Charging System - Generators & Regulators Ford Crown Victoria II

DESCRIPTION

System consists of a generator, voltage regulator, battery, warning indicator, related fuses and wiring. Warning indicator illuminates with ignition on, engine off as a bulb-check. Voltage regulator is integral type and cannot be serviced separately.

BELT TENSION

Vehicles are equipped with automatic drive belt tensioner. Drive belt does not require adjustment. Inspect condition and tension of generator drive belt prior to performing any on-vehicle charging system tests. Replace belt and/or repair tensioner mechanism if necessary.

TROUBLE SHOOTING

Note. For trouble shooting charging system, see BASIC TROUBLE SHOOTING article in GENERAL INFORMATION.

PRELIMINARY CHECKS

1. Verify battery condition.
2. Inspect accessory drive belt and tensioner.
3. Check all connections for looseness or corrosion.
4. Inspect Gray fusible links, battery junction box fuse No. 101 (30-amp) for 2003, or fuse No. 6 (15-amp) for 2004 and central junction box fuse No. 14 (10-amp).

BATTERY LOAD TEST

Connect battery tester according to tool manufacturer's instructions. Load test battery at approximately one-half cold-cranking amperage rating for 15 seconds while observing battery voltage. If voltage reading is 9.6 volts or more, battery is okay. If voltage reading is less than 9.6 volts, charge battery and retest. If loaded battery voltage is still less than 9.6 volts after charging battery, replace battery.

BATTERY TEST WITH DIGITAL BATTERY ANALYZER

Connect digital battery analyzer to battery and follow on screen instructions. If battery test good, return to service. If battery does not test good, replace battery.

GENERATOR LOAD TEST

Ensure drive belt is in good condition. Connect charging system load tester in accordance with manufacturer's instructions. Start and run engine at 2000 RPM, and apply load until generator output levels off. Generator output should be 87 amps at 2000 RPM.

GENERATOR NO-LOAD TEST

Connect voltmeter positive lead to generator B+ terminal and negative lead to ground. Start and run engine at 2000 RPM with all accessories off. Read voltmeter when voltage stabilizes. Voltage should be 13-15 volts. With engine running, turn A/C (if equipped) and headlights on, and turn blower motor to high speed. Increase engine speed to 2000 RPM. Voltage should increase a minimum of .5 volt more than base voltage.

PARASITIC DRAW TEST

Note. Many modules draw 10 mA (0.010 amp) or more continuously. Use an in-line ammeter between the battery positive or negative post and its respective cable. Typically, a drain of approximately one amp can be attributed to an engine compartment lamp, glove compartment lamp, or luggage compartment lamp staying on continually. Other component failures or wiring shorts may be located by selectively pulling fuses to pinpoint the location of the current drain. When the current drain is found, the meter reading will fall to an acceptable level. If the drain is still not located after checking all the fuses, it may be due to the generator. To accurately test the drain on a battery, an in-line digital ammeter must be used. Use of a test lamp or voltmeter is not an accurate method due to the number of electronic modules.

Check for current drains on the battery in excess of 50 milliamps (0.050 amp) with all the electrical accessories off and the vehicle at rest. Current drains can be tested with the following procedure

1. Make sure the junction box/fuse panels are accessible without turning on interior and underhood lights.
2. Drive the vehicle at least 5 minutes and over 30 MPH to turn on and exercise vehicle systems.
3. Allow the vehicle to sit with the key off for at least 40 minutes to allow modules to time out/power down.
4. Connect a fused jumper wire between the negative battery cable and the negative battery post to prevent modules from resetting and to catch capacitive drains.
5. Disconnect the negative battery cable from the post without breaking the connection of the jumper wire.
6. Connect the tester between negative battery cable and the post. The meter must be capable of reading milliamps and should have a 10 amp capability.
7. Remove the jumper wire.
8. If the draw is found to be excessive, pull fuses from the battery/central junction box one at a time and note the current drop. Do not reinstall the fuses until you are finished testing.
9. Check the wiring schematic in the wiring diagram for any circuits that run from the battery without passing through the battery/central junction box. Disconnect these circuits if the draw is still excessive.

ELECTRONIC MODULE PARASITIC DRAW TEST

1. Repeat the steps of the battery drain testing.
2. Make sure all doors are closed and accessories are off. Without starting the engine, turn the ignition switch to RUN for a moment and then OFF. Wait a few minutes for the illuminated entry lamps to turn off if equipped.
3. Connect the ammeter and read the amperage draw.

The current reading (current drain) should be less than 50 mA (0.05 amp). If the current drain exceeds 50 mA (0.05 amp) after a few minutes, and if this drain did not show in previous tests, the drain is most likely caused by an inoperative electronic component. As in previous tests, remove the fuses from the battery/central junction box one at a time to locate the problem circuit.

SELF-DIAGNOSTIC SYSTEM

Note. All diagnostic tests are written specifically for New Generation Star (NGS) tester. Most generic OBD-II compliant scan tools should be able to perform all test procedures.

RETRIEVING & CLEARING DIAGNOSTIC TROUBLE CODES

For retrieving and clearing DTCs, see SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS in ENGINE PERFORMANCE.

Using NGS tester, perform PCM self-test. Perform appropriate test under SYSTEM TEST in accordance with DTC retrieved. See DIAGNOSTIC TROUBLE CODE DEFINITIONS . If no DTCs are retrieved, repair by symptom. See SYMPTOM INDEX table under SYSTEM TESTS.

DIAGNOSTIC TROUBLE CODE DEFINITIONS

DIAGNOSTIC TROUBLE CODE DEFINITIONS

SYSTEM TESTS

Identify symptom and perform appropriate test. See SYMPTOM INDEX .

SYMPTOM INDEX

TEST A: BATTERY IS DISCHARGED OR VOLTAGE IS LOW

1. Check Battery Condition Check battery. See «BATTERY LOAD TEST»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#charging-system-generators-regulators__battery-load-test) or «BATTERY TEST WITH DIGITAL BATTERY ANALYZER»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#charging-system-generators-regulators__battery-test-with-digital-battery-analyzer) under ON-VEHICLE TESTING. If battery is okay, go to next step. If battery is discharged or faulty, charge or replace as necessary.
2. Check The Generator Output Check generator output. See «GENERATOR LOAD TEST»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#charging-system-generators-regulators__generator-load-test) and «GENERATOR NO-LOAD TEST»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#charging-system-generators-regulators__generator-no-load-test) under ON-VEHICLE TESTING. If generator output is okay, go to next step. If generator output is faulty, go to «TEST B: WARNING INDICATOR ON, SYSTEM IS NOT CHARGING»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#charging-system-generators-regulators__test-b-warning-indicator-on-system) .
3. Check For Current Drains Check for parasitic loads. See «PARASITIC DRAW TEST»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#charging-system-generators-regulators__parasitic-draw-test) and «ELECTRONIC MODULE PARASITIC DRAW TEST»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#charging-system-generators-regulators__electronic-module-parasitic-draw-test) under ON-VEHICLE TESTING. If no problem is found, go to next step. If any problem is found, diagnose and repair wiring or components as necessary.
4. Check Vehicle Grounds Start engine. Measure the voltage drop between generator housing and negative battery terminal. If voltage drop is less than 0.1 volt, verify if customer left any component(s) on or if there is an intermittent excessive battery draw. Test the system for normal operation. If voltage drop is not less than 0.1 volt, check engine ground/generator ground and the battery for corrosion. Repair as necessary. Test the system for normal operation.

TEST B: WARNING INDICATOR ON, SYSTEM IS NOT CHARGING

1. Check The Fault Codes In The PCM 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 in appropriate SELF-DIAGNOSTICS in ENGINE PERFORMANCE.
2. Check The Generator B+ (Black/Orange Wire) Turn ignition off. Disconnect the NGS tester. Measure the voltage between the generator C102b (Black/Orange wire), harness side and ground. Is the voltage equal to battery voltage? If yes, go to next step. If no, repair the circuit. Test the system for normal operation.
3. Check The Generator Integrity Disconnect: generator connector C102a or C102c. Start engine. If the generator communication lines are disconnected, the generator will self-excite if it is operated at approximately 2,000 engine RPM for a momentary period of time. It will then operate in a default mode at 13.5 volts until the engine is turned off. With the engine running at approximately 2,000 RPM, measure the battery voltage. Is the battery voltage approximately 13.5 volts? If yes, go to next step. If no, install a new generator. See «GENERATOR»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#charging-system-generators-regulators) under REMOVAL & INSTALLATION. Test the system for normal operation.
4. Check Circuit 904 (Light Green/Orange Wire) For An Open Turn the ignition off. Disconnect the PCM connector C175. Measure the resistance between the generator connector C102a or C102c terminal No. 2 (Light Green/Orange wire), harness side and the PCM connector C175 terminal No. 45, harness side and between the generator connector C102a or C102c terminal No. 2 (Light Green/Red wire) and ground. (Scheme 1)- (Scheme 3). Is the resistance less than 5 ohms between the generator and the PCM and greater than 10,000 ohms between the generator and ground? If yes, go to next step. If no, repair the circuit. Test the system for normal operation.
5. Check For Correct PCM Operation Check for corrosion and pushed-out pins. Connect any disconnected connectors. Make sure all other system connectors are fully seated. Operate the system and verify the concern is still present. Is the concern still present? If yes, install a new PCM. See COMPUTERIZED ENGINE CONTROLS in appropriate REMOVAL & INSTALLATION in ENGINE PERFORMANCE. Repeat the PCM self-test. If no, the system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. Clear the DTCs. Repeat the self-test.

Scheme 1

Scheme 2

Scheme 3

TEST C: SYSTEM OVERCHARGES

1. Check The Fault Codes In The PCM 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 in appropriate SELF-DIAGNOSTICS in ENGINE PERFORMANCE.
2. Check The Battery Voltage Turn ignition off. Disconnect the diagnostic tool. Start engine. With the engine running and all accessories turned off, measure the voltage at the battery while varying the engine RPM. Is the voltage greater than 15.5 volts? If yes, go to next step. If no, go to step 4 .
3. Check For Voltage Drop In Circuit 36 (Yellow/White) Turn ignition off. Disconnect: generator connector C102a or C102c. Measure the voltage between the generator connector C102a or C102c terminal No. 3 (Yellow/White wire), harness side and ground. Is the voltage within 0.5 volt from battery voltage? If yes, reconnect generator connector and go to next step. If no, repair the circuit for high resistance. Test the system for normal operation.
4. Check The Generator PIDs Connect New Generation Star (NGS) tester to Data Link Connector (DLC). Start engine. With the engine running, monitor the generator output fault PID in the PCM. Does the PID read YES? If yes, go to next step. If no, go to step 6 .
5. Check The Generator Integrity Turn ignition off. Disconnect: generator connector C102a or C102c. Start engine. If the generator communication lines are disconnected, the generator will self-excite if it is operated at approximately 2,000 RPM for a momentary period of time. It will then operate in a default mode at 13.5 volts until the engine is turned off. With the engine running at approximately 2,000 RPM, measure the battery voltage. Is the battery voltage approximately 13.5 volts? If yes, go to next step. If no, install a new generator. See «GENERATOR»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#charging-system-generators-regulators) under REMOVAL & INSTALLATION. Test for normal operation.
6. Check For Correct PCM Operation Check for corrosion and pushed-out pins. Connect any disconnected connectors. Make sure all other system connectors are fully seated. Operate the system and verify the concern is still present. Is the concern still present? If yes, install a new PCM. See COMPUTERIZED ENGINE CONTROLS in appropriate REMOVAL & INSTALLATION in ENGINE PERFORMANCE. Repeat the PCM self-test. If no, the system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. Clear the DTCs. Repeat the self-test.

TEST D: WARNING INDICATOR ON WITH ENGINE RUNNING, SYSTEM IS CHARGING

1. Check The Fault Codes In The PCM 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 in appropriate SELF-DIAGNOSTICS in ENGINE PERFORMANCE.
2. Check The System For Overcharging Start engine. With the engine running and all accessories off, measure the voltage at the battery terminals while varying the engine RPM. Is the voltage greater than 15.5 volts? If yes, go to «TEST C: SYSTEM OVERCHARGES»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#charging-system-generators-regulators__test-c-system-overcharges) . If no, go to next step.
3. Check The Charging System Warning Indicator Operation With the engine running, monitor the generator output fault PID in the PCM. Does the PID read YES? If yes, go to next step. If no, see appropriate ANALOG INSTRUMENT PANELS article under ACCESSORIES & EQUIPMENT.
4. Check The Generator Output Verify the generator output. See «GENERATOR LOAD TEST»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#charging-system-generators-regulators__generator-load-test) and «GENERATOR NO-LOAD TEST»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#charging-system-generators-regulators__generator-no-load-test) under ON-VEHICLE TESTING. Did the generator pass the on-vehicle tests? If yes, go to next step. If no, install a new generator. See «GENERATOR»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#charging-system-generators-regulators) under REMOVAL & INSTALLATION. Clear the DTCs. Test the system for normal operation.
5. Check For Correct PCM Operation Check for corrosion and pushed-out pins. Connect any disconnected connectors. Make sure all other system connectors are fully seated. Operate the system and verify the concern is still present. Is the concern still present? If yes, install a new PCM. See COMPUTERIZED ENGINE CONTROLS in appropriate REMOVAL & INSTALLATION in ENGINE PERFORMANCE. Repeat the PCM self-test. If no, the system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. Clear the DTCs. Repeat the self-test.

TEST E: WARNING INDICATOR OFF WITH IGNITION ON

1. Check The Charging System Warning Indicator Operation Turn ignition off. Connect New Generation Star (NGS) tester to Data Link Connector (DLC). Turn ignition switch to RUN position. Turn on the charging system warning indicator using Active Commands. Is the charging system warning indicator on? If yes, go to next step. If no, see appropriate ANALOG INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT.
2. Check For Correct PCM Operation Check for corrosion and pushed-out pins. Connect any disconnected connectors. Make sure all other system connectors are fully seated. Operate the system and verify the concern is still present. Is the concern still present? If yes, install a new PCM. See COMPUTERIZED ENGINE CONTROLS in appropriate REMOVAL & INSTALLATION in ENGINE PERFORMANCE. Repeat the PCM self-test. If no, the system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. Clear the DTCs. Repeat the self-test.

TEST F: GENERATOR NOISY

1. Check For Accessory Drive Noise Check the accessory drive belt for damage and correct installation. Check the accessory mounting brackets and generator pulley for looseness or misalignment. Is the accessory drive okay? If yes, if equipped with a One-Way Clutch (OWC) pulley, go to next step. If not equipped with a OWC pulley, go to step 3 . If no, repair as necessary. Test the system for normal operation.
2. Check One-Way Clutch (OWC) Pulley With the Front-End Accessory Drive (FEAD) belt removed, spin the OWC pulley in a clockwise direction, then reverse the direction of the pulley by spinning it in a counterclockwise direction. Does the OWC pulley engage with the rotor when spun in a clockwise direction and free-wheel when spun in a counterclockwise direction with minimal noise as compared to a known good vehicle? If yes, go to next step. If no, install a new generator assembly with OWC pulley. See «GENERATOR»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#charging-system-generators-regulators) under REMOVAL & INSTALLATION. Test the system for normal operation.
3. Check Generator Mounting Check the generator mounting for loose bolts or misalignment. Is the generator mounted correctly? If yes, go to next step. If no, repair as necessary. Test the system for normal operation.
4. Check Generator For Excessive Electrical Noise Disconnect generator connector C102b (Black/Orange wire). Start engine. With the engine running, determine if the generator is still noisy. Is the noise still present? If yes, go to next step. If no, install a new generator. See «GENERATOR»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#charging-system-generators-regulators) under REMOVAL & INSTALLATION. Test the system for normal operation.
5. Check Generator For Mechanical Noise Turn all accessories off. With the engine running, use a stethoscope or equivalent listening device to probe the generator for unusual mechanical noise. Is the generator the noise source? If yes, install a new generator. See «GENERATOR»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#charging-system-generators-regulators) under REMOVAL & INSTALLATION. Test the system for normal operation. If no, diagnose the source of the engine noise.

TEST G: RADIO INTERFERENCE

Note. If the Original Equipment Manufactured (OEM) audio unit has been replaced with the aftermarket unit, the vehicle may not pass the following test. Return the vehicle to OEM condition before proceeding with this pinpoint test.

1. Verify Generator Is Source Of Radio Interference Start and run the engine. Tune the radio to a station where the interference is present. Turn ignition off. Disconnect: generator connector C102b (Black/Orange wire). Start engine. With the engine running, is the interference present with the generator disconnected? If yes, diagnosis in-vehicle entertainment system. If no, replace generator. See «GENERATOR»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#charging-system-generators-regulators) under REMOVAL & INSTALLATION.

REMOVAL & INSTALLATION

Removal & Installation (2V)

Disconnect negative battery cable. Remove rear engine cover screws. Pull cover forward to disengage front clips, and remove cover. Loosen clamp and remove intake induction resonator. Release tension and remove accessory drive belt from generator pulley. Remove B+ terminal nut and B+ wire. Disconnect wiring from generator. Remove 4 bolts and upper generator bracket. Remove attachment bolts. Remove generator from vehicle. To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .

Removal & Installation (4V)

Disconnect the battery. Release the tension and remove the accessory drive belt from the generator pulley. Remove the pin-type retainer and release the wiring harness from the generator bracket. Remove the nut and disconnect the generator electrical connectors. Remove the bolts and the generator bracket. Loosen the bolts and remove the generator. To install, reverse the removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .

2003

2003 GENERATOR SPECIFICATIONS

2004

2004 GENERATOR SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Crown Victoria

For wiring diagram, see STARTING/CHARGING in SYSTEM WIRING DIAGRAMS.

Grand Marquis

For wiring diagram, see STARTING/CHARGING in SYSTEM WIRING DIAGRAMS.

Marauder

For wiring diagram, see STARTING/CHARGING in SYSTEM WIRING DIAGRAMS.

For wiring diagram, see STARTING/CHARGING in SYSTEM WIRING DIAGRAMS.

For wiring diagram, see STARTING/CHARGING in SYSTEM WIRING DIAGRAMS.

For wiring diagram, see STARTING/CHARGING in SYSTEM WIRING DIAGRAMS.

See also:
• BASIC TROUBLE SHOOTING
• DIAGNOSTIC TROUBLE CODE DEFINITIONS
• SYMPTOM INDEX
• A
• B
• C
• D
• E
• F
• G
• BATTERY LOAD TEST
• BATTERY TEST WITH DIGITAL BATTERY ANALYZER
• GENERATOR LOAD TEST
• GENERATOR NO-LOAD TEST
• PARASITIC DRAW TEST
• ELECTRONIC MODULE PARASITIC DRAW TEST
• TORQUE SPECIFICATIONS