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Inspection and Verification: Notes

WARNING: This page is about a different car, the 2005 Mercury Montego, 2005 Ford Freestyle, and 2005 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Batteries contain sulfuric acid. Avoid contact with skin, eyes, or clothing. Also, shield your eyes when working near batteries to protect against possible splashing of the acid solution. In case of acid contact with skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If acid is swallowed, call a physician immediately. Failure to follow these instructions may result in personal injury.
WARNING: Batteries normally produce explosive gases which can cause personal injury. Therefore, do not allow flames, sparks or lighted substances to come near the battery. When charging or working near a battery, always shield your face and protect your eyes. Always provide ventilation. Failure to follow these instructions may result in personal injury.
WARNING: When lifting a battery, excessive pressure on the end walls could cause acid to spew through the vent caps, resulting in personal injury, damage to the vehicle or battery. Lift with a battery carrier or with your hands on opposite corners. Failure to follow these instructions may result in personal injury.
CAUTION: Do not make jumper connections except as directed. Incorrect connections may damage the voltage regulator test terminals, fuses, or fuse links.
CAUTION: Do not allow any metal object to come in contact with the generator housing and internal diode cooling fins. A short circuit may result and burn out the diodes.
NOTE: While carrying out pinpoint tests, disregard any DTCs that are set. After the completion of any test, be sure to clear all codes in the PCM.
NOTE: All voltage measurements are referenced to the negative (-) battery post unless otherwise specified.
NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) relearns its fuel trim. The vehicle may need to be driven to relearn the strategy.
  1. Verify the customer concern.
  2. Visually inspect for obvious signs of mechanical or electrical damage.
    VISUAL INSPECTION CHART

    Mechanical Electrical
    • Battery
    • Generator drive belt
    • Generator pulley
    • Battery junction box (BJB) fuse 18 (10A)
    • Circuitry
    • Cables
    • Generator
    • Powertrain control module (PCM)
    • Charging system warning indicator
  3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
  4. Verify the battery condition. Refer to BATTERY, MOUNTING AND CABLES .
  5. Check the operation of the charging system warning indicator (instrument cluster). Normal operation is as follows:
    • with the key OFF, the charging system warning indicator should be off
    • with the key ON and the engine OFF, the charging system warning indicator should be on
    • with the engine running, the charging system warning indicator should be off
  6. Turn off the headlamps and the A/C system. Turn the climate control blower to low/off. Check the battery voltage before and after starting the engine to determine if the battery voltage increases.
  7. If the cause is not visually evident, connect the diagnostic tool to the data link connector (DLC) and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle:
    • check that the diagnostic card is correctly installed.
    • check the connections to the vehicle.
    • check the ignition switch position.
  8. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool operating manual.
  9. Carry out the diagnostic tool data link test. If the diagnostic tool responds with:
    • CAN or ISO circuits fault; all electronic control units no response/not equipped, refer to MODULE COMMUNICATIONS NETWORK .
    • No response/not equipped for instrument cluster, refer to INSTRUMENT CLUSTER .
    • No response/not equipped for PCM, refer to the INTRODUCTION - GASOLINE article .
    • System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs, and carry out the self-test diagnostics for the PCM.
  10. If the DTCs retrieved are related to the concern, go to the POWERTRAIN CONTROL MODULE (PCM) DIAGNOSTIC TROUBLE CODE (DTC) INDEX  or the INSTRUMENT CLUSTER DIAGNOSTIC TROUBLE CODE (DTC) INDEX  to continue the diagnosis.
  11. If no DTCs related to the charging system are retrieved, GO to SYMPTOM CHART .
NOTE: DTC P0622 can be set by the loss of the communication lines, GEN COM circuit 1816 (YE/LB) and/or GEN MON circuit 1817 (YE). The charging system warning indicator then illuminates. If the engine is operated at greater than 2,000 rpm momentarily, the generator self-excites, the charging system warning indicator stays illuminated and the generator operates in a default mode (approximately 13.5 volts) until the engine is turned off.
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