G3 For DTC P0A5C, GO to G5

G2 CHECK THE GENERATOR CURRENT SENSOR

Ignition OFF. Inspect the generator current sensor for the following: disconnected electrical connector physical damage corrosion correct installation REFER to: Generator Current Sensor (414-01 Battery, Mounting and Cables, Removal and Installation). debris between the generator current sensor and the generator B+ cable Are any of these conditions found during inspection? Yes REPAIR as necessary or INSTALL a new generator current sensor. REFER to: Generator Current Sensor (414-01 Battery, Mounting and Cables, Removal and Installation). No GO to G9

G3 CHECK THE GENERATOR CURRENT SENSOR REFERENCE VOLTAGE CIRCUIT FOR AN OPEN

Ignition OFF. Disconnect Generator current sensor C1645 . Ignition ON. Measure: Click to display connectors Positive Lead Measurement / Action Negative Lead   C1645-1   Ground Is the voltage between 4.8 and 5.2 volts? Yes GO to G4 No If the voltage is less than 4.8 volts, REPAIR the circuit for an open or high resistance. If the voltage is greater than 5.2 volts, REPAIR the circuit for a short to voltage.

G4 CHECK THE GENERATOR CURRENT SENSOR SIGNAL RETURN CIRCUIT FOR AN OPEN

Measure: Click to display connectors Positive Lead Measurement / Action Negative Lead   C1645-1   C1645-2 Is the voltage between 4.8 and 5.2 volts? Yes GO to G5 No REPAIR the circuit for an open or high resistance.

G5 CHECK THE GENERATOR CURRENT SENSOR FEEDBACK CIRCUIT FOR A SHORT TO VOLTAGE

Ignition OFF. Disconnect PCM C1381B . Ignition ON. Measure: Click to display connectors Positive Lead Measurement / Action Negative Lead   C1381B-83   Ground Is any voltage present? Yes REPAIR the circuit. No GO to G6

G6 CHECK THE GENERATOR CURRENT SENSOR FEEDBACK CIRCUIT FOR A SHORT TO GROUND

Ignition OFF. Measure: Click to display connectors Positive Lead Measurement / Action Negative Lead   C1645-3   Ground Is the resistance greater than 10,000 ohms? Yes GO to G7 No REPAIR the circuit.

G7 CHECK THE GENERATOR CURRENT SENSOR FEEDBACK CIRCUIT FOR A SHORT TO THE SIGNAL RETURN OR VOLTAGE REFERENCE CIRCUIT

Ignition OFF. Measure: Click to display connectors Positive Lead Measurement / Action Negative Lead   C1645-3   C1645-1   C1645-3   C1645-2 Are the resistances greater than 10,000 ohms? Yes GO to G8 No REPAIR the affected circuit.

G8 CHECK THE GENERATOR CURRENT SENSOR FEEDBACK CIRCUIT FOR AN OPEN

Measure: Click to display connectors Positive Lead Measurement / Action Negative Lead   C1381B-83   C1645-3 Is the resistance less than 3 ohms? Yes GO to G9 No REPAIR the circuit.

G9 CHECK THE GENERATOR CURRENT SENSOR CONNECTION

Ignition OFF. Disconnect Generator current sensor C1645 . Inspect the generator current sensor connector for the following: corrosion (install new connector or terminals – clean module pins) damaged or bent pins – install new terminals/pins pushed-out pins – install new pins as necessary Connect and correctly seat all connectors. Ignition ON. Using a diagnostic scan tool, clear all Diagnostic Trouble Codes (DTCs) in all modules. Using a diagnostic scan tool, perform the PCM self-test. Did the DTC return? Yes REPAIR as necessary or INSTALL a new generator current sensor. REFER to: Generator Current Sensor (414-01 Battery, Mounting and Cables, Removal and Installation). CLEAR the Diagnostic Trouble Codes (DTCs). REPEAT the self-test. If the DTC returns, GO to G10 No The system is operating correctly at this time. The concern may have been caused by an intermittently loose or corroded connector. ADDRESS the root cause of any connector or pin issues.

G10 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION

Ignition OFF. Disconnect and inspect all PCM connectors. Repair: corrosion (install new connector or terminals – clean module pins) damaged or bent pins – install new terminals/pins pushed-out pins – install new pins as necessary Connect all connectors. Make sure they seat and latch correctly. Operate the system and determine if the concern is still present. Is the concern still present? Yes CHECK OASIS for any applicable Technical Service Bulletins (TSBs). If a TSB exists for this concern, DISCONTINUE this test and FOLLOW the TSB instructions. If no Technical Service Bulletins (TSBs) address this concern,    Click here to access Guided Routine (PCM). No The system is operating correctly at this time. The concern may have been caused by module connections. ADDRESS the root cause of any connector or pin issues.

Generator Clutch Component Test

Refer to Wiring Diagrams Cell 12 for schematic and connector information.

Normal Operation and Fault Conditions

The generator clutch allows the generator rotor to continue to rotate when the engine or FEAD system slows. The clutch should slip freely and smoothly in a clockwise direction. It should not rotate freely in the counterclockwise direction. A loose FEAD belt or a weak or binding tensioner can cause the pulley to overheat.
REFER to: Charging System - 2.0L EcoBoost (184kW/250PS) – MI4 - System Operation and Component Description (414-00 Charging System - General Information, Description and Operation).