Charging System Ford Transit Connect I рестайлинг

General Specifications

GENERAL SPECIFICATIONS

Torque Specifications

TORQUE SPECIFICATIONS

The charging system is a negative ground system consisting of

1. a generator with an internal voltage regulator.
2. a charging system warning indicator.
3. a battery.
4. circuitry and cables.
5. a PCM.
6. a radial arm adapter (serviceable separately from the generator)

The generator is driven by the accessory drive belt. When the engine is started, the generator begins to generate AC which is internally converted to DC. The DC is controlled by the voltage regulator (located on the rear of the generator) and supplied to the battery. The PCM controls the voltage regulation set point, working with the generator internal voltage regulator over 2 control and communication circuits.

Principles of Operation

The PCM-controlled charging system, or "Smart Charge" charging system, determines the optimal voltage set point for the charging system and communicates this information to the voltage regulator. The "Smart Charge" charging system is designed to set 1 of 5 DTCs anytime a charging system fault is present. All of the DTCs can set continuous faults, but not all DTCs will set as on-demand faults.

DTC CHART

This system uses 2 communication lines between the PCM and the generator/voltage regulator. Both of these communication lines use Pulse-Width Modulation (PWM). The generator communication (GENCOM) line communicates the desired set point from the PCM to the voltage regulator. The generator monitor (GENMON) line communicates the generator load and error conditions to the PCM. The GENCOM command is only sent by the PCM when it is necessary to adjust the voltage set point. If the set point does not need to be changed, several seconds may elapse between PCM GENCOM commands. This normal operation will appear in the PID as occasional "bursts" of pulse-width commands. The third pin on the voltage regulator, the A circuit pin, is a circuit dedicated to monitor or sense battery voltage.

The PCM simultaneously controls and monitors the output of the generator. When the current consumption is high or the battery is discharged, the PCM will raise engine speed as needed to increase generator output. The generator charges the battery and at the same time supplies power for all of the electrical loads that are required. The battery is more effectively charged with a higher voltage when the battery is cold and a lower voltage when the battery is warm. The PCM is able to adjust the charging voltage according to the battery temperature by using a signal from the Intake Air Temperature (IAT) sensor. The PCM also uses other inputs to control charging system voltage such as the Vehicle Speed Sensor (VSS) and Engine Coolant Temperature (ECT). This means the voltage set point is calculated by the PCM and communicated to the voltage regulator by the GENCOM circuit based on the needs of the vehicle and the conditions.

To minimize engine drag when starting the engine, the PCM does not allow the generator to produce any output until the engine has started. The PCM turns off the generator during cranking to reduce the generator load and improve cranking speed. Once the engine starts, the PCM slowly increases generator output to desired voltage.

The PCM controls the charging system warning indicator by sending a message over the High Speed Controller Area Network (HS-CAN) to the Instrument Cluster (IC) module. The IC module will then control charging system warning indication based on the message from the PCM. If equipped with a charging system warning indicator, the IC module will turn the indicator ON or OFF. If equipped with a message center, the IC module will display a CHECK CHARGING SYSTEM message. When the ignition is ON and the engine is OFF on vehicles equipped with a message center, the CHECK CHARGING SYSTEM message may not be displayed. For information regarding the IC module and message center, refer to INSTRUMENTATION & WARNING CHIMES article.

Under certain circumstances, the charging system may have a concern, but still keep the battery charged and the vehicle running. GENCOM is normally used to initiate charging, but the generator may charge with a fault in this circuit. If the engine is operated at greater than 2,000 rpm momentarily, the generator may "self-excite" or start charging on its own. The charging system warning indicator is illuminated and/or CHECK CHARGING SYSTEM message is displayed, and the generator operates in a default mode (approximately 13.5 volts) until the engine is turned off. When the engine is restarted and the engine is operated at greater than 2,000 rpm momentarily, the generator may again self-excite and again the charging system warning indicator is illuminated and/or CHECK CHARGING SYSTEM message is displayed.

The generator (connector C102A) is connected to the PCM and the Battery Junction Box (BJB) along 3 circuits that are part of 2 wire harnesses (14290 - PCM/ BJB and 12C580 - generator). The 2 wire harnesses are connected at C1045. The wire colors and circuit numbers for these circuits will change when passing through C1045. The following chart indicates the circuit number and wire color changes with respect to the harness in which they are located.

WIRE HARNESS REFERENCE CHART

The PIDs and their associated descriptions used in charging system diagnosis are listed in the following table

PID Chart

PID CHART

Special Tool(s)

SPECIAL TOOLS DESCRIPTION Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Scheme 1

Note. Do not make jumper connections except as directed. Incorrect connections may damage the voltage regulator test terminals, fuses or fusible links.

Note. 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 any pinpoint test, disregard any DTCs set while following a specific pinpoint test. After the completion of a test, be sure to clear all DTCs in the PCM.

Note. All voltage measurements are referenced to the negative (-) battery post unless otherwise specified.

1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical or electrical damage. VISUAL INSPECTION CHART Mechanical Electrical Battery Front End Accessory Drive (FEAD) belt Generator pulley Wiring, terminals or connectors Cables Battery Generator
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, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(/ford/transit-connect/i-2009-2013/remont/charging-system/#battery-battery-mounting-system-battery-cables) article.
5. If the cause is not visually evident, connect the scan tool to the Data Link Connector (DLC).
6. If the scan tool does not communicate with the VCM : check the VCM connection to the vehicle. check the scan tool connection to the VCM . refer to «MODULE COMMUNICATIONS NETWORK»(/ford/transit-connect/i-2009-2013/remont/communication-devices/#module-communications-network) article, No Power To The Scan Tool, to diagnose no power to the scan tool.
7. If the scan tool does not communicate with the vehicle: verify the ignition is ON. verify the scan tool operation with a known good vehicle. refer to «MODULE COMMUNICATIONS NETWORK»(/ford/transit-connect/i-2009-2013/remont/communication-devices/#module-communications-network) article to diagnose no response from the PCM.
8. Carry out the network test. If the scan tool responds with no communication for one or more modules, refer to «MODULE COMMUNICATIONS NETWORK»(/ford/transit-connect/i-2009-2013/remont/communication-devices/#module-communications-network) article. NOTE: Use the Integrated Diagnostic System (IDS) feature that retrieves all Continuous Memory Diagnostic Trouble Codes (CMDTCs) from all modules at one time.
9. Retrieve CMDTCs from all modules.
10. If the DTCs retrieved are related to the concern, go to the «DIAGNOSTIC TROUBLE CODE (DTC) CHART»(/ford/transit-connect/i-2009-2013/remont/charging-system/#charging-system) in this service information. For all other DTCs, refer to the Master DTC Chart in «MULTIFUNCTION ELECTRONIC MODULE»(/ford/transit-connect/i-2009-2013/remont/communication-devices/#multifunction-electronic-module) article or «INTRODUCTION»(/ford/transit-connect/i-2009-2013/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) .
11. If no DTCs related to the concern are retrieved, go to the «SYMPTOM CHART»(/ford/transit-connect/i-2009-2013/remont/charging-system/#charging-system__symptom-chart) in this service information.

DTC Chart

DTC CHART

Symptom Chart

SYMPTOM CHART

SPECIAL TOOLS DESCRIPTION Backprobe Pins POM6411 Flex Probe Kit 105-R025D or equivalent Fluke 77-IV Digital Multimeter FLU77-4 or equivalent Test Light SGT27000 or equivalent 250-300 mA incandescent bulb test light Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Scheme 2

Scheme 3

Scheme 4

Pinpoint Test A: System Voltage High

Refer to SYSTEM WIRING DIAGRAMS article, Charging System for schematic and connector information.

Note. DTC B1317 or B1676 can be set if the vehicle has been recently jump started, the battery has been recently charged or the battery has been discharged. The battery may become discharged due to excessive load(s) on the charging system from aftermarket accessories or if vehicle accessories have been operating for an extended period of time without the engine running.

Normal Operation

With the engine running, the charging system supplies voltage to the battery and the vehicle electrical system through the battery B+ cable. The voltage that is supplied to the vehicle electrical system is used for the operation of the various vehicle systems and modules. Many modules monitor this voltage and if it rises above a calibrated set point, a DTC will be set.

The generator (connector C102A) is connected to the PCM and the Battery Junction Box (BJB) along 3 circuits that are part of 2 wire harnesses (14290 - PCM/ BJB and 12C580 - generator). The 2 wire harnesses are connected at C1045. The wire colors and circuit numbers for these circuits will change when passing through C1045. The following chart indicates the circuit number and wire color changes with respect to the harness in which they are located.

WIRE HARNESS REFERENCE CHART

1. DTC B1317 (Battery Voltage High) - Each module within the vehicle system monitors input voltage to the module. If the voltage rises above the calibrated set point of the module (which varies by module), that module will set this DTC. This DTC may also be in memory as a Continuous Memory Diagnostic Trouble Code (CMDTC) if the vehicle has been recently jump started or has had a discharged battery.
2. DTC B1676 (Battery Pack Voltage Out of Range) - Each module within the vehicle system monitors input voltage to the module. If the voltage rises above or drops below the calibrated set point of the module, that module will set this DTC. This DTC may also be in memory ( CMDTC ) if the vehicle has been recently jump started or has had a discharged battery.
3. DTC P0563:00 (System Voltage High: No Sub Type Information) - If the module detects a voltage from the charging system higher than 15.2 volts, this DTC will be set. This DTC will not be set in the PCM unless the vehicle speed is above 8 km/h (5 mph).

This pinpoint test is intended to diagnose the following

1. Fuse
2. Wiring, terminals or connectors
3. Engine, generator and battery grounds
4. Battery
5. Generator
6. PCM

Note. Use the Flex Probe Kit for all test connections to prevent damage to the wiring terminals. Do not use standard multi-meter probes.

Note. Make sure battery voltage is greater than 12.2 volts prior to and during this pinpoint test.

Note. Do not have a battery charger attached during vehicle testing.

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

1. A1 CHECK 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, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(/ford/transit-connect/i-2009-2013/remont/charging-system/#battery-battery-mounting-system-battery-cables) article. Does the battery pass the condition test? Yes: Go to A2 . No: INSTALL a new battery. REFER to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(/ford/transit-connect/i-2009-2013/remont/charging-system/#battery-battery-mounting-system-battery-cables) article. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
2. A2 CHECK FOR DTCs IN THE PCM Enter the following diagnostic mode on the scan tool: Self Test - PCM. Do any charging system DTCs other than P0563:00 exist? Yes: REFER to the «DTC CHART»(/ford/transit-connect/i-2009-2013/remont/charging-system/#charging-system__dtc-chart) for the correct pinpoint test and DIAGNOSE those DTCs first. No: Go to A3 .
3. A3 MONITOR PCM PID GENERATOR VOLTAGE DESIRED (GENVDSD) Start the engine. NOTE: Many of the PCM PIDs selected will be monitored later in this pinpoint test. Select and monitor the following PCM PIDs: Generator Monitor (GENMON) Generator Command (GENCMD) Generator Voltage Desired (GENVDSD) Module Supply Voltage (VPWR) Monitor the GENVDSD PID. Does the GENVDSD PID indicate 15.1 volts or less? Yes: Go to A4 . No: INSTALL a new PCM. REFER to «ELECTRONIC ENGINE CONTROL SYSTEM»(/ford/transit-connect/i-2009-2013/remont/removal-installation/#electronic-engine-control-system) article. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
4. A4 MONITOR PCM PID GENERATOR VOLTAGE DESIRED (GENVDSD) With the engine still running at idle, measure battery voltage and record. Monitor the GENVDSD PID. Is battery voltage within ± 0.6 volts of the PID GENVDSD? Yes: The fault is not present at this time. This may indicate an intermittent fault. CARRY OUT a wiggle test on the charging system circuits to try and RECREATE the concern. CHECK generator connections for corrosion, loose connections and/or bent terminals. REPAIR as necessary. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. No: Go to A5 .
5. A5 CHECK THE A SENSE VOLTAGE Ignition OFF. Disconnect: Generator C102A. Ignition ON. With ignition ON, measure battery voltage and record. Measure the voltage between generator C102A-3, circuit SDC14 (RD), harness side and ground. Is the voltage equal to battery voltage? Yes: Go to A6 . No: VERIFY BJB fuse 6 (15A) is OK. If OK, repair circuit SDC14 (RD)/30-BA10 (RD). If not OK, REFER to the «SYSTEM WIRING DIAGRAMS»(ref-395063) article to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
6. A6 A SENSE CIRCUIT LOAD TEST NOTE: The following step uses a test light to simulate normal circuit loads. Use only the test light recommended in the Special Tools table at the beginning of this service information. To avoid connector terminal damage, use the Flex Probe Kit for the test light probe connection to the vehicle. Do not use the test light probe directly on any connector. Using a 12-volt test lamp connected to ground, check for voltage at generator C102A-3, circuit SDC14 (RD), harness side. Does the test lamp illuminate? Yes: Go to A7 . No: INSPECT generator C102A-3 and circuit SDC14 (RD). REPAIR as necessary. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
7. A7 CHECK THE GENERATOR OUTPUT Start the engine. Increase engine rpm until generator starts to generate output. With the engine running, measure battery voltage and record. Is the voltage above 14.5 volts? Yes: INSTALL a new generator. REFER to «GENERATOR»(/ford/transit-connect/i-2009-2013/remont/charging-system/#charging-system) in this service information. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. No: Go to A8 .
8. A8 MONITOR PCM PIDs GENERATOR COMMAND (GENCMD), GENERATOR MONITOR (GENMON) AND GENERATOR VOLTAGE DESIRED (GENVDSD) Ignition OFF. Connect a fused jumper wire between generator C102A-1, CDC15 (VT), harness side and generator C102A-2, circuit CDC10 (BU/OG), harness side. Start the engine. Monitor the GENVDSD, GENMON and GENCMD PIDs. Using the active command, set GENVDSD PID to 14 volts. Does the GENCMD PID read within 5% of GENMON PID? Yes: Go to A9 . No: INSTALL a new PCM. REFER to «ELECTRONIC ENGINE CONTROL SYSTEM»(/ford/transit-connect/i-2009-2013/remont/removal-installation/#electronic-engine-control-system) article. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
9. A9 COMPARE PCM SUPPLY VOLTAGE (VPWR) PID With the engine still running at idle, measure the battery voltage at the battery and monitor the PCM VPWR PID. Does PCM VPWR PID accurately display battery voltage within ± 0.5 volt? Yes: INSTALL a new generator. REFER to «GENERATOR»(/ford/transit-connect/i-2009-2013/remont/charging-system/#charging-system) in this service information. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. No: Go to A10 .
10. A10 CHECK PCM SUPPLY VOLTAGE CIRCUITS Ignition OFF. Disconnect: PCM C175B. Inspect the connector for pushed-out pins, spread terminals or corrosion. Measure resistance between BJB fuse 28, output side and: PCM C175B-68 circuit 15S-R28 (GN/YE), harness side PCM C175B-67 circuit 15S-R21 (GN/OG), harness side Are the resistances less than 0.5 ohm? Yes: INSTALL a new PCM. REFER to «ELECTRONIC ENGINE CONTROL SYSTEM»(/ford/transit-connect/i-2009-2013/remont/removal-installation/#electronic-engine-control-system) article. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. No: REPAIR high resistance or loose connections in the affected circuit(s). CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.

Pinpoint Test B: System Voltage Low

Refer to SYSTEM WIRING DIAGRAMS article, Charging System for schematic and connector information.

Note. DTC B1318 or B1676 can be set if the vehicle has been recently jump started, the battery has been recently charged or the battery has been discharged. The battery may become discharged due to excessive load(s) on the charging system from aftermarket accessories or if vehicle accessories have been operating for an extended period of time without the engine running.

With the engine running, the charging system supplies voltage to the battery and the vehicle electrical system through the battery B+ cable. The voltage that is supplied to the vehicle electrical system is used for the operation of vehicle and the various modules. Many modules monitor this voltage and if it drops below a calibrated set point, a DTC will be set.

The generator (connector C102A) is connected to the PCM and the Battery Junction Box (BJB) along 3 circuits that are part of 2 wire harnesses (14290 - PCM/ BJB and 12C580 - generator). The 2 wire harnesses are connected at C1045. The wire colors and circuit numbers for these circuits will change when passing through C1045. The following chart indicates the circuit number and wire color changes with respect to the harness in which they are located.

WIRE HARNESS REFERENCE CHART

1. DTC B1318 (Battery Voltage Low) - Each module within the vehicle system monitors input voltage to the module. If the voltage drops below the calibrated set point of the module (which varies between modules), that module will set this DTC.
2. DTC B1676 (Battery Pack Voltage Out of Range) - Each module within the vehicle system monitors input voltage to the module. If the voltage rises above or drops below the calibrated set point of the module, that module will set this DTC. This DTC may also be set if the vehicle has been recently jump started or has had a discharged battery.

This pinpoint test is intended to diagnose the following

1. Circuit high resistance
2. Engine, generator and battery grounds
3. Positive battery cable
4. Battery
5. High ignition-off current drain(s)
6. Generator

Note. Use the Flex Probe Kit for all test connections to prevent damage to the wiring terminals. Do not use standard multi-meter probes.

Note. Make sure battery voltage is greater than 12.2 volts prior to and during this pinpoint test.

Note. Do not have a battery charger attached during vehicle testing.

Scheme 10

Scheme 11

1. B1 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, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(/ford/transit-connect/i-2009-2013/remont/charging-system/#battery-battery-mounting-system-battery-cables) article. Does the battery pass the condition test? Yes: Go to B2 . No: INSTALL a new battery. REFER to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(/ford/transit-connect/i-2009-2013/remont/charging-system/#battery-battery-mounting-system-battery-cables) article. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
2. B2 CHECK THE VEHICLE GROUNDS Start the engine. With the engine running at idle, headlamps on and heater blower on high, measure the voltage drop between the generator housing and the negative battery terminal. Is the voltage drop less than 0.25 volt (250 mV)? Yes: Go to B3 . No: INSPECT and REPAIR the engine ground, generator ground or the battery ground for corrosion. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
3. B3 CHECK THE VOLTAGE DROP IN THE B+ CIRCUIT With the engine running at idle, headlamps on and blower on high, measure the voltage drop between generator B+ C102B, circuit 30-BA6 (RD) and the positive battery terminal. Is the voltage drop less than 0.5 volt? Yes: Go to B4 . No: INSPECT and REPAIR any corrosion in the B+ 30-BA6 (RD) or positive battery cable connections. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
4. B4 CHECK FOR CURRENT DRAINS Carry out the Battery - Drain Testing. Refer to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(/ford/transit-connect/i-2009-2013/remont/charging-system/#battery-battery-mounting-system-battery-cables) article. Are any circuits causing excessive current drains? Yes: REPAIR as necessary. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. No: No problems found at this time. CHECK with the customer to determine if any electrical system(s) may have been accidently left on. If nothing unusual is found, CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. Go to «PINPOINT TEST D»(/ford/transit-connect/i-2009-2013/remont/charging-system/#charging-system__pinpoint-test-d-dtcs-p062500-and) to continue diagnosis of the charging system.

Pinpoint Test C: DTC P0620:00

Refer to SYSTEM WIRING DIAGRAMS article, Charging System for schematic and connector information.

The PCM monitors the generator output via the GENMON circuit. The PCM uses the GENCOM circuit to command the generator to either increase or decrease output. If the GENCOM circuit (generator control circuit) or the A sense circuit are open or shorted to ground, the PCM will be unable to control the generators output. When the engine rises above approximately 2,000 rpm, the generator will default to a steady voltage of approximately 13.5 volts and the PCM will send a request to the Instrument Cluster (IC) to illuminate the charging system warning indicator lamp.

The generator (connector C102A) is connected to the PCM and the Battery Junction Box (BJB) along 3 circuits that are part of 2 wire harnesses (14290 - PCM/ BJB and 12C580 - generator). The 2 wire harnesses are connected at C1045. The wire colors and circuit numbers for these circuits will change when passing through C1045. The following chart indicates the circuit number and wire color changes with respect to the harness in which they are located.

WIRE HARNESS REFERENCE CHART

1. DTC P0620:00 (Generator Control Circuit: No Sub Type Information) - If the GENCOM circuit or A sense circuit are open or shorted to ground the PCM will set this DTC.

This pinpoint test is intended to diagnose the following

1. Fuse
2. Wiring, terminals or connectors
3. Generator
4. PCM

Note. Use the Flex Probe Kit for all test connections to prevent damage to the wiring terminals. Do not use standard multi-meter probes.

Note. Make sure battery voltage is greater than 12.2 volts prior to and during this pinpoint test.

Note. Do not have a battery charger attached during vehicle testing.

Scheme 12

Scheme 13

Scheme 14

1. C1 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, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(/ford/transit-connect/i-2009-2013/remont/charging-system/#battery-battery-mounting-system-battery-cables) article. Does the battery pass the condition test? Yes: Go to C2 . No: INSTALL a new battery. REFER to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(/ford/transit-connect/i-2009-2013/remont/charging-system/#battery-battery-mounting-system-battery-cables) article. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
2. C2 CHECK THE GENERATOR B+ CONNECTION Ignition OFF. Disconnect: Generator C102A. Inspect generator C102A connection. Connector should be installed correctly and tight. Inspect the connector for bent and/or pushed-out pins. Inspect generator C102B. Connection should be tight. Measure the voltage between generator C102B, B+ circuit 30-BA6 (RD) and ground. Are the generator connections OK and does the generator B+ measure battery voltage? Yes: Go to C3 . No: REPAIR the generator connection or circuit 30-BA6 (RD). CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
3. C3 CHECK THE VOLTAGE DROP IN THE B+ CIRCUIT Connect: Generator C102A. Start the engine. With the engine running at idle, headlamps on and blower on high, measure the voltage drop between generator B+ C102B circuit 30-BA6 (RD) and the positive battery terminal. Is the voltage drop less than 0.5 volt? Yes: Go to C4 . No: REPAIR circuit 30-BA6 (RD) and/or the positive battery cable for loose connections, physical damage or wire corrosion. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
4. C4 A SENSE CIRCUIT LOAD TEST NOTE: The following step uses a test light to simulate normal circuit loads. Use only the test light recommended in the Special Tools table at the beginning of this service information. To avoid connector terminal damage, use the Flex Probe Kit for the test light probe connection to the vehicle. Do not use the test light probe directly on any connector. Ignition OFF. Disconnect: Generator C102A. Ignition ON. Using a 12-volt test lamp connected to ground, check for voltage at generator C102A-3, circuit SDC14 (RD) harness side. Does the test lamp illuminate? Yes: Go to C5 . No: VERIFY BJB fuse 6 (15A) is OK. If OK, repair circuit SDC14 (RD) or 30-BA10 (RD). If not OK, REFER to the «SYSTEM WIRING DIAGRAMS»(ref-395063) article to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
5. C5 CHECK THE GENERATOR COMMAND LINE FAULT (GENCMD_LF) PID Connect: Generator C102A. Start the engine. NOTE: Many of the PCM PIDs selected will be monitored later in this pinpoint test. Select and monitor the following PCM PIDs: Generator Monitor (GENMON) Generator Command (GENCMD) Generator Command Line Fault (GENCMD_LF) With the engine running at idle, monitor the GENCMD_LF PID. Is the GENMON_LF PID ON? Yes: Go to C6 . No: Go to C9 .
6. C6 CHECK THE GENCOM CIRCUIT FOR A SHORT TO POWER Ignition OFF. Disconnect: Generator C102A. Ignition ON. Measure the voltage between generator C102A-2, circuit CDC10 (BU/OG), harness side and ground. Does voltage read 1 volt or less? Yes: Go to C7 . No: Go to C11 .
7. C7 COMPARE THE PCM PIDs GENERATOR MONITOR (GENMON) AND GENERATOR COMMAND (GENCMD) Ignition OFF. Connect a fused jumper wire between generator C102A-1, circuit CDC15 (VT), harness side and generator C102A-2, circuit CDC10 (BU/OG), harness side. Start the engine. Monitor the GENMON and GENCMD PIDs while performing a wiggle test on the generator harness. Does the GENMON PID read within 5% of the GENCMD PID? Yes: Go to C8 . No: Go to C12 .
8. C8 CHECK THE GENERATOR COMMAND CIRCUIT FOR DAMAGE OR AN OPEN Ignition OFF. Disconnect: PCM C175B. Inspect the following harness connectors for damaged or pushed-out pins: PCM C175B-53, circuit 30S-DJ1 (RD/YE) Generator C102B-2, circuit CDC10 (BU/OG) Measure the resistance between PCM C175B-53, circuit 30S-DJ1 (RD/YE), harness side and generator C102B-2, circuit CDC10 (BU/OG), harness side. Are the connectors and pins free of damage and is the resistance less than 5 ohms? Yes: Go to C9 . No: REPAIR circuit CDC10 (BU/OG)/30S-DJ1 (RD/YE). CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
9. C9 CHECK THE GENERATOR COMMAND CIRCUIT FOR A SHORT TO GROUND Ignition OFF. Disconnect: Generator C102A (if not previously disconnected). Measure the resistance between the generator C102A-2, circuit CDC10 (BU/OG), harness side and ground. Is the resistance greater than 10,000 ohms? Yes: Go to C10 . No: REPAIR circuit CDC10 (BU/OG)/30S-DJ1 (RD/YE). CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
10. C10 CHECK THE CHARGING SYSTEM CIRCUITS FOR INTERMITTENT FAULTS Connect: Generator C102A. Connect: PCM C175B. Ignition ON. Clear all DTCs. Start the engine and let the engine run for 5 minutes. Enter the following diagnostic mode on the scan tool: Self Test - All CMDTCs . Did any charging system DTC get stored into memory? Yes: INSTALL a new generator. REFER to «GENERATOR»(/ford/transit-connect/i-2009-2013/remont/charging-system/#charging-system) procedure in this service information. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. No: The fault is not present at this time. This may indicate an intermittent fault. CARRY OUT a wiggle test on the charging system circuits to try and RECREATE the concern. CHECK generator connections for corrosion, loose connections and/or bent terminals. REPAIR as necessary. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
11. C11 CHECK THE GENERATOR COMMAND CIRCUIT FOR A SHORT TO VOLTAGE Ignition OFF. Disconnect: PCM C175B. Ignition ON. Measure the voltage between generator C102A-2, circuit CDC10 (BU/OG), harness side and ground. Does voltage read 0 volts? Yes: INSTALL a new PCM. REFER to «ELECTRONIC ENGINE CONTROL SYSTEM»(/ford/transit-connect/i-2009-2013/remont/removal-installation/#electronic-engine-control-system) article. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. No: REPAIR circuit CDC10 (BU/OG)/30S-DJ1 (RD/YE). CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
12. C12 INSPECT GENERATOR CIRCUITS Ignition OFF. Disconnect: PCM C175B. Inspect the following connector pins for damage and/or corrosion: PCM ground C175B-50, circuit 31-RE8 (BK) PCM ground C175B-69, circuit 31-RE21 (BK) PCM ground C175B-70, circuit 31-RE25 (BK) Generator C102A-1, circuit CDC15 (VT) Generator C102A-2, circuit CDC10 (BU/OG) Are the connectors OK? Yes: INSTALL a new PCM. REFER to «ELECTRONIC ENGINE CONTROL SYSTEM»(/ford/transit-connect/i-2009-2013/remont/removal-installation/#electronic-engine-control-system) article. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. No: REPAIR high resistance or loose connections in the affected circuit(s). CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.

Pinpoint Test D: DTCs P0625:00 and P0626:00

Refer to SYSTEM WIRING DIAGRAMS article, Charging System for schematic and connector information.

The PCM monitors the generator output via the GENMON circuit (generator field terminal circuit). If the PCM cannot read the GENMON circuit due to an open or short to ground, when the engine rises above approximately 2,000 rpm, the generator will default to a steady voltage of approximately 13.5 volts and the PCM will send a request to the Instrument Cluster (IC) to illuminate the charging system warning indicator lamp.

The generator (connector C102A) is connected to the PCM and the Battery Junction Box (BJB) along 3 circuits that are part of 2 wire harnesses (14290 - PCM/ BJB and 12C580 - generator). The 2 wire harnesses are connected at C1045. The wire colors and circuit numbers for these circuits will change when passing through C1045. The following chart indicates the circuit number and wire color changes with respect to the harness in which they are located.

WIRE HARNESS REFERENCE CHART

1. DTC P0625:00 (Generator Field Terminal Circuit Low: No Sub Type Information) - If the GENMON circuit is shorted to ground or the A sense is open, the PCM will set this DTC. This DTC can also be set by a faulty PCM or generator.
2. DTC P0626:00 (Generator Field Terminal Circuit High: No Sub Type information) - If the GENMON circuit is open or shorted to power, the PCM will set this DTC. This DTC can also be set by a faulty PCM or generator.

This pinpoint test is intended to diagnose the following

1. Fuse
2. Wiring, terminals or connectors
3. Engine, generator and battery grounds
4. Battery
5. Generator
6. PCM

PINPOINT TEST D: DTCs P0625 AND P0626

Note. Use the Flex Probe Kit for all test connections to prevent damage to the wiring terminals. Do not use standard multi-meter probes.

Note. Make sure battery voltage is greater than 12.2 volts prior to and during this pinpoint test.

Note. Do not have a battery charger attached during vehicle testing.

Scheme 15

Scheme 16

1. D1 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, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(/ford/transit-connect/i-2009-2013/remont/charging-system/#battery-battery-mounting-system-battery-cables) article. Does the battery pass the condition test? Yes: Go to D2 . No: INSTALL a new battery. REFER to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(/ford/transit-connect/i-2009-2013/remont/charging-system/#battery-battery-mounting-system-battery-cables) article. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
2. D2 CHECK THE GENERATOR B+ CONNECTION Ignition OFF. Inspect generator C102B, circuit 30-BA6 (RD), harness side. Connection should be tight. Measure the voltage between generator C102B, circuit 30-BA6 (RD) and ground. Is the generator C102B connection tight and does the generator B+ measure battery voltage? Yes: Go to D3 . No: REPAIR the generator B+ connection and/or circuit 30-BA6 (RD). CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
3. D3 CHECK THE A SENSE VOLTAGE Disconnect: Generator C102A. Ignition ON. Measure battery voltage and record. Measure the voltage between generator C102A-3, circuit SDC14 (RD), harness side and ground. Is the voltage equal to battery voltage? Yes: Go to D4 . No: VERIFY BJB fuse 6 (15A) is OK. If OK, repair circuit SDC14 (RD)/30-BA10 (RD). If not OK, REFER to the «SYSTEM WIRING DIAGRAMS»(ref-395063) article to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
4. D4 MONITOR THE PCM PID GENERATOR MONITOR (GENMON) WITH IGNITION ON/ENGINE OFF Connect: Generator C102A. NOTE: Many of the PCM PIDs selected will be monitored later in this pinpoint test. Select and monitor the following PCM PIDs: Generator Monitor (GENMON) Generator Command (GENCMD) Generator Voltage Desired (GENVDSD) Engine Revolutions Per Minute (RPM) Module Supply Voltage (VPWR) Monitor the GENMON PID. Does the GENMON PID read 0%? Yes: Go to D5 . No: Go to D10 .
5. D5 MONITOR THE PCM PIDs GENERATOR MONITOR (GENMON) AND GENERATOR VOLTAGE DESIRED (GENVDSD) WITH ENGINE RUNNING AND NO LOADS Start the engine and turn all electrical accessories (lights and blower motor) off. With the engine at idle, wait at least 15 seconds for the GENVDSD PID to increase to greater than 13 volts. Monitor PID GENMON at idle. NOTE: On some vehicles equipped with a manual transaxle/transmission, the parking brake must be applied and the clutch pedal depressed in order to use the output state control RPM. Using output state control PID RPM, increase the engine rpm to 3,000 rpm. Monitor PID GENMON at 3,000 rpm. Does the GENMON PID read between 3% and 98% at engine idle speed and at 3,000 rpm? Yes: Go to D6 . No: Go to D11 .
6. D6 MONITOR THE PCM PIDs GENERATOR MONITOR (GENMON), GENERATOR VOLTAGE DESIRED (GENVDSD) WITH THE ENGINE AT IDLE LOADS ON Decrease the engine speed to 500 rpm using output state control PID RPM and monitor PIDs. NOTE: On vehicles with low electrical loads, it is necessary to make sure that all of the vehicle's electrical loads are turned on to determine the maximum GENMON PID value. The GENMON PID value may not reach between the desired 95%-98% on a low load vehicle with minimal electrical accessories. As long as the GENMON PID increases significantly with all of the electrical loads on, answer YES to the question below. Determine the maximum GENMON PID value by lowering engine idle rpm to 500 rpm or less using output state control PID RPM and turn on all electrical accessories until the module supply voltage (VPWR) PID is less than the GENVDSD PID by at least 0.7 volt. Under this condition the GENMON PID should read between 95% and 98%. Does the GENMON PID read between 95% and 98%? Yes: Go to D7 . No: Go to D11 .
7. D7 MONITOR THE PCM PIDs GENERATOR MONITOR (GENMON), MODULE SUPPLY VOLTAGE (VPWR) AND GENERATOR VOLTAGE DESIRED (GENVDSD) WITH THE ENGINE AT 3,000 RPM Increase the engine speed to 3,000 rpm using output state control PID RPM and monitor PIDs. NOTE: If GENMON PID does not remain below 85%, make sure that the battery is at an acceptable state of charge and that all electrical accessories are off. Monitor PIDs VPWR, GENVDSD and GENMON. Does the VPWR PID remain within ± 0.5 volt of the GENVDSD PID when the GENMON PID is less than 85%? Yes: Go to D8 . No: Go to D11 .
8. D8 CHECK THE GENERATOR B+ RESISTANCE Ignition OFF. NOTE: Failure to disconnect the battery will result in false resistance readings. Disconnect the battery. Refer to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(/ford/transit-connect/i-2009-2013/remont/charging-system/#battery-battery-mounting-system-battery-cables) article. Disconnect: Generator C102B. Measure the resistance between generator C102B, component side and the generator housing. Is the resistance greater than 25K ohms? Yes: Go to D9 . No: INSTALL a new generator. REFER to «GENERATOR»(/ford/transit-connect/i-2009-2013/remont/charging-system/#charging-system) in this service information. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
9. D9 CHECK THE RESISTANCE OF THE VOLTAGE REGULATOR INTERNAL CIRCUITS TO GROUND Disconnect: Generator C102A. Measure the resistance between generator C102A, component side and ground. Refer to the following table. RESISTANCE REFERENCE CHART Pin Expected Resistance 1 Greater than 10K ohms 2 Greater than 10K ohms 3 Greater than 10K ohms Are the resistance values as indicated? Yes: The fault is not present at this time. This may indicate an intermittent fault. CARRY OUT a wiggle test on the charging system circuits to try and RECREATE the concern. CHECK generator connections for corrosion, loose connections and/or bent terminals. REPAIR as necessary. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. No: INSTALL a new generator. REFER to «GENERATOR»(/ford/transit-connect/i-2009-2013/remont/charging-system/#charging-system) in this service information. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
10. D10 CHECK THE PCM PID GENERATOR MONITOR (GENMON) INPUT TO THE PCM Ignition OFF. Disconnect: Generator C102A. Connect a fused jumper wire between generator C102A-1, circuit CDC15 (VT), harness side and ground. Ignition ON. Monitor the GENMON PID while performing a wiggle test on the generator wiring harness. Does the GENMON PID read 0%? Yes: Go to D14 . No: Go to D15 .
11. D11 A SENSE CIRCUIT LOAD TEST NOTE: The following step uses a test light to simulate normal circuit loads. Use only the test light recommended in the Special Tools table at the beginning of this service information. To avoid connector terminal damage, use the Flex Probe Kit for the test light probe connection to the vehicle. Do not use the test light probe directly on any connector. Ignition OFF. Disconnect: Generator C102A (if not previously disconnected). Ignition ON. Using a 12-volt test lamp connected to ground, check for voltage at C102A-3, circuit SDC14 (RD), harness side. Does the test lamp illuminate? Yes: Go to D12 . No: VERIFY BJB fuse 6 (15A) is OK. If OK, repair circuit SDC14 (RD)/30-BA10 (RD). If not OK, REFER to the «SYSTEM WIRING DIAGRAMS»(ref-395063) article to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
12. D12 B+ CIRCUIT LOAD TEST NOTE: The following step uses a test light to simulate normal circuit loads. Use only the test light recommended in the Special Tools table at the beginning of this service information. To avoid connector terminal damage, use the Flex Probe Kit for the test light probe connection to the vehicle. Do not use the test light probe directly on any connector. Ignition OFF. Disconnect: Generator C102B. Using a 12-volt test lamp connected to ground, check for voltage at C102B-1, circuit 30-BA6 (RD), harness side. Does the test lamp illuminate? Yes: Go to D13 . No: REPAIR circuit 30-BA6 (RD) for high resistance. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
13. D13 CHECK CIRCUIT CDC10 (BU/OG) FOR DAMAGE OR AN OPEN Ignition OFF. Disconnect: PCM C175B. Inspect the following harness connectors for damaged or pushed-out pins: PCM C175B-53, circuit 30S-DJ1 (RD/YE) Generator C102A-2, circuit CDC10 (BU/OG) Measure the resistance between PCM C175B-53, circuit 30S-DJ1 (RD/YE), harness side and generator C102A-2, circuit CDC10 (BU/OG), harness side. Are the connectors and pins free of damage and is the resistance less than 0.5 ohm? Yes: Go to D14 . No: REPAIR circuit CDC10 (BU/OG)/30S-DJ1 (RD/YE). CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
14. D14 COMPARE THE PCM PIDs GENERATOR MONITOR (GENMON) AND GENERATOR COMMAND (GENCMD) Connect: Generator C102B (if previously disconnected). Connect: PCM C175B. Connect a fused jumper wire between generator C102A-1, circuit CDC15 (VT), harness side and generator C102A-2, circuit CDC10 (BU/OG), harness side. Start the engine. Using output state control, set the GENVDSD PID to 14.0 volts. Monitor the GENMON and GENCMD PIDs while performing a wiggle test on the generator wiring harness. Does the GENMON PID read within 2% of the GENCMD PID? Yes: INSTALL a new generator. REFER to «GENERATOR»(/ford/transit-connect/i-2009-2013/remont/charging-system/#charging-system) in this service information. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. No: Go to D16 .
15. D15 INSPECT GENERATOR CIRCUITS Ignition OFF. Disconnect: PCM C175B. Inspect the following connector pins for damage and/or corrosion: Generator C102A-1 circuit CDC15 (VT) PCM C175B-14, circuit 30-DJ1 (RD) Are the connectors OK? Yes: INSTALL a new PCM. REFER to «ELECTRONIC ENGINE CONTROL SYSTEM»(/ford/transit-connect/i-2009-2013/remont/removal-installation/#electronic-engine-control-system) article. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. No: REPAIR the affected circuit(s). CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
16. D16 INSPECT PCM CIRCUITS Ignition OFF. Disconnect: PCM C175B. Inspect the following connector pins for damage and/or corrosion: PCM C175B-53, circuit 30-DJ1 (RD) PCM C175B-14, circuit 30S-DJ1 (RD/YE) Generator C102B Are the connectors OK? Yes: INSTALL a new PCM. REFER to «ELECTRONIC ENGINE CONTROL SYSTEM»(/ford/transit-connect/i-2009-2013/remont/removal-installation/#electronic-engine-control-system) article. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. No: REPAIR the affected circuit(s). CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.

Pinpoint Test E: DTC P065B:00

Refer to SYSTEM WIRING DIAGRAMS article, Charging System for schematic and connector information.

The PCM monitors the generator output via the GENMON circuit. The signal that is monitored by the PCM on the GENMOM circuit is a controlled frequency range. If the signal is outside of this prescribed range, the PCM will be unable to read the signal. When the engine rises above approximately 2,000 rpm, the generator will default to a steady voltage of approximately 13.5 volts and the PCM will send a request to the Instrument Cluster (IC) to illuminate the charging system warning indicator lamp.

The generator (connector C102A) is connected to the PCM and the Battery Junction Box (BJB) along 3 circuits that are part of 2 wire harnesses (14290 - PCM/ BJB and 12C580 - generator). The 2 wire harnesses are connected at C1045. The wire colors and circuit numbers for these circuits will change when passing through C1045. The following chart indicates the circuit number and wire color changes with respect to the harness in which they are located.

WIRE HARNESS REFERENCE CHART

1. DTC P065B:00 (Generator Control Circuit Range/Performance: No Sub Type Information) - If the input frequency was continuously less than 80 Hz or more than 200 Hz the PCM will set this DTC.

This pinpoint test is intended to diagnose the following

1. Wiring, terminals or connectors
2. Generator
3. PCM

Note. Use the Flex Probe Kit for all test connections to prevent damage to the wiring terminals. Do not use standard multi-meter probes.

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.

1. E1 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, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(/ford/transit-connect/i-2009-2013/remont/charging-system/#battery-battery-mounting-system-battery-cables) article. Does the battery pass the condition test? Yes: Go to E2 . No: INSTALL a new battery. REFER to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(/ford/transit-connect/i-2009-2013/remont/charging-system/#battery-battery-mounting-system-battery-cables) article. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
2. E2 CHECK THE PCM GENERATOR MONITOR FREQUENCY (GENMON_HZ) PID Start the engine. NOTE: Many of the PCM PIDs selected will be monitored later in this pinpoint test. Select and monitor the following PCM PIDs: Generator Voltage Desired (GENVDSD) Generator Monitor Frequency (GENMON_HZ) Monitor the GENMON_HZ PID. Is the PID below 80 Hz or above 200 Hz? Yes: Go to E3 . No: The fault is not present at this time. This may indicate an intermittent fault. CARRY OUT a wiggle test on the charging system circuits to try and RECREATE the concern. CHECK generator connections for corrosion, loose connections and/or bent terminals. REPAIR as necessary. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
3. E3 CHECK THE PCM GENERATOR MONITOR FREQUENCY (GENMON_HZ) PID WITH GENERATOR C102A DISCONNECTED Ignition OFF. Disconnect: Generator C102A. Start the engine. Monitor the GENMON_HZ PID. Does the PID read between 0-2 Hz? Yes: Go to E5 . No: Go to E4 .
4. E4 CHECK GENERATOR CIRCUITRY Ignition OFF. NOTE: This pinpoint test step directs testing circuits using a back-probe method. Use the special back-probe tool specified in the tool list in this service information. Do not force test leads or other probes into connectors. Adequate care must be exercised to avoid connector terminal damage while ensuring that good electrical contact is made with the circuit or terminal. Failure to follow these instructions may cause damage to wiring, terminals or connectors and subsequent electrical faults. With the PCM connected, connect a fused jumper wire between PCM C175B-14, circuit 30-DJ1 (RD) and ground by carefully back probing the PCM. Start the engine. Monitor the GENMON_HZ PID. 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 and REPAIR generator circuit 30-DJ1 (RD) as needed. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. No: INSTALL a new PCM. REFER to «ELECTRONIC ENGINE CONTROL SYSTEM»(/ford/transit-connect/i-2009-2013/remont/removal-installation/#electronic-engine-control-system) article. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
5. E5 MONITOR THE PCM PID GENERATOR MONITOR FREQUENCY (GENMON_HZ) WHILE ACTIVATING THE GENERATOR VOLTAGE DESIRED (GENVDSD) PID Ignition OFF. Connect a fused jumper wire between generator C102A-1, circuit CDC15 (VT), harness side and generator C102A-2, circuit CDC10 (BU/OG), harness side. Start the engine. With the engine at idle, set the output state control GENVDSD PID to 14 volts. Monitor the GENMON_HZ PID. Does the GENMON_HZ PID read between 120-130 Hz? Yes: INSTALL a new generator. REFER to «GENERATOR»(/ford/transit-connect/i-2009-2013/remont/charging-system/#charging-system) in this service information. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. No: INSTALL a new PCM. REFER to «ELECTRONIC ENGINE CONTROL SYSTEM»(/ford/transit-connect/i-2009-2013/remont/removal-installation/#electronic-engine-control-system) article. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.

Pinpoint Test F: The Generator is Noisy

Refer to SYSTEM WIRING DIAGRAMS article, Charging System for schematic and connector information.

The generator is belt-driven by the engine accessory drive system. There are many sources of generator noise: bearing noise, electrical fault noise and/or belt pulley misalignment. A generator with certain types of diode or stator failures may also produce an audible noise.

This pinpoint test is intended to diagnose the following

1. Accessory drive belt
2. Loose bolts/brackets
3. Generator/pulley

1. 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 «ENGINE ACCESSORY DRIVE BELTS»(/ford/transit-connect/i-2009-2013/remont/accessory-drive-belts/#accessory-drive-system) article. 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 «ENGINE ACCESSORY DRIVE BELTS»(/ford/transit-connect/i-2009-2013/remont/accessory-drive-belts/#accessory-drive-system) article for diagnosis and testing of the accessory drive system. TEST the system for normal operation.
2. 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. TEST the system for normal operation.
3. F3 CHECK THE GENERATOR FOR NOISE With the engine running, use a stethoscope or equivalent listening device to probe the generator and the accessory drive area for unusual mechanical noise. Is the generator the noise source? Yes: INSTALL a new generator. REFER to the «GENERATOR»(/ford/transit-connect/i-2009-2013/remont/charging-system/#charging-system) procedure in this service information. No: REFER to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-system-general-information) article to diagnose the source of the engine noise.

Pinpoint Test G: Radio Interference

Refer to SYSTEM WIRING DIAGRAMS article, Charging System for schematic and connector information.

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

This pinpoint test is intended to diagnose the following

1. Generator
2. Wiring, terminals or connectors
3. In-vehicle entertainment system

Note. If the OEM audio unit has been replaced with an aftermarket unit, the vehicle may not pass this test. Return the vehicle to OEM condition before following this pinpoint test.

Note. If the engine is operated at greater than 2,000 rpm momentarily, the generator will self-excite. Make sure when the generator is disconnected the engine rpm stays below 2,000 rpm. If it does rise above 2,000 rpm, turn the ignition to the off position and start the test over again.

Note. Inspect for any after market accessories that have been added to the vehicle. Check the wiring for these accessories and be sure they have not been attached to the generator circuits and are positioned away from the generator wiring.

1. 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, determine if the interference is still present. Is the interference present with the generator disconnected? Yes: REFER to «DRIVER INFORMATION SYSTEM & ENTERTAINMENT SYSTEM»(/ford/transit-connect/i-2009-2013/remont/entertainment-systems/#driver-information-system-entertainment-system) article for diagnosis and testing of the in-vehicle entertainment system. No: INSTALL a new generator. REFER to «GENERATOR»(/ford/transit-connect/i-2009-2013/remont/charging-system/#charging-system) in this service information. TEST the system for normal operation.

Scheme 17

GENERATOR PARTS DESCRIPTION CHART

Removal

Installation

See also:
• INSTRUMENTATION & WARNING CHIMES
• BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES
• MODULE COMMUNICATIONS NETWORK
• MULTIFUNCTION ELECTRONIC MODULE
• INTRODUCTION
• ELECTRONIC ENGINE CONTROL SYSTEM
• ENGINE ACCESSORY DRIVE BELTS
• ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION
• DRIVER INFORMATION SYSTEM & ENTERTAINMENT SYSTEM
• JACKING & LIFTING
• FRONT DRIVE HALFSHAFTS
• DIAGNOSTIC TROUBLE CODE (DTC) CHART
• SYMPTOM CHART
• PINPOINT TEST A
• PINPOINT TEST C
• PINPOINT TEST D
• PINPOINT TEST E
• PINPOINT TEST B
• PINPOINT TEST F
• PINPOINT TEST G
• DTC CHART