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Home >> Ford Truck >> 2012 >> Explorer FWD L4-2.0L Turbo >> Repair and Diagnosis >> Starting and Charging >> Charging System >> Testing and Inspection >> Pinpoint Tests >> Diagnostic Routine E

Diagnostic Routine E




Diagnostic Routine E

Diagnostic Overview

P065B

Refer to Wiring Diagram Set 12 for schematic and connector information Electrical Diagrams.

Normal Operation and Fault Conditions

With the engine running, the PCM (Powertrain Control Module) monitors and expects to receive a valid generator monitor (GENMON) signal with a duty cycle greater than 5% and less than 98%. The PCM (Powertrain Control Module) also monitors the state of the generator command (GENCMD) signal line to make sure it is not stuck high or stuck low. A DTC (Diagnostic Trouble Code) sets if the GENMON or GENCMD signal fluctuates between out-of-valid range, stuck high, stuck low, or some combination and normal. When the engine speed is greater than approximately 2,000 RPM (Revolutions Per Minute), the generator defaults to a steady voltage of approximately 13.5 volts and the PCM (Powertrain Control Module) sends a request to the IPC (Instrument Panel Cluster) to illuminate the charging system warning indicator.

DTC (Diagnostic Trouble Code) Fault Trigger Conditions






Visual Inspection and Diagnostic Pre-checks

- Inspect fusible links.

- Inspect the radial arm adapter.

- Inspect the wiring, terminals or connectors.

- Inspect for loose or corroded connections.

- Inspect high current BJB (Battery Junction Box) for loose or corroded connections.

Special Tool(s)






Pinpoint Test

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. CHECK THE BATTERY CONDITION

1. Carry out Battery Condition Test to determine if the battery can hold a charge and is OK for use. REFER to Diagnostic Routine A: Battery Condition Test Pinpoint Tests.

Does the battery pass the condition test?






2. CHECK THE GENERATOR CONNECTIONS

1. Ignition OFF.

2. Disconnect and inspect all generator connectors.

3. Repair:

- corrosion (install new connector or terminals - clean module pins)
- damaged or bent pins - install new terminals/pins
- pushed-out pins - install new pins as necessary

4. Connect the generator connectors. Make sure they seat, latch correctly and are tightened to specification. REFER to Torque Specifications .

5. Measure and record battery voltage at the battery.

6. Measure:





Is the voltage within 0.5 volt of recorded battery voltage?






3. "A" SENSE CIRCUIT LOAD TEST

NOTICE: 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. 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.

NOTE: This step puts a load on the "A" sense circuit. If there are corroded or loose connections, loading the circuit may help show the fault. A 250-350 mA incandescent 12-volt test lamp is required for this step. This circuit will not be loaded properly using an LED (Light-emitting Diode)-style test lamp.

1. Disconnect: Generator C102A.

2. Using a 12-volt test lamp, check for voltage:





Does the test lamp illuminate?






4. CHECK THE GENERATOR MONITOR FREQUENCY (GENMON_HZ) PID (Parameter Identification)

1. Connect: Generator C102A.

2. Start the engine.

3. Using a scan tool, view the PCM (Powertrain Control Module) PIDs (Parameter Identifications).

4. Monitor the GENMON_HZ PID (Parameter Identification).

Does the PID (Parameter Identification) read between 80-200 Hz?






5. CHECK THE GENERATOR MONITOR FREQUENCY (GENMON_HZ) PID (Parameter Identification) WITH GENERATOR DISCONNECTED

1. Ignition OFF.

2. Disconnect: Generator C102A.

3. Start the engine.

4. Using a scan tool, view the PCM (Powertrain Control Module) PIDs (Parameter Identifications).

5. Monitor the GENMON_HZ PID (Parameter Identification).

Does the PID (Parameter Identification) read between 0-2 Hz?






6. CHECK GENERATOR MONITOR CIRCUIT

NOTICE: This pinpoint test step directs testing circuits using a back-probe method. Use the special back-probe tool specified in the tool list. Do not force test leads or other probes into connectors. Adequate care must be exercised to avoid connector terminal damage while making sure 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.

1. Ignition OFF.

2. With PCM (Powertrain Control Module) C175B (3.5L) or C1381B (2.0L) connected, carefully back-probe and connect a fused jumper wire:









3. Start the engine.

4. Using a scan tool, view the PCM (Powertrain Control Module) PIDs (Parameter Identifications).

5. Monitor the GENMON_HZ PID (Parameter Identification).

Does the PID (Parameter Identification) read 0 Hz?






7. MONITOR THE GENERATOR MONITOR FREQUENCY (GENMON_HZ) PID (Parameter Identification) WHILE ACTIVATING THE GENERATOR VOLTAGE DESIRED (GENVDSD) PID (Parameter Identification)

1. Ignition OFF.

2. Connect a fused jumper wire:





3. Start the engine.

4. Using a scan tool, view the PCM (Powertrain Control Module) PIDs (Parameter Identifications).

5. With the engine running at idle, set the active command GENVDSD PID (Parameter Identification) to 14 volts.

6. Monitor the GENMON_HZ PID (Parameter Identification).

Does the PID (Parameter Identification) read between 120-130 Hz?






8. CHECK THE GENERATOR COMMAND LINE FAULT (GENCMD_LF) PID (Parameter Identification)

1. Start the engine.

2. Using a scan tool, view the PCM (Powertrain Control Module) PIDs (Parameter Identifications).

3. With the engine running and all selectable loads OFF, monitor the GENCMD_LF PID (Parameter Identification).

Does the PID (Parameter Identification) fluctuate from YES FAULT to NO FAULT?






9. CHECK FOR CORRECT PCM (Powertrain Control Module) OPERATION

1. Ignition OFF.

2. Disconnect and inspect all PCM (Powertrain Control Module) connectors.

3. Repair:

- corrosion (install new connector or terminals - clean module pins)
- damaged or bent pins - install new terminals/pins
- pushed-out pins - install new pins as necessary

4. Reconnect the PCM (Powertrain Control Module) connectors. Make sure they seat and latch correctly.

5. Operate the system and determine if the concern is still present.

Is the concern still present?





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