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Test C: Warning Indicator Is On With Engine Running, System Is Charging

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Connect New Generation Star (NGS) tester to Data Link Connector (DLC). Turn ignition switch to RUN position. Using NGS tester, perform Powertrain Control Module (PCM) self-test. If no DTCs exist, go to next step. If any DTCs exist, perform appropriate test. See DIAGNOSTIC TROUBLE CODE DEFINITIONS  under SELF-DIAGNOSTIC SYSTEM.
  2. Turn ignition switch to LOCK position. Disconnect NGS tester. Start engine and let idle. Turn off all accessories. Measure voltage between primary battery terminals while varying engine speed. If voltage is less than 15 volts, go to next step. If voltage is 15 volts or more, go to TEST G: SYSTEM OVERCHARGES (BATTERY VOLTAGE GREATER THAN 15 VOLTS) .
  3. Turn ignition switch to LOCK position. Disconnect upper generator 3-pin harness connector. Turn ignition switch to RUN position. Measure voltage between ground and generator harness connector terminal "A" (Orange/Light Blue wire). See Figure. If battery voltage is present, go to next step. If battery voltage is not present, repair circuit between upper generator and battery junction box. See WIRING DIAGRAMS .
  4. Turn ignition switch to LOCK position. Connect upper generator harness connector. Disconnect lower generator 3-pin harness connector. Turn ignition switch to RUN position. Measure voltage between ground and lower generator harness connector terminal "A" (Orange/Light Blue wire). See Figure. If battery voltage is present, go to next step. If battery voltage is not present, repair circuit between lower generator and battery junction box. See WIRING DIAGRAMS .
  5. Turn ignition switch to LOCK position. Connect lower generator connector. Disconnect PCM 104-pin harness connector. Turn ignition switch to RUN position. Observe warning indicator. If warning indicator does not illuminate, go to next step. If warning indicator illuminates, repair short to ground in circuit between PCM and instrument cluster. See WIRING DIAGRAMS .
  6. Turn ignition switch to LOCK position. Connect PCM harness connector. Disconnect lower generator 3-pin harness connector. Load test upper generator. See GENERATOR LOAD TEST  under ON-VEHICLE TESTING. If upper generator is okay, go to next step. If upper generator is not okay, replace upper generator. See UPPER GENERATOR  under REMOVAL & INSTALLATION.
  7. Connect lower generator harness connector. Disconnect upper generator 3-pin harness connector. Load test lower generator. See GENERATOR LOAD TEST  under ON-VEHICLE TESTING. If lower generator is okay, go to next step. If lower generator is not okay, replace lower generator. See LOWER GENERATOR  under REMOVAL & INSTALLATION.
  8. Disconnect PCM harness connector. Inspect PCM harness connector for corrosion and pushed out pins. Connect PCM harness connector, ensuring it is connected properly. Connect all disconnected connectors. Operate system. If fault is still present, replace PCM. See REMOVAL, OVERHAUL & INSTALLATION in ENGINE PERFORMANCE. If fault is not present, system is operating properly at this time.
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