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Power Windows System: Diagnosis Ford Windstar I

Windows 4 illustrations ~3714 words

INSPECTION & VERIFICATION

Verify customer concern by operating windows to duplicate condition. Visually inspect components. If inspection reveals an obvious concern which can be easily serviced, correct malfunction before continuing inspection and verification.

MOTOR TEST

Disconnect window motor harness connector for inoperative window. Using jumper wires, connect battery power and ground to window motor connector terminals. To reverse motor direction, reverse polarity of jumper wires. Motor should operate rapidly in both directions. Replace motor if necessary.

SELF-DIAGNOSTICS

The power windows utilize a self-diagnostic system which may store a Diagnostic Trouble Code (DTC) if a problem exists in the system. DTCs may be retrieved using NGS tester and Data Link Connector (DLC) for diagnosis of system. Before performing any testing, a preliminary procedure should be performed. See PRELIMINARY PROCEDURE.

TEST A: NO COMMUNICATION WITH GEM

  1. Check For Remote Anti-Theft Personality (RAP) Module - Using NGS tester, check to see if vehicle is equipped with a RAP module. If vehicle is equipped with RAP module, go to next step. If vehicle is not equipped with RAP module, go to step 6).
  2. Check For Communication To Remote Anti-Theft Personality (RAP) Module - Using NGS tester, perform DATA LINK DIAGNOSTIC TEST. If NGS tester indicates NO RESPONSE/NOT EQUIPPED, go to next step. If NGS tester does not indicate NO RESPONSE/NOT EQUIPPED, go to step 6).
  3. Check Fuse - Check condition of instrument panel fuse block fuse No. 19 (15-amp). If fuse is not okay, go to next step. If fuse is okay, repair open in Black/Light Green wire and retest system operation.
  4. Check GEM - Turn ignition off. Disconnect GEM 26-pin connector C233 (located behind instrument panel, on left side of steering column). Using an ohmmeter, check resistance between ground and output cavity of instrument panel fuse No. 19 (15-amp). Ohmmeter should indicate above one megohm and drop to less than 3 k/ohms steadily. If ohmmeter does not operate as specified, disconnect ohmmeter and go to next step. If ohmmeter operates as specified, replace GEM and retest system operation.
  5. Check RAP Module - Disconnect RAP module connectors (located behind center of instrument panel). Using an ohmmeter, check resistance between ground and output cavity of instrument panel fuse No. 19 (15-amp). Ohmmeter should indicate above one megohm and drop to less than 3 k/ohms steadily. If ohmmeter operates as specified, replace RAP module and retest system operation. If ohmmeter does not operate as specified, repair short to ground in Black/Light Green wire and retest system operation.
  6. Check Black/Light Green Wire For Power - Disconnect GEM 26-pin connector C233 (located behind instrument panel, on left side of steering column). Using a voltmeter, check voltage between ground and GEM 26-pin connector C233 terminal No. 13 (Black/Light Green wire). see scheme 2 If battery voltage is not present, go to next step. If battery voltage is present, go to step 10).
  7. Check Black/Light Green Wire For Short To Ground - Remove instrument panel fuse block fuse No. 19 (15-amp). Using an ohmmeter, check resistance between ground and GEM 26-pin connector C233 terminal No. 13 (Black/Light Green wire). If resistance is 10 k/ohms or more, go to next step. If resistance is less than 10 k/ohms, repair short to ground in Black/Light Green wire. Replace fuse No. 19 (15-amp) and retest system operation.
  8. Check Power Supply To Fuse - Remove instrument panel fuse block fuse No. 19 (15-amp). Using a voltmeter, check voltage between ground and input cavity (Tan/Black wire) of instrument panel fuse No. 19 (15-amp). If battery voltage is present, go to next step. If battery voltage is not present, repair Tan/Black wire and retest system operation.
  9. Check Black/Light Green Wire For Open - Using an ohmmeter, check resistance in Black/Light Green wire between GEM 26-pin connector C233 terminal No. 13 and output cavity of instrument panel fuse No. 19 (15-amp). see scheme 2 If resistance is 5 ohms or less, replace fuse No. 19 (15-amp) and retest system operation. If resistance is more than 5 ohms, repair open in Black/Light Green wire and retest system operation.
  10. Check Pink/Black Wire For Power - Disconnect GEM 22-pin connector C234 (located behind instrument panel, on left side of steering column). Turn ignition switch to RUN position. Using a voltmeter, check voltage between ground and GEM 22-pin connector C234 terminal No. 22 (Pink/Black wire). see scheme 2 If battery voltage is not present, go to next step. If battery voltage is present, go to step 14).
  11. Check Pink/Black Wire For Short To Ground - Remove instrument panel fuse block fuse No. 21 (10-amp). Using an ohmmeter, check resistance between ground and GEM 22-pin connector C234 terminal No. 22 (Pink/Black wire). If resistance is 10 k/ohms or more, go to next step. If resistance is less than 10 k/ohms, repair short to ground in Pink/Black wire. Replace fuse No. 21 (10-amp) and retest system operation.
  12. Check Power Supply To Fuse - Remove instrument panel fuse block fuse No. 21 (10-amp). Using a voltmeter, check voltage between ground and input cavity (Gray/Yellow wire) of instrument panel fuse No. 21 (10-amp). If battery voltage is present, go to next step. If battery voltage is not present, repair Gray/Yellow wire and retest system operation.
  13. Check Pink/Black Wire For Open - Using an ohmmeter, check resistance in Pink/Black wire between GEM 22-pin connector C234 terminal No. 22 and output cavity of instrument panel fuse No. 21 (10-amp). see scheme 2 If resistance is 5 ohms or less, replace fuse No. 21 (10-amp) and retest system operation. If resistance is more than 5 ohms, repair open in Pink/Black wire and retest system operation.
  14. Check Black/White Wire For Open - Using an ohmmeter, check resistance between ground and GEM 26-pin connector C233 terminals No. 25 and 26. Check resistance between ground and GEM 22-pin connector C234 terminal No. 15. see scheme 2 If resistances are less than 5 ohms, go to MODULE COMMUNICATIONS NETWORK article to continue diagnosis. If resistance is 5 ohms or more, repair open in appropriate Black/White wire and retest system operation.

TEST B: POWER WINDOWS COMPLETELY INOPERATIVE

  1. Check For DTCs - Using NGS tester, perform GEM self-test. If DTC B1398 is not retrieved, go to next step. If DTC B1398 is retrieved, go to «DTC B1398»(ref-29374-S03839535152001010800000): LEFT FRONT POWER WINDOW ONE-TOUCH DOWN RELAY COIL CIRCUIT FAILURE under DIAGNOSTIC TESTING. NOTE: Driver master window switch contains 2 separate 7-pin connectors. On connector C501, all 7 terminals are used. On connector C514, only 4 terminals are used.
  2. Check For Power To Driver Door Master Window Switch - Ensure ignition is off. Disconnect driver door master window switch 7-pin connector C501. Turn ignition switch to RUN position. Using a voltmeter, check voltage between ground and driver door master window switch connector C501 terminal No. 6 (Light Blue/Black wire). (Scheme 1) If battery voltage is present, go to next step. If battery voltage is not present, repair open in Light Blue/Black wire and retest system operation.
  3. Check Black Wire For Open - Turn ignition off. Using an ohmmeter, check resistance between ground and driver door master window switch connector C501 terminal No. 7 (Black wire). (Scheme 1) If resistance is 5 ohms or less, replace driver door master window switch and retest system operation. If resistance is more than 5 ohms, repair open in Black wire and retest system operation.

Scheme 1

Scheme 1
Scheme 1

Scheme 2

Scheme 2: TEST C: SINGLE POWER WINDOW INOPERATIVE
Scheme 2: TEST C: SINGLE POWER WINDOW INOPERATIVE
  1. Determine Which Window Is Inoperative - Determine which window is inoperative. If right door window is inoperative, go to step 9). If left door window is inoperative, go to next step.
  2. Check For Power To Left Door Window Switch - To check for inoperative left window power supply, remove master window switch (without disconnecting wiring harness). See «MASTER WINDOW CONTROL SWITCH & RIGHT WINDOW CONTROL SWITCH»(ref-29374-S02720570762001010800000) under REMOVAL & INSTALLATION. Connect a voltmeter between ground and circuits as indicated in MASTER WINDOW SWITCH table. see scheme 1 Actuate master switch in appropriate direction and observe reading. If battery voltage is present, go to next step. If battery voltage is not present, replace master window switch and retest system operation. MASTER WINDOW SWITCH Terminal No. (Wire Color) Switch Position 6 (WHT/YEL) Right Window Down 4 (TAN/LT BLU) Right Window Up 1 (WHT/BLK) Left Window Up 2 (YEL) Left Window Down
  3. Check Inoperative Window Motor Circuits - Gain access to inoperative window motor connector. See «WINDOW MOTOR»(ref-29374-S30095289252001010800000) under REMOVAL & INSTALLATION. Disconnect motor connector. Connect voltmeter between ground and motor connector circuits as indicated in «MASTER WINDOW SWITCH»(ref-29374-S33526749882001010800000) table. Actuate master switch in appropriate direction and observe reading. If battery voltage is present, go to step 8). If battery voltage is not present, go to next step. NOTE: Driver master window switch contains 2 separate 7-pin connectors. On connector C501, all 7 terminals are used. On connector C514, only 4 terminals are used.
  4. Check White/Black Wire For Open - Disconnect driver door master window switch 7-pin connector C501. Using an ohmmeter, check resistance between driver door master window switch connector C501 terminal No. 1 (White/Black wire) and window motor connector White/Black wire terminal. If resistance is 5 ohms or less, go to next step. If resistance is more than 5 ohms, repair open in White/Black wire and retest system operation.
  5. Check Tan/Black Or Tan/Red Wire For Open - Remove one-touch down relay (located in instrument panel fuse block). Using an ohmmeter, check resistance between one-touch down relay terminal No. 30 (Tan/Red wire) and window motor connector Tan/Black wire terminal. If resistance is 5 ohms or less, go to next step. If resistance is more than 5 ohms, repair open in Tan/Black and/or Tan/Red wire. Retest system operation.
  6. Check Yellow Wire For Open - Using an ohmmeter, check resistance between one-touch down relay terminal No. 87A (Yellow wire) and window motor connector Yellow wire terminal. If resistance is 5 ohms or less, go to next step. If resistance is more than 5 ohms, repair open in Yellow wire. Retest system operation.
  7. Check One-Touch Down Relay - Using an ohmmeter, check resistance between one-touch down relay terminals No. 87A and No. 30. (Scheme 2) If resistance is 5 ohms or less, replace driver door master window switch and retest system operation. If resistance is more than 5 ohms, replace one-touch down relay and retest system operation.
  8. Check Power Window Motor - Connect a jumper wire between battery voltage to terminal No. 1 at power window motor. With a second jumper, connect one end to ground and momentarily connect other end to terminal No. 2 of window motor. To reverse motor direction, switch jumper leads at window motor. If power window motor operates correctly, motor is okay. Reconnect all connectors and retest system operation. If motor does not operate correctly, replace window motor and retest system operation.
  9. Check Inoperative Right Door Window - Remove right door window switch (without disconnecting wiring harness). See «MASTER WINDOW CONTROL SWITCH & RIGHT WINDOW CONTROL SWITCH»(ref-29374-S02720570762001010800000) under REMOVAL & INSTALLATION. Connect a voltmeter between ground and right window control switch connector C600, terminal No. 7 (White/Yellow wire). Actuate right window at left door master window control switch in DOWN position and observe reading. Move voltmeter probe from terminal No. 7 to pin No. 2 (Tan/Light Blue wire). Actuate right window control switch in UP position and observe reading. If battery voltage is observed in either direction, go to next step. If battery voltage was not observed, replace master window control switch and retest system operation.
  10. Check For Power To Right Door Window Switch - Connect voltmeter between ground and right window control switch connector C600, terminal No. 4 (Light Blue/Black wire). (Scheme 3) If voltage is 10 volts or more, go to next step. If voltage is less than 10 volts, repair open in Light Blue/Black wire and retest system operation.
  11. Check Passenger Door Window Motor Down Circuit - Using a voltmeter, check voltage between ground and right window control switch connector C600, terminal No. 3 (Yellow/Red wire) while actuating control switch in DOWN position. (Scheme 3) If battery voltage is present, go to next step. If battery voltage is not present, replace right door window control switch and retest system operation. See «MASTER WINDOW CONTROL SWITCH & RIGHT WINDOW CONTROL SWITCH»(ref-29374-S02720570762001010800000) under REMOVAL & INSTALLATION.
  12. Check Passenger Door Window Motor Up Circuit - Using a voltmeter, check voltage between ground and right window control switch connector C600, terminal No. 6 (Red/Yellow wire) while actuating control switch in UP position. (Scheme 3) If battery voltage is present, go to next step. If battery voltage is not present, replace right door window control switch and retest system operation. See «MASTER WINDOW CONTROL SWITCH & RIGHT WINDOW CONTROL SWITCH»(ref-29374-S02720570762001010800000) under REMOVAL & INSTALLATION.
  13. Check Passenger Window Motor Down Voltage Supply - Gain access to passenger window motor connector. See «WINDOW MOTOR»(ref-29374-S30095289252001010800000) under REMOVAL & INSTALLATION. Disconnect motor connector. Using a voltmeter, check voltage between ground and window motor connector C608 Yellow/Red wire terminal while pressing passenger window control switch in DOWN position. If battery voltage is present, go to next step. If battery voltage is not present, repair open in Yellow/Red wire and retest system operation.
  14. Check Passenger Window Motor Up Voltage Supply - Using a voltmeter, check voltage between ground and window motor connector C608 Red/Yellow wire terminal while pressing passenger window control switch in UP position. If battery voltage is present, go to step 8). If battery voltage is not present, repair open in Red/Yellow wire and retest system operation.

Scheme 3

Scheme 3
Scheme 3

TEST D: REAR QUARTER GLASS INOPERATIVE

  1. Check Power Window Operation - Turn ignition switch to RUN position. Operate driver's door power window. If driver's door power window operates, go to next step. If driver's door power window does not operate, go to «TEST B: POWER WINDOWS COMPLETELY INOPERATIVE»(ref-29374-S00653502552001010800000).
  2. Identify Inoperative Window - Operate left rear quarter window. If left quarter window is inoperative, go to next step. If left quarter window is not inoperative, go to step 11).
  3. Check Power Supply To Left Rear Quarter Window Motor In Open Position - Gain access to left rear quarter window motor connector C418. Turn ignition switch to RUN position. Using a voltmeter, check voltage between ground and left rear quarter window motor connector C418 Brown wire terminal while pressing left rear quarter window control switch to OPEN position. If battery voltage is not present, go to next step. If battery voltage is present, go to step 7).
  4. Check Left Rear Quarter Window Switch - Turn ignition off. Ensure left rear quarter window control switch is in NEUTRAL position. Using an ohmmeter, check resistance between ground and left rear quarter window motor connector C418 Brown wire terminal. If resistance is more than 5 ohms, go to next step. If resistance is 5 ohms or less, go to step 6). NOTE: Driver master window switch contains 2 separate 7-pin connectors. On connector C501, all 7 terminals are used. On connector C514, only 4 terminals are used.
  5. Check Brown Wire For Open - Gain access to left rear quarter window switch. Disconnect rear quarter window switch 7-pin connector C514. Using an ohmmeter, check resistance between rear quarter window switch connector C514 terminal No. 5 (Brown wire) and left rear quarter window motor connector C418 Brown wire terminal. (Scheme 4) If resistance is 5 ohms or less, replace window switch and retest system operation. If resistance is more than 5 ohms, repair open in Brown wire and retest system operation.
  6. Check Brown Wire For Short To Ground - Gain access to left rear quarter window switch. Disconnect rear quarter window switch 7-pin connector C514. Using an ohmmeter, check resistance between ground and left rear quarter window motor connector C418 Brown wire terminal. If resistance is 10 k/ohms or less, repair short to ground in Brown wire and retest system operation. If resistance is more than 10 k/ohms, replace window switch and retest system operation.
  7. Check Power Supply To Motor In Close Position - Using a voltmeter, check voltage between ground and left rear quarter window motor connector C418 Brown/Yellow wire terminal while pressing left rear quarter window switch to CLOSED position. If battery voltage is not present, go to next step. If battery voltage is present, replace left rear quarter window motor and retest system operation.
  8. Check Left Rear Quarter Window Switch - Turn ignition off. Ensure left rear quarter window switch is in NEUTRAL position. Using an ohmmeter, check resistance between ground and left rear quarter window motor connector C418 Brown/Yellow wire terminal. If resistance is more than 5 ohms, go to next step. If resistance is 5 ohms or less, go to step 10). NOTE: Driver master window switch contains 2 separate 7-pin connectors. On connector C501, all 7 terminals are used. On connector C514, only 4 terminals are used.
  9. Check Brown/Yellow Wire For Open - Gain access to left rear quarter window switch. Disconnect rear quarter window switch 7-pin connector C514. Using an ohmmeter, check resistance between rear quarter window switch connector C514 terminal No. 4 (Brown/Yellow wire) and left rear quarter window motor connector C418 Brown/Yellow wire terminal. (Scheme 4) If resistance is 5 ohms or less, replace window switch and retest system operation. If resistance is more than 5 ohms, repair open in Brown/Yellow wire and retest system operation.
  10. Check Brown/Yellow For Short To Ground - Gain access to left rear quarter window switch. Disconnect rear quarter window switch 7-pin connector C514. Using an ohmmeter, check resistance between ground and left rear quarter window motor connector C418 Brown/Yellow wire terminal. If resistance is 10 k/ohms or less, repair short to ground in Brown/Yellow wire and retest system operation. If resistance is more than 10 k/ohms, replace window switch and retest system operation.
  11. Check Power Supply To Right Rear Quarter Window Motor In Open Position - Gain access to right rear quarter window motor connector C419. Turn ignition switch to RUN position. Using a voltmeter, check voltage between ground and right rear quarter window motor connector C419 Yellow/Black wire terminal while pressing right rear quarter window switch to OPEN position. If battery voltage is not present, go to next step. If battery voltage is present, go to step 15).
  12. Check Right Rear Quarter Window Switch - Turn ignition off. Ensure right rear quarter window switch is in NEUTRAL position. Using an ohmmeter, check resistance between ground and right rear quarter window motor connector C419 Yellow/Black wire terminal. If resistance is more than 5 ohms, go to next step. If resistance is 5 ohms or less, go to step 14). NOTE: Driver master window switch contains 2 separate 7-pin connectors. On connector C501, all 7 terminals are used. On connector C514, only 4 terminals are used.
  13. Check Yellow/Black Wire For Open - Gain access to right rear quarter window switch. Disconnect rear quarter window switch 7-pin connector C514. Using an ohmmeter, check resistance between rear quarter window switch connector C514 terminal No. 7 (Yellow/Black wire) and right rear quarter window motor connector C419 Yellow/Black wire terminal. (Scheme 4) If resistance is 5 ohms or less, replace window switch and retest system operation. If resistance is more than 5 ohms, repair open in Yellow/Black wire and retest system operation.
  14. Check Yellow/Black Wire For Short To Ground - Gain access to right rear quarter window switch. Disconnect rear quarter window switch 7-pin connector C514. Using an ohmmeter, check resistance between ground and right rear quarter window motor connector C419 Yellow/Black wire terminal. If resistance is 10 k/ohms or less, repair short to ground in Yellow/Black wire and retest system operation. If resistance is more than 10 k/ohms, replace window switch and retest system operation.
  15. Check Power Supply To Motor In Close Position - Using a voltmeter, check voltage between ground and right rear quarter window motor connector C419 Yellow/Light Blue wire terminal while pressing right rear quarter window switch to CLOSED position. If battery voltage is not present, go to next step. If battery voltage is present, replace right rear quarter window motor and retest system operation.
  16. Check Right Rear Quarter Window Switch - Turn ignition off. Ensure right rear quarter window switch is in NEUTRAL position. Using an ohmmeter, check resistance between ground and right rear quarter window motor connector C419 Yellow/Light Blue wire terminal. If resistance is more than 5 ohms, go to next step. If resistance is 5 ohms or less, go to step 18). NOTE: Driver master window switch contains 2 separate 7-pin connectors. On connector C501, all 7 terminals are used. On connector C514, only 4 terminals are used.
  17. Check Yellow/Light Blue Wire For Open - Gain access to right rear quarter window switch. Disconnect rear quarter window switch 7-pin connector C514. Using an ohmmeter, check resistance between rear quarter window switch connector C514 terminal No. 6 (Yellow/Light Blue wire) and right rear quarter window motor connector C419 Yellow/Light Blue wire terminal. (Scheme 4) If resistance is 5 ohms or less, replace window switch and retest system operation. If resistance is more than 5 ohms, repair open in Yellow/Light Blue wire and retest system operation.
  18. Check Yellow/Light Blue Wire For Short To Ground - Gain access to right rear quarter window switch. Disconnect rear quarter window switch 7-pin connector C514. Using an ohmmeter, check resistance between ground and right rear quarter window motor connector C419 Yellow/Light Blue wire terminal. If resistance is 10 k/ohms or less, repair short to ground in Yellow/Light Blue wire and retest system operation. If resistance is more than 10 k/ohms, replace window switch and retest system operation.

Scheme 4

Scheme 4
Scheme 4

TEST E: WINDOW STUCK/BINDING

  1. Window Motor Runs Slow - Remove front door trim at suspect window. Actuate window in DOWN position. Check window glass runs. If there is an obstruction in glass run, remove obstruction, clean and lubricate glass, and retest system operation. If no obstruction is present, go to next step.
  2. Check Window Regulator Operation - Actuate window to UP position and observe window regulator operation. If window regulator skips or binds, go to next step. If window regulator does not skip or bind, adjust regulator and guides, and retest system operation.
  3. Check Regulator & Motor - Remove motor. See «WINDOW MOTOR»(ref-29374-S30095289252001010800000) under REMOVAL & INSTALLATION. Carefully inspect motor and regulator gears. If there is damage to regulator gears, replace regulator and retest system operation. If there is no gear damage, replace window motor and retest system operation. See «WINDOW MOTOR»(ref-29374-S30095289252001010800000) under REMOVAL & INSTALLATION.

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