Charging System - General Information: Other Ford Taurus IV рестайлинг

Battery

The battery is a 12-volt direct current source connected in a negative ground system. The battery case is sealed and includes two vent holes to release gases. The battery has three major functions

1. engine cranking power source
2. voltage stabilizer for the electrical system
3. temporary power when electrical loads exceed the generator output current

Refer to STARTING/CHARGING (Taurus) or STARTING/CHARGING (Sable) for schematic and connector information.

Circuit 36 (YE/WH) B+ Output Terminal

The generator output voltage is supplied through the battery positive (B+) output terminal circuit 36 (YE/WH) on the rear of the generator to the battery and electrical system.

Circuit 1182 (OG/YE)

This is the A terminal battery voltage sense circuit and is used to sense battery voltage.

Circuit 1181 (GY/YE) (GEN MON)

This is the generator monitor (GEN MON) circuit. The PCM monitors this circuit to determine the generator load and error conditions to the PCM.

Circuit 3990 (LB/RD) (GEN COM)

This is the generator communication (GEN COM) circuit. The PCM determines the optimal voltage setpoint for the charging system and communicates this information to the voltage regulator through the GEN COM circuit.

Pinpoint Tests

Note. While carrying out any pinpoint test, disregard any DTCs set while following any specific pinpoint test. After the completion of any test, be sure to clear all DTCs.

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 PCM relearns its fuel trim. The vehicle may need to be driven to relearn the strategy.

Scheme 30

Scheme 31

1. A1 CHECK THE BATTERY CONDITION Carry out the Battery - Condition Test to determine if the battery can hold a charge and is OK for use. REFER to «BATTERY, MOUNTING AND CABLES»(ref-233724) . Did the battery pass the condition test? Yes : GO to A2 . No : INSTALL a new battery. REFER to «BATTERY, MOUNTING AND CABLES»(ref-233724) . TEST the system for normal operation.
2. A2 CHECK THE GENERATOR OUTPUT Carry out the Generator On-Vehicle Load Test and No Load Test. Refer to «COMPONENT TESTS»(ref-233727-S29169507932006052600000) . Did the generator pass the component tests? Yes : GO to A3 . No : INSTALL a new generator. REFER to «GENERATOR AND REGULATOR»(ref-233701) . TEST the system for normal operation.
3. A3 CHECK FOR CURRENT DRAINS Carry out the Battery - Drain Testing. Refer to «COMPONENT TESTS»(ref-233727-S29169507932006052600000) . Are any circuits causing excessive current drains? Yes : REPAIR as necessary. TEST the system for normal operation. No : GO to A4 .
4. A4 CHECK THE VEHICLE GROUNDS Key in START position. Measure the voltage drop between the generator housing and the negative battery terminal. Is the voltage drop less than 0.1 volt? Yes : GO to A5 . No : CHECK the engine ground, generator ground and the battery ground for corrosion. REPAIR as necessary. TEST the system for normal operation.
5. A5 CHECK THE VOLTAGE DROP IN B+ CIRCUIT 36 (YE/WH) Measure the voltage drop between the generator B+ C102b, circuit 36 (YE/WH) and the positive battery terminal. Is the voltage drop less than 0.1 volt? Yes : Verify if the customer left any component(s) on or if there is an intermittent excessive battery draw. TEST the system for normal operation. No : CHECK for any corrosion in the positive battery cable and/or connections. REPAIR as necessary. TEST the system for normal operation.

Scheme 32

Scheme 33

Scheme 34

Scheme 35

1. B1 CHECK THE FAULT CODES IN THE PCM Connect the diagnostic tool. Key in ON position. Enter the following diagnostic mode on the diagnostic tool: Retrieve PCM DTCs. Use the recorded PCM DTCs from the continuous and on-demand self-tests. If DTC P0622 was retrieved, follow the NO direction. Are any PCM DTCs recorded? Yes : See «INTRODUCTION - GASOLINE»(ref-229953) . No : GO to B2 .
2. B2 CHECK THE GENERATOR B+ CIRCUIT 36 (YE/WH) FOR VOLTAGE Key in OFF position. Measure the voltage between the generator C102b, circuit 36 (YE/WH) and ground. Is the voltage approximately equal to battery positive voltage? Yes : GO to B3 . No : REPAIR the circuit. TEST the system for normal operation.
3. B3 CHECK THE GENERATOR INTEGRITY Disconnect: Generator C102a (4V), C1104 (2V). Key in ON position. Measure and record the battery voltage. Key in START position. NOTE: If the generator communication lines are disconnected (DTC P0622 may set), the generator will self-excite if the engine is operated at greater than 4,500 rpm (approximately wide open throttle [WOT]) for a minimum of 3 seconds. It will then operate in a default mode of approximately 13.5 volts until the engine is turned off. With the engine running (after the brief WOT has been carried out), measure the battery voltage. Does the battery voltage increase a minimum of 0.5 volts from the key on, engine off measurement to the key on, engine running measurement (after the brief WOT or snap acceleration has been carried out)? Yes : GO to B4 . No : INSTALL a new generator. REFER to «GENERATOR AND REGULATOR»(ref-233701) . TEST the system for normal operation.
4. B4 CHECK CIRCUIT 3990 (LB/RD) FOR AN OPEN OR SHORT TO GROUND Key in OFF position. Disconnect: PCM C175. Measure the resistance between the generator C102a pin 2 (4V), C1104 pin 2 (2V), circuit 3990 (LB/RD), harness side and the PCM C175 pin 45, circuit 3990 (LB/RD), harness side and between the generator C102a pin 2 (4V), C1104 pin 2 (2V), circuit 3990 (LB/RD), harness side and ground Is the resistance less than 5 ohms between the generator and the PCM and greater than 10,000 ohms between the generator and ground? Yes : GO to B5 . No : REPAIR the circuit. TEST the system for normal operation.
5. B5 CHECK CIRCUIT 1181 (GY/YE) FOR AN OPEN OR SHORT TO GROUND Measure the resistance between the generator C102a pin 1 (4V), C1104 pin 1 (2V), circuit 1181 (GY/YE), harness side and the PCM C175 pin 20, circuit 1181 (GY/YE), harness side and between the generator C102a pin 1 (4V), C1104 pin 1 (2V), circuit 1181 (GY/YE), harness side and ground Is the resistance less than 5 ohms between the generator and the PCM and greater than 10,000 ohms between the generator and ground? Yes : GO to B6 . No : REPAIR the circuit. TEST the system for normal operation.
6. B6 CHECK FOR CORRECT PCM OPERATION Disconnect all PCM connectors. Check for: corrosion pushed-out pins Connect all PCM connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present? Yes : INSTALL a new PCM. REFER to «ELECTRONIC ENGINE CONTROLS»(ref-233703) for the removal and installation procedure. TEST the system for normal operation. No : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.

Scheme 36

1. C1 CHECK THE FAULT CODES IN THE PCM Connect the diagnostic tool. Key in ON position. Enter the following diagnostic mode on the diagnostic tool: Retrieve PCM DTCs. Use the recorded PCM DTCs from the continuous and on-demand self-tests. If DTC P0622 was retrieved, follow the NO direction. Are any PCM DTCs recorded? Yes : If DTC P0622 was retrieved, GO to C2 . For all other DTCs, See «INTRODUCTION - GASOLINE»(ref-229953) . No : GO to C2 .
2. C2 CHECK THE BATTERY VOLTAGE Key in OFF position. Disconnect the diagnostic tool. Key in START position. With the engine running and all the accessories turned off, measure the voltage at the battery while varying the engine rpm. Is the voltage greater than 15.5 volts? Yes : GO to C3 . No : GO to C4 .
3. C3 CHECK FOR VOLTAGE DROP IN CIRCUIT 1182 (OG/YE) Key in OFF position. Disconnect: Generator C102a (4V), C1104 (2V). Measure the voltage between the generator C102a pin 3 (4V), C1104 pin 3 (2V), circuit 1182 (OG/YE), harness side and ground. Is the voltage within 0.5 volt from battery voltage? Yes : RECONNECT the generator C102a (4V), C1104 (2V). GO to C4 . No : REPAIR the circuit for high resistance. TEST the system for normal operation.
4. C4 CHECK THE GENERATOR PIDS Connect the diagnostic tool. Key in START position. Enter the following diagnostic mode on the diagnostic tool: Monitor PCM PIDs. With the engine running, monitor the generator output fault PID in the PCM. Does the PID read YES? Yes : GO to C5 . No : GO to C6 .
5. C5 CHECK THE GENERATOR INTEGRITY Key in OFF position. Disconnect: Generator C102a (4V), C1104 (2V). Key in ON position. Measure and record the battery voltage. Key in START position. NOTE: If the generator communication lines are disconnected (DTC P0622 may be set), the generator will self-excite if it is operated at greater than 4,500 rpm (approximately wide open throttle [WOT]) for a minimum of 3 seconds. It will then operate in a default mode of approximately 13.5 volts until the engine is turned off. With the engine running (after the brief WOT has been carried out), measure the battery voltage. Does the battery voltage increase a minimum of 0.5 volts from the key on, engine off measurement to the key on, engine running measurement (after the brief WOT or snap acceleration has been carried out)? Yes : GO to C6 . No : INSTALL a new generator. REFER to «GENERATOR AND REGULATOR»(ref-233701) . TEST the system for normal operation.
6. C6 CHECK FOR CORRECT PCM OPERATION Disconnect all the PCM connectors. Check for: corrosion pushed-out pins Connect all the PCM connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present? Yes : INSTALL a new PCM. REFER to «ELECTRONIC ENGINE CONTROLS»(ref-233703) for the removal and installation procedure. REPEAT the self-test. TEST the system for normal operation. No : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.

Generator On-Vehicle Tests

Note. Battery posts and cable clamps must be clean and tight for accurate meter indications.

Note. Refer to the battery tester manual for complete directions for testing the charging system.

1. Turn off all lamps and electrical components.
2. Place the transmission in NEUTRAL and apply the parking brake.
3. Carry out the Load Test and No Load Test according to the following component tests

Scheme 37

1. Switch the tester to the ammeter function.
2. Connect the positive and negative leads of the tester to the corresponding battery terminals.
3. Connect the current probe to the generator B+ output terminal, circuit 36 (YE/WH).
4. With the engine running at approximately 2,000 rpm, adjust the tester load bank to determine the output of the generator. Generator output should be greater than the graph shown below. If not, refer back to the pinpoint test or GO to «SYMPTOM CHART»(ref-233727-S22201621782006052600000) .