2014 Flex Workshop Manual

SECTION 414-00: Charging System	2014 Flex Workshop Manual
DIAGNOSIS AND TESTING	Procedure revision date: 05/02/2013

Charging System

Special Tool(s)
	Backprobe Pins POM6411 or equivalent
	Flex Probe Kit NUD105-R025D or equivalent
	GR 1 190 V3.0 Intelligent Diagnostic Charger 162-00036 or equivalent
	Test Light SGT27000 or equivalent 250-350 mA incandescent bulb test lamp SGT27000

DTC Charts

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. REFER to Diagnostic Methods in Section 100-00 for more information.

NOTE: The BCM utilizes a 5-character DTC followed by a 2-character failure-type code. The failure-type code provides information about specific fault conditions such as opens or shorts to ground. CMDTCs have an additional 2-character DTC status code suffix to assist in determining DTC history.

PCM DTC Chart

DTC	Description	Action
P0562	System Voltage Low	GO to Pinpoint Test B .
P0563	System Voltage High	GO to Pinpoint Test A .
P0620	Generator Control Circuit	GO to Pinpoint Test C .
P0625	Generator Field Terminal Circuit Low	GO to Pinpoint Test D .
P0626	Generator Field Terminal Circuit High	GO to Pinpoint Test D .
P065B	Generator Control Circuit Range/Performance	If combined with P0625, GO to Pinpoint Test d . If P0625 is not present, GO to Pinpoint Test E .
P0A5A	Generator Current Sensor Circuit Range/Performance	GO to Pinpoint Test H .
P0A5B	Generator Current Sensor Circuit Low	GO to Pinpoint Test H .
P0A5C	Generator Current Sensor Circuit High	GO to Pinpoint Test H .
P1397	System Voltage Out Of Self-Test Range	If combined with P0562, GO to Pinpoint Test B . If combined with P0563, GO to Pinpoint Test A .
All other DTCs	—	REFER to the PCM DTC Chart in Section 303-14 . If directed to this section from another section, GO to Symptom Chart in this section.

BCM DTC Chart

DTC	Description	Action
U1007:31	Lost Communication With Battery Monitoring Sensor "A": No Signal	GO to Pinpoint Test I .
U3003:16	Battery Voltage: Circuit Voltage Below Threshold	GO to Pinpoint Test B .
U3003:17	Battery Voltage: Circuit Voltage Above Threshold	GO to Pinpoint Test A .
All other DTCs	—	REFER to Section 419-10 .

Symptom Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. REFER to Diagnostic Methods in Section 100-00 for more information.

Preliminary Inspection

Before diagnosing or repairing the charging system inspect the following items:
- Fusible links
- Abnormal ignition-off current drain(s)
- Battery
- High current BJB for loose or corroded connections
- Radial arm adapter
- Wiring, terminals or connectors

Symptom Chart — Charging System
Condition	Possible Sources	Action
System voltage high	Fuse Wiring, terminals or connectors Engine, generator and battery ground Battery Generator PCM	GO to Pinpoint Test A .
System voltage low or battery is discharged	Fuse Fusible link Wiring, terminals or connectors Engine, generator and battery grounds Abnormal ignition-off current drain(s) Radial arm adapter Battery Generator PCM High current BJB	GO to Pinpoint Test B .
The generator is noisy	FEAD belt Loose bolts/brackets Generator/pulleys	GO to Pinpoint Test F .
Radio interference	Generator Wiring, terminals or connectors In-vehicle entertainment system	GO to Pinpoint Test G .
Charging system warning indicator is never/always on	Wiring, terminals or connectors IPC Generator PCM	RETRIEVE CMDTCs from all modules. If any charging system DTCs are found, REFER to DTC Charts. If no charging system DTCs are found, REFER to Section 413-01 .

Pinpoint Tests

Pinpoint Test A: System Voltage High

Diagnostic Overview

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. Refer to Diagnostic Methods in Section 100-00 for more information.

Refer to Wiring Diagrams Cell 12 , Charging System 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 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.

Visual Inspection and Diagnostic Pre-checks

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

Fusible links
Wiring, terminals or connectors
High current BJB for loose or corroded connections

NOTE: DTC P1397 can be set if the vehicle has been recently jump started, the battery has been recently charged or the battery has been discharged. 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.

DTC Fault Trigger Conditions

DTC	Description	Fault Trigger Conditions
P0563	System Voltage High	If the module detects a voltage from the charging system higher than 15.2 volts, this DTC sets. This DTC does not set in the PCM unless the vehicle speed is above 8 km/h (5 mph).
P1397	System Voltage Out of Self-Test Range	If the voltage rises above or drops below the calibrated set point, the PCM sets this DTC. This DTC may also be set if the vehicle has been recently jump started or has had a discharged battery.
U3003:17	Battery Voltage: Circuit Voltage Above Threshold	Sets in the BCM when the BCM detects that battery voltage has gone above 15.9 volts from the voltage supply circuit.

This pinpoint test is intended to diagnose the following:

Fuse
Wiring, terminals or connectors
Engine, generator and battery grounds
Battery
Generator
PCM

PINPOINT TEST A: SYSTEM VOLTAGE 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.

Test Step

Result / Action to Take

A1 CHECK BATTERY CONDITION

Refer to Section 414-01 to determine if the battery can hold a charge and is OK for use.
Does the battery pass the condition test?

Yes
GO to A2 .

No
INSTALL a new battery. REFER to Section 414-01 .

A2 RETRIEVE DTCs

Enter the following diagnostic mode on the scan tool: Self Test — PCM.
Is DTC P0620, P0625, P0626 or P065B present?

Yes
For DTC P0620, GO to Pinpoint Test C .

For DTCs P0625 and P0626, GO to Pinpoint Test D .

For DTC P065B, GO to Pinpoint Test E .

No
GO to A3 .

A3 MONITOR THE GENERATOR VOLTAGE DESIRED (GENVDSD) PID

Start the engine.
Enter the following diagnostic mode on the scan tool: DataLogger — PCM.
NOTE: Many of the PCM PIDs selected will be monitored later in this pinpoint test.

Generator Monitor (GENMON)

Generator Command (GENCMD)

Generator Voltage Desired (GENVDSD)

Module Supply Voltage (VPWR)

Monitor the PCM PID GENVDSD.
Does the PID indicate 15.1 volts or less?

Yes
GO to A4 .

No
GO to A12 .

A4 COMPARE THE GENERATOR VOLTAGE DESIRED (GENVDSD) PID WITH BATTERY VOLTAGE

With the engine still running at idle, measure and record battery voltage at the battery.
Monitor the PCM PID GENVDSD.
Is 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 a loose or corroded connector. ADDRESS the root cause of any connector or pin issues.

No
GO to A5 .

A5 MEASURE THE "A" SENSE VOLTAGE

Ignition OFF.
Disconnect: Generator C102A.
Ignition ON.
Measure and record the battery voltage at both battery posts.
Measure the voltage between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C102A-3	SBB58 (YE/RD)	—	Ground

Is the "A" sense voltage equal to the recorded battery voltage?

Yes
GO to A6 .

No
VERIFY high current fuse 58 (5A) 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.

A6 "A" SENSE CIRCUIT LOAD TEST

NOTICE: 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 section. 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 cannot be loaded correctly using an LED-style test lamp.

Install a test lamp between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C102A-3	SBB58 (YE/RD)	—	Ground

Does the test lamp illuminate?

Yes
GO to A7 .

No
REPAIR the circuit.

A7 CHECK THE VOLTAGE DROP IN THE VEHICLE GROUNDS

Connect: Generator C102A.
Start the engine.
With the engine running at idle, headlamps on and blower on high, measure the voltage drop between generator case and the battery negative terminal.
Is the voltage drop less than 0.5 volt?

Yes
GO to A8 .

No
INSPECT and REPAIR the engine ground, generator ground or the battery ground for corrosion.

A8 CHECK THE GENERATOR OUTPUT

Increase the engine rpm until the generator starts to generate output.
With the engine running, measure and record battery voltage at the battery.
Is the voltage above 15.2 volts?

Yes
INSTALL a new generator. REFER to Generator .

No
GO to A9 .

A9 MONITOR THE GENERATOR COMMAND (GENCMD), GENERATOR MONITOR (GENMON) AND GENERATOR VOLTAGE DESIRED (GENVDSD) PIDs

Ignition OFF.
Disconnect: Generator C102A.
Connect a fused jumper wire between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C102A-1	CDC15 (VT)	C102A-2	CDC10 (BU/OG)

Start the engine.
Enter the following diagnostic mode on the scan tool: DataLogger — PCM.
Using the active command, set the PID GENVDSD to 14 volts.
Monitor the PCM PIDs GENMON and GENVDSD.
Do the PIDs read within 5% of each other?

Yes
GO to A10 .

No
GO to A12 .

A10 COMPARE THE SUPPLY VOLTAGE (VPWR) PID TO BATTERY VOLTAGE

With the engine still running at idle, measure and record the battery voltage at the battery.
Enter the following diagnostic mode on the scan tool: DataLogger — PCM.
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 .

No
GO to A11 .

A11 CHECK PCM SUPPLY VOLTAGE CIRCUITS

Ignition OFF.
Remove the fused jumper wire.
Remove high current BJB fuse 69 (20A).
Disconnect: PCM C175B (3.5L Ti-VCT ).
Disconnect: PCM 1381B (3.5L GTDI ).
3.5L Ti-VCT engine, measure resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
High current BJB Fuse-69 (20A)	CBB69 (WH/VT)	C175B-67	CBB69 (WH/VT)
High current BJB Fuse-69 (20A)	CBB69 (WH/VT)	C175B-68	CBB69 (WH/VT)

3.5L GTDI engine, measure resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
High current BJB Fuse-69 (20A)	CBB69 (WH/VT)	C1381B-101	CBB69 (WH/VT)
High current BJB Fuse-69 (20A)	CBB69 (WH/VT)	C1381B-102	CBB69 (WH/VT)
High current BJB Fuse-69 (20A)	CBB69 (WH/VT)	C1381B-103	CBB69 (WH/VT)

Are the resistances less than 0.5 ohm?

Yes
GO to A12 .

No
REPAIR the affected circuit(s).

A12 CHECK FOR CORRECT PCM OPERATION

Ignition OFF.
Disconnect all of the PCM 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

Reinstall high current BJB fuse 69 (20A).
Reconnect the PCM and generator 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 for any applicable . If a exists for this concern, DISCONTINUE this test and FOLLOW the instructions. If no address this concern, INSTALL a new PCM. REFER to Section 303-14 .

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.

Pinpoint Test B: System Voltage Low or Battery is Discharged

Diagnostic Overview

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. Refer to Diagnostic Methods in Section 100-00 for more information.

Refer to Wiring Diagrams Cell 12 , Charging System 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 battery B+ cable. The PCM monitors this voltage through the battery positive post through the high current BJB . If voltage drops 1.5 volts or more below the generator voltage desired, this DTC sets after 30 seconds.

Visual Inspection and Diagnostic Pre-checks

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

Fusible links
Abnormal ignition-off current drain(s)
Battery
Wiring, terminals or connectors
High current BJB for loose or corroded connections
Radial arm adapter

NOTE: DTC P0562 or P1397 can be set if the vehicle has been recently jump started, the battery has been recently charged or the battery has been discharged. 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.

DTC Fault Trigger Conditions

DTC	Description	Fault Trigger Conditions
P0562	System Voltage Low	If the PCM detects voltage from the charging system that is 1.5 volts lower than the generator voltage desired, this DTC sets.
P1397	System Voltage Out of Self-Test Range	If the voltage rises above or drops below the calibrated set point, the PCM sets this DTC. This DTC may also be set if the vehicle has been recently jump started or has had a discharged battery.
U3003:16	Battery Voltage: Circuit Voltage Below Threshold	Sets in the BCM when the BCM detects that battery voltage has dropped below 9 volts from the voltage supply circuit.

This pinpoint test is intended to diagnose the following:

Fuse
Fusible link
Wiring, terminals or connectors
Engine, generator and battery grounds
Abnormal ignition-off current drain(s)
Radial arm adapter
Battery
Generator
PCM
High current BJB

PINPOINT TEST B: SYSTEM VOLTAGE LOW OR BATTERY IS DISCHARGED

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.

Test Step	Result / Action to Take
B1 CHECK BATTERY CONDITION
Refer to Section 414-01 , to determine if the battery can hold a charge and is OK for use. Does the battery pass the condition test?	Yes GO to B2 . No INSTALL a new battery. REFER to Section 414-01 .
B2 RETRIEVE PCM DTCs
Enter the following diagnostic mode on the scan tool: Self Test — PCM. Is DTC P0620, P0625, P0626 or P065B present?	Yes For DTC P0620, GO to Pinpoint Test C . For DTCs P0625 and P0626, GO to Pinpoint Test D . For DTC P065B, GO to Pinpoint Test E . 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 Connect the generator connectors. Make sure they seat, latch correctly and are tightened to specification. Measure and record battery voltage. Measure the voltage at the battery and the generator B+ terminal. Is the voltage within 0.5 volt of battery voltage?	Yes GO to B4 . No VERIFY the fusible links are 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 B+ CIRCUIT
Start the engine. With the engine running at idle, headlamps on and blower on high, measure the voltage between the battery positive post and the generator B+ terminal. 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 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 blower on high, measure the voltage drop between generator case and the battery negative terminal. 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 WHILE COMMANDED
Enter the following diagnostic mode on the scan tool: DataLogger — PCM. Using the active command, set PID GENVDSD to 14 volts. Monitor the PCM PID GENVDSD. With the engine still running at idle, measure and record the battery voltage at the battery. Is the recorded battery voltage within ±0.5 volt of the PID?	Yes GO to B7 . No INSTALL a new generator. REFER to Generator .
B7 COMPARE THE SUPPLY VOLTAGE (VPWR) PID TO BATTERY VOLTAGE
With the engine still running at idle, headlamps on and blower on high, measure and record the battery voltage at the battery. Enter the following diagnostic mode on the scan tool: DataLogger — PCM. Monitor 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 GROUND FOR HIGH RESISTANCE
Enter the following diagnostic mode on the scan tool: DataLogger — PCM. Monitor PCM PID VPWR. With the engine still running at idle, turn off all accessory loads, measure the battery voltage at the battery and note the PCM PID VPWR. With the engine still running at idle, turn headlamps on and blower on high, measure the battery voltage at the battery and monitor the PCM PID VPWR. Does the PID read within ±0.5 volt with accessory loads on as compared to accessory loads off?	Yes GO to B9 . No REPAIR the affected PCM ground circuits.
B9 MONITOR THE SUPPLY VOLTAGE (VPWR) PID
With the engine still running at idle, turn off all accessory loads, measure and record the battery voltage at the battery and monitor the PCM PID VPWR. Monitor the PID VPWR and momentarily accelerate the engine to 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 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, CARRY OUT the battery drain test. REFER to Section 414-01 . No GO to B10 .
B10 CHECK FOR CORRECT PCM OPERATION
Ignition OFF. Disconnect all of the PCM 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 PCM and generator 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 TSBs . If a TSB exists for this concern, DISCONTINUE this test and FOLLOW the TSB instructions. If no TSBs address this concern, INSTALL a new PCM. REFER to Section 303-14 . 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.

Pinpoint Test C: DTC P0620

Diagnostic Overview

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. Refer to Diagnostic Methods in Section 100-00 for more information.

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

Normal Operation and Fault Conditions

The PCM monitors the generator output via the generator monitor (GENMON) circuit. The PCM uses the generator command (GENCOM) circuit to command the generator to either increase or decrease output. If the GENCOM circuit (generator control circuit) or the "A" sense circuit are open or shorted to ground, the PCM will not be able to control the generator output. When the engine speed is greater than 2,000 rpm, the generator defaults to a steady voltage output of 13.5 volts and the PCM sends a request to the IPC to illuminate the charging system warning indicator. A GENCOM circuit fault can be confirmed by viewing the PCM PID generator command line fault (GENCMD_LF) (YES status indicator fault).

Visual Inspection and Diagnostic Pre-checks

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

Fusible links
Wiring, terminals or connectors
High current BJB for loose or corroded connections
Radial arm adapter

DTC Fault Trigger Conditions

DTC	Description	Fault Trigger Conditions
P0620	Generator Control Circuit	The PCM sets this DTC if the GENCOM circuit or "A" sense circuit are open or shorted to ground.

This pinpoint test is intended to diagnose the following:

Fuse
Wiring, terminals or connectors
Generator
PCM
Radial arm adapter

PINPOINT TEST C: DTC P0620

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.

Test Step

Result / Action to Take

C1 CHECK THE BATTERY CONDITION

Carry out Battery Condition Test to determine if the battery can hold a charge and is OK for use. REFER to Section 414-01 .
Does the battery pass the condition test?

Yes
GO to C2 .

No
INSTALL a new battery. REFER to Section 414-01 .

C2 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

Connect the generator connectors. Make sure they seat, latch correctly and are tightened to specification.
Measure and record the battery voltage between both of the battery posts.
Measure and record the battery voltage between the generator B+ terminal and the battery negative post.
Is the voltage within 0.5 volt of recorded battery voltage?

Yes
GO to C3 .

No
VERIFY the fusible links are OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams manual to identify the possible causes of the circuit short.

C3 CHECK THE VOLTAGE DROP IN THE B+ CIRCUIT

Start the engine.
With the engine running at idle, headlamps on and blower on high, measure the voltage between the generator B+ terminal and the battery positive post.
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 and REPAIR any corrosion in the generator B+ circuit or positive battery cable connections.

C4 "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 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.
Install a test lamp between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C102A-3	SBB58 (YE/RD)	—	Ground

Does the test lamp illuminate?

Yes
GO to C5 .

No
VERIFY high current fuse 58 (5A) 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.

C5 CHECK THE GENERATOR COMMAND CIRCUIT FOR A SHORT TO VOLTAGE

Ignition OFF.
Disconnect: PCM C175B (3.5L Ti-VCT ).
Disconnect: PCM 1381B (3.5L GTDI ).
Ignition ON.
Measure the voltage between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C102A-2	CDC10 (BU/OG)	—	Ground

Is any voltage present?

Yes
REPAIR the circuit.

No
GO to C6 .

C6 CHECK THE GENERATOR COMMAND CIRCUIT FOR A SHORT TO GROUND

Ignition OFF.
Measure the resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C102A-2	CDC10 (BU/OG)	—	Ground

Is the resistance greater than 10,000 ohms?

Yes
GO to C7 .

No
REPAIR the circuit.

C7 CHECK THE GENERATOR COMMAND CIRCUIT FOR AN OPEN

Ignition OFF.
3.5L Ti-VCT engine, measure the resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C175B-53	CDC10 (BU/OG)	C102A-2	CDC10 (BU/OG)

3.5L GTDI engine, measure the resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C1381B-59	CDC10 (BU/OG)	C102A-2	CDC10 (BU/OG)

Is the resistance less than 3 ohms?

Yes
GO to C8 .

No
REPAIR the circuit.

C8 COMPARE THE GENERATOR MONITOR (GENMON) AND GENERATOR COMMAND (GENCMD) PIDs

Ignition OFF.
Connect: PCM C175B (3.5L Ti-VCT ).
Connect: PCM 1381B (3.5L GTDI ).
Connect a fused jumper wire between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C102A-1	CDC15 (VT)	C102A-2	CDC10 (BU/OG)

Start the engine.
Enter the following diagnostic mode on the scan tool: DataLogger — PCM.
Monitor the PCM PIDs GENMON and GENCMD while performing a wiggle test on the generator harness.
Do the PIDs read within 5% of each other?

Yes
REMOVE the fused jumper wire. INSTALL a new generator. REFER to Generator .

No
REMOVE the fused jumper wire. GO to C9 .

C9 CHECK FOR CORRECT PCM OPERATION

Ignition OFF.
Disconnect all of the PCM 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 PCM and generator connectors. Make sure they seat and latch correctly.
Operate the system and determine if the concern is still present.
Is the concern still present?

Pinpoint Test D: DTC P0625 or P0626

Diagnostic Overview

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. Refer to Diagnostic Methods in Section 100-00 for more information.

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

Normal Operation and Fault Conditions

The PCM monitors the generator output via the generator monitor (GENMON) circuit (generator field terminal circuit). If the PCM cannot read the GENMON circuit due to an open or short to ground, when the engine speed is greater than 2,000 rpm, the generator defaults to a steady voltage of 13.5 volts and the PCM sends a request to the IPC to illuminate the charging system warning indicator. A GENMON duty cycle of 3% or less indicates a short to ground fault is present and results in DTC P0625 setting in the PCM. A GENMON duty cycle of 98% or more indicates an open or short to voltage fault is present and results in DTC P0626 setting in the PCM.

Visual Inspection and Diagnostic Pre-checks

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

Fusible links
Abnormal ignition-off current drain(s)
Battery
Wiring, terminals or connectors
High current BJB for loose or corroded connections
Radial arm adapter

DTC Fault Trigger Conditions

DTC	Description	Fault Trigger Conditions
P0625	Generator Field Terminal Circuit Low	The PCM sets this DTC if the GENMON circuit is shorted to ground, the "A" sense circuit is open or the B+ circuit is open. This DTC also sets by a faulted PCM or generator.
P0626	Generator Field Terminal Circuit High	The PCM sets this DTC if the GENMON circuit is open or shorted to power. This DTC can also be set by a faulted PCM or generator.

This pinpoint test is intended to diagnose the following:

Fuse
Wiring, terminals or connectors
Engine, generator and battery grounds
Battery
Generator
PCM
Radial arm adapter

PINPOINT TEST D: DTC P0625 or P0626

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.

Test Step

Result / Action to Take

D1 CHECK THE BATTERY CONDITION

Carry out Battery Condition Test to determine if the battery can hold a charge and is OK for use. Refer to Section 414-01 .
Does the battery pass the condition test?

Yes
GO to D2 .

No
INSTALL a new battery. REFER to Section 414-01 .

D2 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

Connect the generator connectors. Make sure they seat, latch correctly and are tightened to specification.
Measure and record the battery voltage at both battery posts.
Is the voltage within 0.5 volt of recorded battery voltage?

Yes
GO to D3 .

No
VERIFY the fusible links are OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams manual to identify the possible causes of the circuit short.

D3 CHECK THE VOLTAGE DROP IN THE B+ CIRCUIT

Start the engine.
With the engine running at idle, headlamps on and blower on high, measure the voltage between the battery positive post and the generator B+ terminal.
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
For DTC P0625, GO to D4 .

For DTC P0626, GO to D5 .

No
INSPECT and REPAIR any corrosion in the generator B+ circuit or positive battery cable connections.

D4 "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 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.
Install a test lamp between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C102A-3	SBB58 (YE/RD)	—	Ground

Does the test lamp illuminate?

Yes
GO to D5 .

No
VERIFY high current fuse 58 (5A) 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.

D5 CHECK THE GENERATOR MONITOR CIRCUIT FOR A SHORT TO VOLTAGE

Disconnect: PCM C175B (3.5L Ti-VCT ).
Disconnect: PCM 1381B (3.5L GTDI ).
Ignition ON.
Measure the voltage between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C102A-1	CDC15 (VT)	—	Ground

Is any voltage present?

Yes
REPAIR the circuit.

No
GO to D6 .

D6 CHECK THE GENERATOR MONITOR CIRCUIT FOR A SHORT TO GROUND

Ignition OFF.
Measure the resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C102A-1	CDC15 (VT)	—	Ground

Is the resistance greater than 10,000 ohms?

Yes
GO to D7 .

No
REPAIR the circuit.

D7 CHECK THE GENERATOR MONITOR CIRCUIT FOR AN OPEN

3.5L Ti-VCT engine, measure the resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C175B-14	CDC15 (VT)	C102A-1	CDC15 (VT)

3.5L GTDI engine, measure the resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C1381B-26	CDC15 (VT)	C102A-1	CDC15 (VT)

Is the resistance less than 3 ohms?

Yes
GO to D8 .

No
REPAIR the circuit.

D8 CHECK THE GENERATOR B+ INTERNAL RESISTANCE

NOTE: Failure to disconnect the battery will result in false resistance readings.
Disconnect the battery. Refer to Section 414-01 .
Disconnect: Generator C102B.
Measure the resistance between the generator B+ terminal and the generator case.
Is the resistance greater than 25K ohms?

Yes
GO to D9 .

No
INSTALL a new generator. REFER to Generator .

D9 CHECK THE RESISTANCE OF THE VOLTAGE REGULATOR INTERNAL CIRCUITS TO GROUND

Measure the resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C102A-1 (component side)	—	—	Ground
C102A-2 (component side)	—	—	Ground
C102A-3 (component side)	—	—	Ground

Are the resistances greater than 10,000 ohms?

Yes
GO to D10 .

No
INSTALL a new generator. REFER to Generator .

D10 COMPARE THE GENERATOR MONITOR (GENMON) AND GENERATOR COMMAND (GENCMD) PIDs

Connect: PCM C175B (3.5L Ti-VCT ).
Connect: PCM 1381B (3.5L GTDI ).
Connect a fused jumper wire between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C102A-1	CDC15 (VT)	C102A-2	CDC10 (BU/OG)

Start the engine.
Enter the following diagnostic mode on the scan tool: DataLogger — PCM.
Using the active command, set the GENVDSD PID to 14.0 volts.
Monitor the GENMON and GENCMD PIDs while carrying out a wiggle test on the generator wiring harness.
Do the PIDs read within 2% of each other?

Yes
REMOVE the fused jumper wire. INSTALL a new generator. REFER to Generator .

No
REMOVE the fused jumper wire. GO to D11 .

D11 CHECK FOR CORRECT PCM OPERATION

Ignition OFF.
Disconnect all of the PCM 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 PCM and generator connectors. Make sure they seat and latch correctly.
Operate the system and determine if the concern is still present.
Is the concern still present?

Pinpoint Test E: DTC P065B

Diagnostic Overview

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. Refer to Diagnostic Methods in Section 100-00 for more information.

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

Normal Operation and Fault Conditions

With the engine running, the PCM monitors and expects to receive a valid generator monitor (GENMON) signal with a duty cycle greater than 5% and less than 98%. The PCM also monitors the state of the generator command (GENCMD) signal line to make sure it is not stuck high or stuck low. A DTC sets if the GENMON or GENCMD signal fluctuates between out-of-valid range, stuck high, stuck low, or some combination and normal. When the engine speed is greater than 2,000 rpm, the generator defaults to a steady voltage of 13.5 volts and the PCM sends a request to the IPC to illuminate the charging system warning indicator lamp.

Visual Inspection and Diagnostic Pre-checks

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

Fusible links
Wiring, terminals or connectors
High current BJB for loose or corroded connections
Radial arm adapter

DTC Fault Trigger Conditions

DTC	Description	Fault Trigger Conditions
P065B	Generator Control Circuit Range/Performance	The PCM sets this DTC if the input frequency was continuously less than 80 Hz or more than 200 Hz. Additionally, if the signal shows a faulted condition that is happening in a fluctuating manner, the PCM tracks the fluctuations between faulted and normal conditions. This DTC can also set if the fluctuations occur frequently within a short amount of time.

This pinpoint test is intended to diagnose the following:

Wiring, terminals or connectors
Radial arm adapter
Generator
PCM

PINPOINT TEST E: DTC P065B

NOTE: Make sure battery voltage is greater than 12.2 volts prior to carrying out this pinpoint test.

NOTE: Do not have a battery charger attached during vehicle testing.

Test Step

Result / Action to Take

E1 CHECK THE BATTERY CONDITION

Carry out Battery Condition Test to determine if the battery can hold a charge and is OK for use. Refer to Section 414-01 .
Does the battery pass the condition test?

Yes
GO to E2 .

No
INSTALL a new battery. REFER Section 414-01 .

E2 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

Connect the generator connectors. Make sure they seat, latch correctly and are tightened to specification.
Measure and record the battery voltage at both battery posts.
Measure and record the battery voltage between the generator B+ terminal and the battery negative post.
Is the voltage within 0.5 volt of recorded battery voltage?

Yes
GO to E3 .

No
VERIFY the fusible links are OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams manual to identify the possible causes of the circuit short.

E3 "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 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.

Disconnect: Generator C102A.
Install a test lamp between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C102A-3	SBB58 (YE/RD)	—	Ground

Does the test lamp illuminate?

Yes
GO to E4 .

No
VERIFY high current fuse 58 (5A) 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.

E4 CHECK THE GENERATOR MONITOR FREQUENCY (GENMON_HZ) PID

Connect: Generator C102A.
Start the engine.
Enter the following diagnostic mode on the scan tool: DataLogger — PCM.
Monitor the GENMON_HZ PID.
Does the PID read between 80-200 Hz?

Yes
GO to E8 .

No
GO to E5 .

E5 CHECK THE GENERATOR MONITOR FREQUENCY (GENMON_HZ) PID WITH GENERATOR DISCONNECTED

Ignition OFF.
Disconnect: Generator C102A.
Start the engine.
Enter the following diagnostic mode on the scan tool: DataLogger — PCM.
Monitor the GENMON_HZ PID.
Does the PID read between 0-2 Hz?

Yes
GO to E7 .

No
GO to E6 .

E6 CHECK GENERATOR MONITOR CIRCUIT

NOTICE: This pinpoint test step directs testing circuits using a back-probe method. Use the special back-probe tool specified in the tool list in this section. Do not force test leads or other probes into connectors. Use care to avoid connector terminal damage while making sure that good electrical contact is made with the circuit or terminal. Failure to follow these instructions may cause damage to wiring, terminals, or connectors and subsequent electrical faults.

Ignition OFF.
3.5L Ti-VCT engine, connect a fused jumper wire between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C175B-14	CDC15 (VT)	—	Ground

3.5L GTDI engine, connect a fused jumper wire between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C1381B-26	CDC15 (VT)	—	Ground

Start the engine.
Enter the following diagnostic mode on the scan tool: DataLogger — PCM.
Monitor the GENMON_HZ PID.
Does the PID read 0 Hz?

Yes
INSPECT the harness for wire to wire shorts or insulation chaffing, mis-pinned connectors and correct wire colors and REPAIR the circuit as needed.

No
GO to E9 .

E7 MONITOR THE GENERATOR MONITOR FREQUENCY (GENMON_HZ) PID WHILE ACTIVATING THE GENERATOR VOLTAGE DESIRED (GENVDSD) PID

Ignition OFF.
Connect a fused jumper wire between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C102A-1	CDC15 (VT)	C102A-2	CDC10 (BU/OG)

Start the engine.
Enter the following diagnostic mode on the scan tool: DataLogger — PCM.
With the engine running at idle, set the active command GENVDSD PID to 14 volts.
Monitor the GENMON_HZ PID.
Does the PID read between 120-130 Hz?

Yes
INSTALL a new generator. REFER to Generator .

No
GO to E9 .

E8 CHECK THE GENERATOR COMMAND LINE FAULT (GENCMD_LF) PID

Start the engine.
Enter the following diagnostic mode on the scan tool: DataLogger — PCM.
With the engine running and all selectable loads OFF, monitor the GENCMD_LF PID.
Does the PID fluctuate from YES FAULT to NO FAULT?

Yes
INSTALL a new generator. REFER to Generator .

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.

E9 CHECK FOR CORRECT PCM OPERATION

Ignition OFF.
Disconnect all of the PCM 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 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?

Pinpoint Test F: The Generator is Noisy

Diagnostic Overview

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. Refer to Diagnostic Methods in Section 100-00 for more information.

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

Normal Operation and Fault Conditions

The generator is belt-driven by the engine accessory drive 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 may also produce an audible noise.

Visual Inspection and Diagnostic Pre-checks

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

Fusible links
Wiring, terminals or connectors
High current BJB for loose or corroded connections
Radial arm adapter

This pinpoint test is intended to diagnose the following:

FEAD belt
Loose bolts/brackets
Generator/pulleys

PINPOINT TEST F: THE GENERATOR IS NOISY

Test Step	Result / Action to Take
F1 CHECK FOR ACCESSORY DRIVE BELT NOISE AND LOOSE MOUNTING BRACKETS
Ignition OFF. Check the accessory drive belt and tensioner for damage and correct installation. REFER to Section 303-05 . Check the accessory mounting brackets and generator pulley for looseness or misalignment. Is the accessory drive OK?	Yes GO to F2 . No REPAIR as necessary. REFER to Section 303-05 .
F2 CHECK THE GENERATOR MOUNTING
Check the generator mounting for loose bolts or misalignment. Is the generator mounted correctly?	Yes GO to F3 . No REPAIR as necessary.
F3 CHECK THE GENERATOR FOR NOISE
With the engine running, use a stethoscope or equivalent listening device to probe the generator and the accessory drive area for unusual mechanical noise. Is the generator the noise source?	Yes INSTALL a new generator. REFER to Generator . No REFER to Section 303-00 , to diagnose the source of the engine noise.

Pinpoint Test G: Radio Interference

Diagnostic Overview

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. Refer to Diagnostic Methods in Section 100-00 for more information.

Refer to Wiring Diagrams Cell 12 , Charging System 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.

Visual Inspection and Diagnostic Pre-checks

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

Generator
In-vehicle entertainment system
Wiring, terminals or connectors

This pinpoint test is intended to diagnose the following:

Generator
Wiring, terminals or connectors
In-vehicle entertainment system

PINPOINT TEST G: RADIO INTERFERENCE

NOTE: If the OEM ACM has been replaced with an aftermarket unit, the vehicle may not pass this test. Return the vehicle to OEM condition before following this pinpoint test.

NOTE: If the engine is operated at greater than 2,000 rpm momentarily, the generator self-excites. Make sure when the generator is disconnected the engine rpm stays below 2,000 rpm. If it exceeds 2,000 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.

Test Step	Result / Action to Take
G1 VERIFY THE GENERATOR IS THE SOURCE OF THE RADIO INTERFERENCE
Start the engine. Tune the ACM to a station where the interference is present. Ignition OFF. Disconnect: Generator C102B. Start the engine. Is the interference present with the generator disconnected?	Yes Refer to the appropriate section in Group 415 for the procedure. No INSTALL a new generator. REFER to Generator . TEST the system for normal operation.

Pinpoint Test H: DTC P0A5A, P0A5B, P0A5C

Diagnostic Overview

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. Refer to Diagnostic Methods in Section 100-00 for more information.

Refer to Wiring Diagrams Cell 13 , Power Distribution/BCM 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.

Visual Inspection and Diagnostic Pre-checks

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

Generator current sensor
Wiring, terminals or connectors

DTC Fault Trigger Conditions

DTC	Description	Fault Trigger Conditions
P0A5A	Generator Current Sensor Circuit Range/Performance	The PCM does not detect current through the generator current sensor and there are no generator current sensor circuit DTCs set.
P0A5B	Generator Current Sensor Circuit Low	The PCM senses lower than expected voltage on the generator current sensor feedback circuit, indicating an open or a short directly to ground.
P0A5C	Generator Current Sensor Circuit High	The PCM senses higher than expected voltage on the generator current sensor feedback circuit, indicating a short directly to voltage.

This pinpoint test is intended to diagnose the following:

Wiring, terminals or connectors
Battery current sensor
PCM

PINPOINT TEST H: DTC P0A5A, P0A5B, P0A5C

Test Step

Result / Action to Take

H1 CHECK THE PCM DTCs

Ignition ON.
Enter the following diagnostic mode on the scan tool: Self Test — PCM.
Is DTC P0A5A present?

Yes
GO to H2 .

No
For DTC P0A5B, GO to H3 .

For DTC P0A5C, GO to H7 .

H2 CHECK THE GENERATOR CURRENT SENSOR

Ignition OFF.
Inspect the generator current sensor for the following:

physical damage
corrosion
disconnected electrical connector
disconnected from generator B+ cable
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 Section 414-01 .

No
GO to H9 .

H3 CHECK THE GENERATOR CURRENT SENSOR REFERENCE VOLTAGE CIRCUIT FOR AN OPEN

Ignition OFF.
Disconnect: Generator Current Sensor C1645.
Ignition ON.
Measure the voltage between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C1645-1	LE424 (YE/GN)	—	Ground

Is the voltage between 4.7 and 5.1 volts?

Yes
GO to H4 .

No
If the voltage is less than 4.7 volts, REPAIR the circuit for an open or high resistance.

If the voltage is greater than 5.1 volts, REPAIR the circuit for a short to voltage.

H4 CHECK THE GENERATOR CURRENT SENSOR SIGNAL RETURN CIRCUIT FOR AN OPEN

Measure the voltage between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C1645-1	LE424 (YE/GN)	C1645-2	RE407 (YE/VT)

Is the voltage between 4.7 and 5.1 volts?

Yes
GO to H5 .

No
REPAIR the circuit for an open or high resistance.

H5 CHECK THE GENERATOR CURRENT SENSOR FEEDBACK CIRCUIT FOR A SHORT TO GROUND

Ignition OFF.
Disconnect: PCM C175B (3.5L Ti-VCT ).
Disconnect: PCM 1381B (3.5L GTDI ).
Measure the resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C1645-3	VDC61 (VT/GN)	—	Ground

Is the resistance greater than 10,000 ohms?

Yes
GO to H6 .

No
REPAIR the circuit.

H6 CHECK THE GENERATOR CURRENT SENSOR FEEDBACK CIRCUIT FOR AN OPEN

3.5L Ti-VCT engine, measure the resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C1645-3	VDC61 (VT/GN)	C175B-33	VDC61 (VT/GN)

3.5L GTDI engine, measure the resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C1645-3	VDC61 (VT/GN)	C1381B-94	VDC61 (VT/GN)

Is the resistance less than 3 ohms?

Yes
GO to H7 .

No
REPAIR the circuit.

H7 CHECK THE GENERATOR CURRENT SENSOR FEEDBACK CIRCUIT FOR A SHORT TO VOLTAGE

Ignition OFF.
Disconnect: Generator Current Sensor C1645.
Disconnect: PCM C175B (3.5L Ti-VCT ).
Disconnect: PCM 1381B (3.5L GTDI ).
Ignition ON.
Measure the voltage between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C1645-3	VDC61 (VT/GN)	—	Ground

Is any voltage present?

Yes
REPAIR the circuit.

No
GO to H8 .

H8 CHECK THE GENERATOR CURRENT SENSOR FEEDBACK CIRCUIT FOR A SHORT TO THE SIGNAL RETURN OR VOLTAGE REFERENCE CIRCUIT

Ignition OFF.
Measure the resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C1645-3	VDC61 (VT/GN)	C1645-1	LE424 (YE/GN)
C1645-3	VDC61 (VT/GN)	C1645-2	RE407 (YE/VT)

Are the resistances greater than 10,000 ohms?

Yes
GO to H9 .

No
REPAIR the affected circuit.

H9 CHECK THE GENERATOR CURRENT SENSOR CONNECTION

Ignition OFF.
Disconnect: Generator Current Sensor C1645 (if not previously disconnected).
Inspect the generator current sensor connector 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

Connect and correctly seat the generator current sensor connector.
Ignition ON.
Clear the DTCs.
Enter the following diagnostic mode on the scan tool: Self Test — PCM.
Did the DTC return?

Yes
REPAIR as necessary or INSTALL a new generator current sensor. REFER to Section 414-01 . CLEAR the DTCs. REPEAT the self-test. If the DTC returns, GO to H10 .

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.

H10 CHECK FOR CORRECT PCM OPERATION

Ignition OFF.
Disconnect all of the PCM 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 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?

Pinpoint Test I: DTC U1007:31

Diagnostic Overview

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. Refer to Diagnostic Methods in Section 100-00 for more information.

Refer to Wiring Diagrams Cell 13 , Power Distribution/BCM for schematic and connector information.

Normal Operation and Fault Conditions

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

Visual Inspection and Diagnostic Pre-checks

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

Battery current sensor
Inspect the wiring, terminals or connectors

DTC Fault Trigger Conditions

DTC	Description	Fault Trigger Conditions
U1007:31	Lost Communication With Battery Monitoring Sensor "A": No Signal	The BCM does not indicate current from the battery current sensor.

This pinpoint test is intended to diagnose the following:

Wiring, terminals or connectors
Battery current sensor
BCM

PINPOINT TEST I: U1007:31

Test Step

Result / Action to Take

I1 CHECK THE BATTERY CURRENT SENSOR

Inspect the battery current sensor for the following:

physical damage
corrosion
disconnected electrical connector
disconnected from battery ground cable
debris between the battery current sensor and the battery ground cable

Are any of these conditions found during inspection?

Yes
GO to I13 .

No
GO to I2 .

I2 CHECK THE BATTERY CURRENT SENSOR REFERENCE VOLTAGE CIRCUIT

Ignition OFF.
Disconnect: Battery Current Sensor C1646.
Ignition ON.
Measure the voltage between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C1646-1	SDC57 (BU/OG)	—	Ground

Is the voltage between 4.7 and 5.1 volts?

Yes
GO to I6 .

No
If the voltage is less than 4.7 volts, GO to I4 .

If the voltage is greater than 5.1 volts, GO to I3 .

I3 CHECK THE BATTERY CURRENT SENSOR REFERENCE VOLTAGE CIRCUIT FOR A SHORT TO VOLTAGE

Ignition OFF.
Disconnect: BCM C2280F.
Remove the RUN/START relay.
Connect a fused jumper wire between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C2280F-3	—	C2280F-5	—

Ignition ON.
Measure the voltage between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C1646-1	SDC57 (BU/OG)	—	Ground

Is any voltage present?

Yes
REPAIR the circuit.

No
REMOVE the fused jumper wire. INSTALL the RUN/START relay and GO to I13 .

I4 CHECK THE BATTERY CURRENT SENSOR REFERENCE VOLTAGE CIRCUIT FOR A SHORT TO GROUND

Ignition OFF.
Disconnect: BCM C2280F.
Measure the resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C1646-1	SDC57 (BU/OG)	—	Ground

Is the resistance greater than 10,000 ohms?

Yes
GO to I5 .

No
REPAIR the circuit.

I5 CHECK THE BATTERY CURRENT SENSOR REFERENCE VOLTAGE CIRCUIT FOR AN OPEN

Measure the resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C1646-1	SDC57 (BU/OG)	C2280F-21	SDC57 (BU/OG)

Is the resistance less than 3 ohms?

Yes
GO to I13 .

No
REPAIR the circuit.

I6 CHECK THE BATTERY CURRENT SENSOR SIGNAL RETURN CIRCUIT

Measure the voltage between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C1646-1	SDC57 (BU/OG)	C1646-2	RDC59 (GY/BN)

Is the voltage between 4.7 and 5.1 volts?

Yes
GO to I9 .

No
GO to I7 .

I7 CHECK THE BATTERY CURRENT SENSOR SIGNAL RETURN CIRCUIT FOR VOLTAGE

Measure the voltage between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C1646-2	RDC59 (GY/BN)	—	Ground

Is any voltage present?

Yes
If the voltage is 5.1 volts or less, REPAIR signal return circuit for a short to reference voltage circuit.

If the voltage is greater than 5.1 volts, REPAIR signal return circuit for a short to voltage.

No
GO to I8 .

I8 CHECK THE BATTERY CURRENT SENSOR SIGNAL RETURN CIRCUIT FOR AN OPEN

Ignition OFF.
Disconnect: BCM C2280F.
Measure the resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C1646-2	RDC59 (GY/BN)	C2280F-14	RDC59 (GY/BN)

Is the resistance less than 3 ohms?

Yes
GO to I13 .

No
REPAIR the circuit.

I9 CHECK THE BATTERY CURRENT SENSOR FEEDBACK CIRCUIT FOR A SHORT TO VOLTAGE

Ignition OFF.
Disconnect: BCM C2280F.
Remove the RUN/START relay.
Connect a fused jumper wire between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C2280F-3	—	C2280F-5	—

Ignition ON.
Measure the voltage between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C1646-3	LDC59 (BU/WH)	—	Ground

Is any voltage present?

Yes
REPAIR the circuit.

No
REMOVE the fused jumper wire. INSTALL the RUN/START relay and GO to I10 .

I10 CHECK THE BATTERY CURRENT SENSOR FEEDBACK CIRCUIT FOR A SHORT TO GROUND

Ignition OFF.
Measure the resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C1646-3	LDC59 (BU/WH)	—	Ground

Is the resistance greater than 10,000 ohms?

Yes
GO to I11 .

No
REPAIR the circuit.

I11 CHECK THE BATTERY CURRENT SENSOR FEEDBACK CIRCUIT FOR AN OPEN

Measure the resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C1646-3	LDC59 (BU/WH)	C2280F-20	LDC59 (BU/WH)

Is the resistance less than 3 ohms?

Yes
GO to I12 .

No
REPAIR the circuit.

I12 CHECK THE BATTERY CURRENT SENSOR FEEDBACK CIRCUIT FOR A SHORT TO THE SIGNAL RETURN OR REFERENCE CIRCUIT

Measure the resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C1646-3	LDC59 (BU/WH)	C1646-2	RDC59 (GY/BN)
C1646-3	LDC59 (BU/WH)	C1646-1	SDC57 (BU/OG)

Are the resistances greater than 10,000 ohms?

Yes
GO to I13 .

No
REPAIR the affected circuit.

I13 CHECK THE BATTERY CURRENT SENSOR CONNECTION

Ignition OFF.
Disconnect: Battery Current Sensor C1646 (if not previously disconnected).
Inspect the battery current sensor connector 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

Connect: Battery Current Sensor C1646.
Connect: BCM C2280F.
Ignition ON.
Clear the DTCs.
Enter the following diagnostic mode on the scan tool: Self Test — BCM .
Did the DTC return?

Yes
REPAIR as necessary or INSTALL a new battery current sensor. REFER to Section 414-01 . CLEAR the DTCs. REPEAT the self-test. If the DTC returns, GO to I14 .

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.

I14 CHECK FOR CORRECT BCM OPERATION

Ignition OFF.
Disconnect all of the BCM 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 BCM 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 for any applicable . If a exists for this concern, DISCONTINUE this test and FOLLOW the instructions. If no address this concern, INSTALL a new . REFER to Section 419-10 .

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.