Initial Inspection and Diagnostic Overview

WARNING:
^ BATTERIES CONTAIN SULFURIC ACID. AVOID CONTACT WITH SKIN, EYES, OR CLOTHING. ALSO, SHIELD YOUR EYES WHEN WORKING NEAR BATTERIES TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION. IN CASE OF ACID CONTACT WITH SKIN OR EYES, FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF 15 MINUTES AND GET PROMPT MEDICAL ATTENTION. IF ACID IS SWALLOWED, CALL A PHYSICIAN IMMEDIATELY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES WHICH CAN CAUSE PERSONAL INJURY. THEREFORE, DO NOT ALLOW FLAMES, SPARKS OR LIGHTED SUBSTANCES TO COME NEAR THE BATTERY. WHEN CHARGING OR WORKING NEAR A BATTERY, ALWAYS SHIELD YOUR FACE AND PROTECT YOUR EYES. ALWAYS PROVIDE VENTILATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ WHEN LIFTING A PLASTIC-CASED BATTERY, EXCESSIVE PRESSURE ON THE END WALLS COULD CAUSE ACID TO SPEW THROUGH THE VENT CAPS RESULTING IN PERSONAL INJURY, DAMAGE TO THE VEHICLE OR TO THE BATTERY. LIFT WITH A BATTERY CARRIER OR WITH YOUR HANDS ON OPPOSITE CORNERS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.

1. Verify the customer concern by operating the engine to duplicate the concern.

Visual Inspection Chart:

2. Inspect to determine if one of the mechanical or electrical concerns apply
3. If the inspection reveals obvious concerns that can be readily identified, repair as necessary. Check the generator sense fuse 11 located in the battery junction box.
4. Measure the open circuit battery voltage. (The battery is located in the luggage compartment on the RH side). If the battery voltage is less than 12.0 volts, test and recharge the battery before continuing with diagnosis.
5. Check the operation of the charging system warning indicator lamp (instrument cluster). Normal operation is as follows:
^ With the ignition switch OFF, the charging system warning indicator should be OFF.
^ With the ignition switch in RUN and the engine off, the charging system warning indicator light should be ON.
^ With the engine running, the charging system warning indicator light should be OFF.

Normal Charging System Voltages:

6. Check the battery voltage before and after starting the engine to determine if the battery voltage increases. Refer to the Normal Charging System Voltages chart.

7. If any Powertrain Control Module (PCM) Diagnostic Trouble Codes (DTCs) are retrieved, go to the PCM Index below to check if the codes retrieved are related to the charging system and continue diagnosis. Diagnostic Trouble Code Tests and Associated Procedures
8. If no DTCs related to the charging system are retrieved, go to the Symptom Chart to continue diagnosis. Symptom Related Diagnostic Procedures

NOTE: DTC P1246 can be set by the loss of the communication lines, GEN COM Circuit 920 (BN/WH) and/or GEN MON Circuit 921 (GY/OG). However, the generator warning indicator lamp will not illuminate since the generator is self-regulating and will function normally.

9. On the Duratec engine if the customer concern is verified after the initial inspection, refer to the Symptom Chart to determine which tests to carry out. Symptom Related Diagnostic Procedures