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Contents Section: Charging System All sections

Generators & Regulators: Diagnosis Lincoln LS I рестайлинг

Charging System 2 illustrations ~2152 words

TROUBLE SHOOTING

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

Verify customer's concern. Verify battery condition. Inspect accessory drive belt and tensioner. Inspect battery junction box fuse No. 15 (5-amp). Inspect central junction box fuse No. 13 (5-amp) and fuse No. 20 (10-amp). Check all connections for looseness or corrosion. If problem is found, repair as necessary. If problem is not found, perform self-diagnostics. See SELF-DIAGNOSTIC SYSTEM .

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.

BATTERY DRAIN TEST

  1. Ensure junction box/fuse panels are accessible without turning on interior and hood lights. Drive vehicle over 30 MPH for at least 5 minutes. Park vehicle and allow to sit with ignition off for at least 40 minutes to allow electronic modules to power down. Go to next step.
  2. Connect a fused jumper wire between negative battery cable and negative battery post. Disconnect negative battery cable from negative battery post, without breaking the jumper wire connection to prevent modules from resetting. Go to next step. NOTE: It is very important that continuity is not broken between negative battery post and negative battery cable when disconnecting battery cable or connecting ammeter. If continuity is broken, go to step 1 .
  3. Ensure ammeter is set to read milliamps with at least a 10 amp capability. Connect ammeter between negative battery cable and negative battery post. Remove fused jumper wire. Go to next step.
  4. If excessive current draw is present, pull fuses from battery/central junction box one at a time and note any current drop when each fuse is removed. DO NOT reinstall fuses until test is complete. Go to next step.
  5. Check wiring diagrams for any circuits that run from battery without passing through battery/central junction box. Disconnect these circuits if current draw still exists.

BATTERY DRAINS THAT SHUT OFF WHEN BATTERY CABLE IS DISCONNECTED TEST

  1. Perform battery drain test. See «BATTERY DRAIN TEST»(ref-164721-S01228715432004081300000) . Ensure all doors are closed and accessories are off. Without starting engine, turn ignition switch to RUN position for a moment, and then turn ignition OFF. Wait a few minutes for illuminated entry lamps to turn off (if equipped).
  2. Connect ammeter between negative battery cable and negative battery post. Disconnect negative battery cable from negative battery post, without breaking the ammeter connection to prevent modules from resetting. Read amperage draw.
  3. Amperage draw should be less than 50 milliamps. If current draw exceeds 50 milliamps, remove fuses from battery/central junction box one at a time to locate problem circuit.

GENERATOR LOAD TEST

  1. Ensure drive belt is in good condition. Replace belt as necessary. If belt is okay, 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 amperage should be at least 70 amps with engine at 2000 RPM. Go to next step.
  2. Turn A/C system on. Turn blower speed to high. Turn headlights on to high beams. Voltage should increase a minimum of .5 volts. If voltage is as specified, system is operating properly at this time. If voltage is not as specified, perform «GENERATOR NO-LOAD TEST»(ref-164721-S14505684672004081300000) .

GENERATOR NO-LOAD TEST

Switch tester to voltmeter function. Connect voltmeter positive lead to B+ terminal on generator and negative lead to ground. Turn all electrical accessories off. Start and run engine up to 2000 RPM. Read voltmeter when voltage stabilizes. Voltage should be 13-15 volts. If voltage is not as specified, repair by symptom. See SYMPTOM INDEX table under SYSTEM TESTS.

SELF-DIAGNOSTIC SYSTEM

Connect New Generation Star (NGS) tester to Data Link Connector (DLC). Using NGS tester, perform Powertrain Control Module (PCM) self-test. If any DTCs exist, perform appropriate test in accordance with DTC retrieved. See appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE. If no DTCs are present, repair by symptom. See SYMPTOM INDEX table under SYSTEM TESTS.

TEST A: BATTERY IS DISCHARGED OR VOLTAGE IS LOW

  1. Check The Battery Condition Test battery condition. See «BATTERY TEST WITH DIGITAL BATTERY ANALYZER»(ref-164721-S16409585822004081300000) under ON-VEHICLE TESTING. If battery is okay, go to next step. If battery is not okay, replace battery.
  2. Check The Generator Output Perform generator load and no-load tests. See «GENERATOR LOAD TEST»(ref-164721-S15274836002004081300000) and «GENERATOR NO-LOAD TEST»(ref-164721-S14505684672004081300000) under ON-VEHICLE TESTING. If generator is okay, go to next step. If generator is not okay, perform «TEST B: WARNING INDICATOR ON WITH ENGINE RUNNING, SYSTEM NOT CHARGING»(ref-164721-S17715248522004081300000) .
  3. Check For Current Drains Perform «BATTERY DRAIN TEST»(ref-164721-S01228715432004081300000) under ON-VEHICLE TESTING. If no excessive current draw was not found, go to next step. If any excessive current draw was found, repair as necessary.
  4. Check For Battery Drains Which Shut Off When The Battery Is Disconnected Perform «BATTERY DRAINS THAT SHUT OFF WHEN BATTERY CABLE IS DISCONNECTED TEST»(ref-164721-S25398909682004081300000) under ON-VEHICLE TESTING. If there are any current drains that shut off when the battery is disconnected, repair as necessary. If no drains were found, perform «TEST B: WARNING INDICATOR ON WITH ENGINE RUNNING, SYSTEM NOT CHARGING»(ref-164721-S17715248522004081300000) .

TEST B: WARNING INDICATOR ON WITH ENGINE RUNNING, SYSTEM NOT CHARGING

  1. Check Generator B+ Output Circuit (Red Wire) Turn ignition off. Measure the voltage between the generator B+ output terminal (Red wire) and ground. Is the voltage within 0.5 volt of battery voltage? If yes, go to next step. If no, repair the circuit. Test the system for normal operation.
  2. Check "I" Circuit (Gray/Red Wire) For An Open Start the engine. With the engine running, measure the voltage between the generator connector terminal No. 2 (Gray/Red wire) and ground. (Scheme 1) Is the voltage approximately 1 - 8 volts? If yes, go to next step. If no, repair the circuit. Test the system for normal operation.
  3. Check For Voltage Drop In B+ Output Circuit (Red Wire) With the engine running, turn on the headlamps and the rear defroster and position the blower motor to the HIGH position. With the engine at 2,000 RPM, measure the voltage drop between the generator B+ circuit (Red wire) and the positive battery terminal. Is the voltage drop less than 0.5 volt? If yes, install a new generator. See «GENERATOR»(ref-164721-S33998350412004081300000) under REMOVAL & INSTALLATION. If no, repair the high resistance in the B+ circuit (Red wire). Test the system for normal operation.

Scheme 1

Scheme 1
Scheme 1

TEST C: SYSTEM OVERCHARGES

  1. Check For Voltage Drop In "A" Circuit (Red Wire) Turn the ignition off. Disconnect generator 3-pin connector. Measure the voltage drop between the generator connector terminal No. 3 (Red wire) and the positive battery terminal. (Scheme 1) Is the voltage drop less than 0.5 volt? If yes, go to next step. If no, repair high resistance in "A" circuit (Red wire). See «WIRING DIAGRAMS»(ref-164721-S13848182822004081300000). Test the system for normal operation.
  2. Check Generator & Battery Ground Connections Check the ground connections between the generator and the engine, and the battery and the engine. Are all ground connections clean and tight? If yes, install a new generator. See «GENERATOR»(ref-164721-S33998350412004081300000) under REMOVAL & INSTALLATION. Test the system for normal operation. If no, repair ground connections as necessary. Test the system for normal operation.

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

  1. Check "I" Circuit (Gray/Red Wire) Integrity Turn ignition off. Disconnect generator 3-pin connector. Disconnect PCM connector C175c. Measure the resistance between the PCM connector C175c terminal No. 19 (Gray/Red wire) and the generator connector terminal No. 2, and between the PCM connector C175c terminal No. 19 (Gray/Red wire) and ground. (Scheme 1)and (Scheme 2). Is the resistance less than 5 ohms between the PCM and the generator; and greater than 10,000 ohms between the PCM and ground? If yes, go to next step. If no, repair "I" circuit (Gray/Red wire). Test the system for normal operation.
  2. Check "S" Circuit (White/Red wire) Measure the resistance between the PCM connector C175c terminal No. 50 (White/Red wire) and the generator connector terminal No. 1, and between the PCM connector C175c terminal No. 50 (White/Red wire) and ground. (Scheme 1)and (Scheme 2). Is the resistance less than 5 ohms between the PCM and the generator and greater than 10,000 ohms between the PCM and ground? If yes, go to next step. If no, repair the circuit. Test the system for normal operation.
  3. Check "A" Circuit (Red Wire) Measure the voltage between the generator connector terminal No. 3 (Red) and ground. (Scheme 1) Is the voltage greater than 10 volts? If yes, install a new generator. See «GENERATOR»(ref-164721-S33998350412004081300000) under REMOVAL & INSTALLATION. Test the system for normal operation. If no, repair the circuit. Test the system for normal operation.

Scheme 2

Scheme 2
Scheme 2

TEST E: WARNING INDICATOR OFF WITH IGNITION ON

  1. Check The Charging System Warning Indicator Turn the ignition off. Disconnect generator 3-pin connector. With the engine off, connect a fused jumper wire (15A) between the generator connector terminal No.1, GEN MON circuit (White/Red wire) and ground. (Scheme 1) Turn ignition on. Is the charging system warning indicator illuminated? If yes, install a new generator. See «GENERATOR»(ref-164721-S33998350412004081300000) under REMOVAL & INSTALLATION. Test the system for normal operation. If no, see appropriate ANALOG INSTRUMENT PANEL article in ACCESSORIES & EQUIPMENT for diagnosis and testing of the instrument cluster.

TEST F: WARNING INDICATOR FLICKERS, OR IS INTERMITTENT

  1. Check For Loose Connections Turn ignition off. Check all generator, battery, rear battery distribution box connections for looseness, corrosion, loose or bent terminals, or loose eyelets. Are all connections clean and tight? If yes, if the warning indicator flickers, install a new instrument cluster. See appropriate ANALOG INSTRUMENT PANEL article in ACCESSORIES & EQUIPMENT. If the warning indicator is intermittent, go to next step. If no, repair as necessary. Test the system for normal operation.
  2. Check Fuse Connections Start engine. Check the rear Battery Junction Box (BJB) fuse 15 (5A) in "A" circuit (Red wire) for looseness by wiggling the fuse and noting the charging system warning indicator operation. Does the charging system warning indicator flicker? If yes, repair loose fuse connection(s) as necessary. Test the system for normal operation. If no, go to next step.
  3. Check "A" Circuit (Red Wire) Connections Turn ignition off. Connect a fused jumper wire (15A) between the generator connector terminal No. 3 (Red wire) and the positive battery terminal. (Scheme 1) Start engine. Note the charging system warning indicator operation. Does the charging system warning indicator illuminate? If yes, go to next step. If no, repair loose connection(s) in "A" circuit (Red wire). Test the system for normal operation.
  4. Check "I" Circuit (Gray/Red wire) Turn ignition off. Disconnect PCM connector C175c. Disconnect generator 3-pin connector. Measure the resistance between the PCM connector C175c terminal No. 19 (Gray/Red wire) and the generator connector terminal No. 2, and between the PCM connector C175c terminal No. 19 (Gray/Red wire) and ground. (Scheme 1)and (Scheme 2). Is the resistance less than 5 ohms between the PCM and the generator and greater than 10,000 ohms between the PCM and ground? If yes, install a new generator. See «GENERATOR»(ref-164721-S33998350412004081300000) under REMOVAL & INSTALLATION. Test the system for normal operation. If no, repair the circuit. Test the system for normal operation.

TEST G: GENERATOR NOISY

  1. Check For Accessory Drive Noise Turn ignition off. 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, go to next step. If no, repair as necessary. Test the system for normal operation.
  2. 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.
  3. Check Generator For Electrical Noise Disconnect generator 3-pin connector. Start engine. Use a stethoscope or equivalent listening device to probe the generator. Do not exceed 3000 RPM or the generator may become electrically functional. Is the noise still present? If yes, go to next step. If no, install a new generator. See «GENERATOR»(ref-164721-S33998350412004081300000) under REMOVAL & INSTALLATION. Test the system for normal operation.
  4. Check Generator For Mechanical Noise 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? If yes, install a new generator. See «GENERATOR»(ref-164721-S33998350412004081300000) under REMOVAL & INSTALLATION. Test the system for normal operation. If no, diagnose the source of the engine noise.

TEST H: RADIO INTERFERENCE

  1. Verify The Generator Is The Source Of The Radio Interference Start engine. Tune the audio unit to a station where the interference is present. Turn ignition off. Disconnect generator 3-pin connector. Start engine. With the engine running, note any audio unit interference. Do not exceed 3000 RPM or the generator may become electrically functional. Is the interference present with the generator disconnected? If yes, diagnose entertainment system. In no, install a new generator. See «GENERATOR»(ref-164721-S33998350412004081300000) under REMOVAL & INSTALLATION. Test the system for normal operation.

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