fuses generator pcm visual inspection and diagnostic pre ... · no verify bjb fuse 58 (10a) is ok....

8/6/2019 Charging System - Diagnosis and Testing • 2013 Ford Explorer • MotoLogic

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Is the concern still present?

Yes CHECK OASIS for any applicable TSBs . If a TSB exists for this concern, DISCONTINUE this test and FOLLOW theTSB instructions. If no TSBs address this concern, INSTALL a new PCM . REFER to Section 303-14, PowertrainControl Module (PCM) - 2.0L GTDI or REFER to Section 303-14, Powertrain Control Module (PCM) - 3.5L GTDI orREFER to Section 303-14, Powertrain Control Module - 3.5L Ti-VCT, 3.7L Ti-VCT

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.

P065B

Diagnostic Overview

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

Refer to Wiring Diagrams Cell 12 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 dutycycle greater than 5% and less than 98%. The PCM also monitors the state of the generator command (GENCMD) signal lineto make sure it is not stuck high or stuck low. A DTC sets if the GENMON or GENCMD signal fluctuates between out-of-validrange, stuck high, stuck low, or some combination and normal. When the engine speed is greater than 2,000 Revolutions PerMinute (RPM), the generator defaults to a steady voltage of 13.5 volts and the PCM sends a request to the IPC to illuminatethe charging system warning indicator.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Conditions

P065B Generator ControlCircuitRange/Performance

The PCM sets this DTC if the input frequency was continuously less than 80 Hz or more than200 Hz. Additionally, if the signal shows a faulted condition the PCM tracks the fluctuationsbetween faulted and normal conditions. This DTC can also set if the fluctuations occurfrequently within a short amount of time.

Possible Sources

Battery

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Engine, generator and battery groundsFusesGeneratorPCMWiring, terminals or connectors

Visual Inspection and Diagnostic Pre-checks

Inspect fusible links.Inspect for loose or corroded connections.Inspect high current BJB for loose or corroded connections.

PINPOINT TEST E : 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.

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 Section414-01, GO to Pinpoint Test A

Does the battery pass the condition test?

Yes GO to E2.

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

E2 CHECK THE GENERATOR CONNECTIONS

Ignition OFF.

Disconnect and inspect all generator connectors.

Repair:corrosion (install new connector or terminals - clean module pins)damaged or bent pins - install new terminals/pinspushed-out pins - install new pins as necessary

Connect the generator connectors. Make sure they seat, latch correctly and are tightened to specification. Refer to ,Torque Specifications.

Measure and record battery voltage at the battery.

Measure:

Positive Lead Measurement / Action Negative Lead

C102B-1 Ground

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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 toidentify the Possible Sources of the circuit short.

E3 "A" SENSE CIRCUIT LOAD TEST

Disconnect: Generator C102A.

Using a 12-volt test lamp, check for voltage:


C102A-3 Ground

Does the test lamp illuminate?

Yes GO to E4.

No VERIFY BJB fuse 58 (10A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams manual toidentify the Possible Sources of the circuit short.

E4 CHECK THE GENERATOR MONITOR FREQUENCY (GENMON_HZ) PID

Connect: Generator C102A.

Start the engine.

Using a scan tool, view the PCM PIDs .

Monitor the GENMON_HZ PID .

Does the PID read between 80-200 Hz?

Yes GO to E8.

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No GO to E5.

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

Ignition OFF.

Disconnect: Generator C102A.

Start the engine.




Yes GO to E7.

No GO to E6.

E6 CHECK GENERATOR MONITOR CIRCUIT

Ignition OFF.

With PCM C175B (3.5L Ti-VCT and 3.7L Ti-VCT) or C1381B (2.0L GTDI) or C1551B (3.5L GTDI) connected,carefully back-probe and connect a fused jumper wire:

With 3.5L Ti-VCT and 3.7L Ti-VCT engines:


C175B-14 Ground

With 2.0L GTDI engine:



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C1381B-29 Ground

With 3.5L GTDI engine:


C1551B-26 Ground

Start the engine.



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 andREPAIR the circuit as needed.

No GO to E9.

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

Ignition OFF.

Connect a fused jumper wire:


C102A-1 C102A-2

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Start the engine.


With the engine running at idle, set the active command GENVDSD PID to 14 volts.



Yes INSTALL a new generator. Refer to Generator — 2.0L GTDI or Refer to Generator — 3.5L GTDI or Refer toGenerator — 3.5L Ti-VCT, 3.7L Ti-VCT.

No GO to E9.

E8 CHECK THE GENERATOR COMMAND LINE FAULT (GENCMD_LF) PID

Start the engine.


With the engine running and all selectable loads OFF, monitor the GENCMD_LF PID .

Does the PID fluctuate from YES FAULT to NO FAULT?


No The system is operating correctly at this time. The concern may have been caused by an intermittently loose orcorroded connector. ADDRESS the root cause of any connector or pin issues.

E9 CHECK FOR CORRECT PCM OPERATION

Ignition OFF.

Disconnect and inspect all PCM connectors.


Reconnect the PCM connectors. Make sure they seat and latch correctly.

Operate the system and determine if the concern is still present.

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Yes CHECK OASIS for any applicable TSBs . If a TSB exists for this concern, DISCONTINUE this test and FOLLOW theTSB instructions. If no TSBs address this concern, INSTALL a new PCM . REFER to Section 303-14, PowertrainControl Module (PCM) - 2.0L GTDI or REFER to Section 303-14, Powertrain Control Module (PCM) - 3.5L GTDI orREFER to Section 303-14, Powertrain Control Module - 3.5L Ti-VCT, 3.7L Ti-VCT


The Generator is Noisy

Diagnostic Overview


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


The generator is belt-driven by the engine accessory drive system. There are several sources of generator noise which includebearing noise, electrical fault noise, generator or belt pulley misalignment. A generator with certain types of diode or statorfailures can also produce an audible noise.

Possible Sources

FEAD beltLoose bolts/bracketsGenerator/pulleys


Inspect the FEAD belt.Inspect for loose bolts/brackets.Inspect the generator/pulleys.

PINPOINT TEST F : THE GENERATOR IS NOISY

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,Accessory Drive or REFER to Section 303-05, Accessory Drive






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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, Accessory Drive, Symptom Chart: FEAD for diagnosis and testingof the accessory drive system.

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 accessorydrive area for unusual mechanical noise.

Is the generator the noise source?


No REFER to Section 303-00, Engine , Symptom Chart: NVH to diagnose the source of the engine noise.

Radio Interference

Diagnostic Overview

Radio Interference






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

Possible Sources

GeneratorIn-vehicle entertainment systemWiring, terminals or connectors


Inspect the generator.Inspect the in-vehicle entertainment system.Inspect for loose or corroded connections.

PINPOINT TEST G : RADIO INTERFERENCE

NOTE: If the OEM audio unit has been replaced with an aftermarket unit, the vehicle may not pass this test. Return thevehicle to 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 Revolutions Per Minute (RPM) stays below 2,000 Revolutions PerMinute (RPM). If it exceeds 2,000 Revolutions Per Minute (RPM), turn the ignition to the OFF position and start the test overagain.

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

G1 VERIFY THE GENERATOR IS THE SOURCE OF THE RADIO INTERFERENCE

Start the engine and allow the engine to idle.

Tune the audio unit to a station where the interference is present.

Ignition OFF.

Disconnect: Generator C102B.

Start the engine and allow the engine to idle.

Is the interference present with the generator disconnected?

Yes REFER to Section 415-00A, GO to Pinpoint Test A (Premium), REFER to Section 415-00B, GO to Pinpoint Test A(Premium Plus), or REFER to Section 415-00C, GO to Pinpoint Test A (Sony Sound).

No INSTALL a new generator. Refer to Generator — 2.0L GTDI or Refer to Generator — 3.5L GTDI or Refer toGenerator — 3.5L Ti-VCT, 3.7L Ti-VCT.


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P0A5A:00, P0A5B:00, P0A5C:00

Diagnostic Overview




The generator current sensor is a hall effect sensor attached to the generator B+ cable. It is supplied a 5 volt reference andground from the PCM . The PCM reads the generator current sensor feedback voltage to determine how much current isflowing through the generator B+ cable.



P0A5A Generator Current SensorCircuit Range/Performance

This DTC sets when the PCM PCM does not detect current through the generatorcurrent sensor and there are no generator current sensor circuit DTCs set.

P0A5B Generator Current SensorCircuit Low

This DTC sets when the PCM senses lower than expected voltage on the generatorcurrent sensor feedback circuit, indicating an open or a short directly to ground.

P0A5C Generator Current SensorCircuit High

This DTC sets when the PCM senses higher than expected voltage on the generatorcurrent sensor feedback circuit, indicating a short directly to voltage.

Possible Sources

Generator current sensorPCMWiring, terminals or connectors


Inspect the generator current sensor.Inspect the wiring, terminals or connectors.Inspect for loose or corroded connections.

PINPOINT TEST I : P0A5A:00, P0A5B:00, P0A5C:00

I1 CHECK THE PCM DTCs





Ignition ON.

Using a scan tool, perform PCM self-test.

Is DTC P0A5A present?

Yes GO to I2.

No For DTC P0A5B, GO to I3. For DTC P0A5C, GO to I7.

I2 CHECK THE GENERATOR CURRENT SENSOR

Ignition OFF.

Inspect the generator current sensor for the following:Physical damageCorrosionDisconnected electrical connectorDisconnected from generator B+ cableDebris 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, Generator CurrentSensor

No GO to I9.

I3 CHECK THE GENERATOR CURRENT SENSOR REFERENCE VOLTAGE CIRCUIT FOR AN OPEN

Ignition OFF.

Disconnect: Generator Current Sensor C1645.

Ignition ON.

Measure:


C1645-1 Ground

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Is the voltage greater than 4.7 volts?

Yes GO to I4.

No REPAIR the circuit.

I4 CHECK THE GENERATOR CURRENT SENSOR SIGNAL RETURN CIRCUIT FOR AN OPEN

Measure:


C1645-1 C1645-2

Is the voltage greater than 4.7 volts?

Yes GO to I5.


I5 CHECK THE GENERATOR CURRENT SENSOR FEEDBACK CIRCUIT FOR A SHORT TO GROUND

Ignition OFF.

Disconnect: PCM C175B (3.5L Ti-VCT and 3.7L Ti-VCT ) or C1381B (2.0L GTDI) or C155B (3.5L GTDI).

Measure:


C1645-3 Ground

Is the resistance greater than 10,000 ohms?

Yes GO to I6.







I6 CHECK THE GENERATOR CURRENT SENSOR FEEDBACK CIRCUIT FOR AN OPEN

3.5L Ti-VCT and 3.7L Ti-VCT engines, measure:


C1645-3 C175B-33

2.0L GTDI engine, measure:


C1645-3 C1381B-50

3.5L GTDI engine, measure:


C1645-3 C1551B-94

Is the resistance less than 3 ohms?

Yes GO to I7.


I7 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 and 3.7L Ti-VCT ) or C1381B (2.0L GTDI) or C155B (3.5L GTDI).

Ignition ON.


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Measure:


C1645-3 Ground

Is any voltage present?

Yes REPAIR the circuit.

No GO to I8.

I8 CHECK THE GENERATOR CURRENT SENSOR FEEDBACK CIRCUIT FOR A SHORT TO THE SIGNAL RETURN ORVOLTAGE REFERENCE CIRCUIT

Ignition OFF.

Measure:


C1645-3 C1645-1

C1645-3 C1645-2

Are the resistances greater than 10,000 ohms?

Yes GO to I9.

No REPAIR the affected circuit.

I9 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 .

Using a scan tool, perform PCM self-test.

Did the DTC return?

Yes REPAIR as necessary or INSTALL a new generator current sensor. REFER to Section 414-01, Generator CurrentSensor. CLEAR the DTCs . REPEAT the self-test. If the DTC returns, GO to I10.

No The system is operating correctly at this time. The concern may have been caused by an intermittently loose orcorroded connector. ADDRESS the root cause of any connector or pin issues.

I10 CHECK FOR CORRECT PCM OPERATION

Ignition OFF.

Disconnect and inspect all PCM connectors.


Reconnect the PCM connectors. Make sure they seat and latch correctly.



Yes CHECK OASIS for any applicable TSBs . If a TSB exists for this concern, DISCONTINUE this test and FOLLOW theTSB instructions. If no TSBs address this concern, INSTALL a new PCM . REFER to Section 303-14, PowertrainControl Module (PCM) - 2.0L GTDI or REFER to Section 303-14, Powertrain Control Module (PCM) - 3.5L GTDI orREFER to Section 303-14, Powertrain Control Module - 3.5L Ti-VCT, 3.7L Ti-VCT CLEAR all DTCs in all modules.


U1007:31

Diagnostic Overview

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



U1007:31 Lost Communication With Battery MonitoringSensor "A": No Signal

This DTC sets when the BCM does not indicate current flowthrough the battery current sensor.

Possible Sources

BCMBattery current sensorWiring, terminals or connectors


Inspect the battery current sensor.Inspect the wiring, terminals or connectors.Inspect for loose or corroded connections.

PINPOINT TEST J : U1007:31

J1 CHECK THE BATTERY CURRENT SENSOR

Inspect the battery current sensor for the following:Physical damageCorrosionDisconnected electrical connectorDisconnected from battery ground cableDebris between the battery current sensor and the battery ground cable

Are any of these conditions found during inspection?





Yes GO to J13.

No GO to J2.

J2 CHECK THE BATTERY CURRENT SENSOR REFERENCE VOLTAGE CIRCUIT

Ignition OFF.

Disconnect: Battery Current Sensor C1646.

Ignition ON.

Measure:


C1646-1 Ground

Is the voltage between 4.7 and 5.1 volts?

Yes GO to J6.

No If the voltage is less than 4.7 volts, GO to J4. If the voltage is greater than 5.1 volts, GO to J3.

J3 CHECK THE BATTERY CURRENT SENSOR REFERENCE VOLTAGE CIRCUIT FOR A SHORT TO VOLTAGE

Ignition OFF.

Disconnect: BCM C2280F.

Remove the RUN/START relay.


Positive Lead Measurement /Action

Negative Lead

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Negative Lead

CRUN/START RELAY-3 CRUN/START RELAY-5

Ignition ON.

Measure:


C1646-1 Ground



No REMOVE the fused jumper wire. INSTALL the RUN/START relay and GO to J13.

J4 CHECK THE BATTERY CURRENT SENSOR REFERENCE VOLTAGE CIRCUIT FOR A SHORT TO GROUND

Ignition OFF.


Measure:


C1646-1 Ground


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Yes GO to J5.


J5 CHECK THE BATTERY CURRENT SENSOR REFERENCE VOLTAGE CIRCUIT FOR AN OPEN

Measure:


C1646-1 C2280F-20


Yes GO to J13.


J6 CHECK THE BATTERY CURRENT SENSOR SIGNAL RETURN CIRCUIT

Measure:


C1646-1 C1646-2

Is the voltage between 4.7 and 5.1 volts?

Yes GO to J9.

No GO to J7.

J7 CHECK THE BATTERY CURRENT SENSOR SIGNAL RETURN CIRCUIT FOR VOLTAGE

Measure:








C1646-2 Ground


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

No GO to J8.

J8 CHECK THE BATTERY CURRENT SENSOR SIGNAL RETURN CIRCUIT FOR AN OPEN

Ignition OFF.


Measure:


C1646-2 C2280F-14


Yes GO to J13.


J9 CHECK THE BATTERY CURRENT SENSOR FEEDBACK CIRCUIT FOR A SHORT TO VOLTAGE

Ignition OFF.


Remove the RUN/START relay.










Negative LeadPositive Lead Measurement /Action

Negative Lead

CRUN/START RELAY-3 CRUN/START RELAY-5

Ignition ON.

Measure:


C1646-3 Ground



No REMOVE the fused jumper wire. INSTALL the RUN/START relay and GO to J10.

J10 CHECK THE BATTERY CURRENT SENSOR FEEDBACK CIRCUIT FOR A SHORT TO GROUND

Ignition OFF.

Measure:


C1646-3 Ground


Yes GO to J11.








J11 CHECK THE BATTERY CURRENT SENSOR FEEDBACK CIRCUIT FOR AN OPEN

Measure:


C1646-3 C2280F-21


Yes GO to J12.


J12 CHECK THE BATTERY CURRENT SENSOR FEEDBACK CIRCUIT FOR A SHORT TO THE SIGNAL RETURN ORREFERENCE CIRCUIT

Measure:


C1646-3 C1646-2

C1646-3 C1646-1

Are the resistances greater than 10,000 ohms?

Yes GO to J13.

No REPAIR the affected circuit.

J13 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/pinspushed-out pins - install new pins as necessary

Connect and correctly seat the battery current sensor connector.

Connect: BCM C2280F.

Ignition ON.

Clear the DTCs .

Using a scan tool, perform BCM self-test.

Did the DTC return?

Yes REPAIR as necessary or INSTALL a new battery current sensor. REFER to Section 414-01, Battery Current Sensor.CLEAR the DTCs . REPEAT the self-test. If the DTC returns, GO to J14.

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.

J14 CHECK FOR CORRECT BCM OPERATION

Ignition OFF.

Disconnect and inspect all BCM connectors.


Reconnect the BCM connectors. Make sure they seat and latch correctly.



Yes CHECK OASIS for any applicable TSBs . If a TSB exists for this concern, DISCONTINUE this test and FOLLOW theTSB instructions. If no TSBs address this concern, INSTALL a new BCM . REFER to Section 419-10, Body ControlModule (BCM) - With Intelligent Access or REFER to Section 419-10, Body Control Module (BCM) - WithoutIntelligent Access




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fuses generator pcm visual inspection and diagnostic pre ... · no verify bjb fuse 58 (10a) is ok....

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