Charging System - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma

Inspection and Verification

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
for information about these practices.

WARNING: Batteries contain sulfuric acid and produce explosive gases. Work in a well-ventilated area. Do not allow the battery to come in contact with flames, sparks or burning substances. Avoid contact with skin, eyes or clothing. Shield eyes when working near the battery to protect against possible splashing of acid solution. In case of acid contact with skin or eyes, flush immediately with water for a minimum of 15 minutes, then get prompt medical attention. If acid is swallowed, call a physician immediately. Failure to follow these instructions may result in serious personal injury.

WARNING: Always lift a plastic-cased battery with a battery carrier or with hands on opposite corners. Excessive pressure on the battery end walls may cause acid to flow through the vent caps, resulting in personal injury and/or damage to the vehicle or battery.

NOTICE: Do not make jumper connections except as directed. Incorrect connections may damage the voltage regulator test terminals or fuses.

NOTICE: 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 Diagnostic Trouble Codes (DTCs) set while following a specific pinpoint test. After the completion of a test, be sure to clear all Diagnostic Trouble Codes (DTCs) in the PCM .

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

1. Verify the customer concern by operating the charging system.
   

1. Check the battery condition and state of charge.
   REFER to: Battery (414-01 Battery, Mounting and Cables, Diagnosis and Testing).
   
   

1. Before diagnosing or repairing the charging system inspect the following items:
   

• Fusible links
• Abnormal ignition-off current drain(s).
  REFER to: Battery Drain Check (414-01 Battery, Mounting and Cables, General Procedures).
  
• FEAD belt
• Generator pulley
• High current BJB for loose or corroded connections
• Wiring, terminals or connectors

1. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding.
   

DTC Charts

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
for information about these practices.

  PCM DTC Chart

Symptom Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
for information about these practices.

  Symptom Chart

Pinpoint Tests

System Voltage High

Refer to Wiring Diagrams Cell 12 for schematic and connector information.

NOTE: DTC P0563 can be set if the vehicle has been recently jump started or the battery has been recently charged. 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 and Fault Conditions

With the engine running, the charging system supplies voltage to the battery and the vehicle electrical system through the high current BJB and 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 or below their calibrated setpoints, a DTC sets.

  Diagnostic Trouble Code (DTC) Fault Trigger Conditions

Possible Sources

• Battery
• Generator
• Engine, generator or battery ground
• PCM
• Wiring, terminals or connectors

Visual Inspection and Diagnostic Pre-checks

• Inspect high current BJB for loose or corroded connections.

System Voltage Low or Battery is Discharged

Refer to Wiring Diagrams Cell 12 for schematic and connector information.

Normal Operation and Fault Conditions

With the engine running, the charging system supplies voltage to the battery and the vehicle electrical system through the high current BJB and battery B+ cable. The PCM monitors this B+ voltage through its own voltage supply circuit.

  Diagnostic Trouble Code (DTC) Fault Trigger Conditions

Possible Sources

• Wiring, terminals or connectors
• Excessive ignition-OFF current drain
• Battery
• Generator
• PCM
• High current BJB

Visual Inspection and Diagnostic Pre-checks

• Inspect for abnormal ignition-off current drain(s).
• Inspect the battery.
• Inspect high current BJB for loose or corroded connections.
• Inspect the generator clutch.

The Generator is Noisy

Normal Operation and Fault Conditions

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

  DTC Fault Trigger Conditions

Possible Sources

• FEAD belt
• Loose bolts/brackets
• Generator/pulleys

Visual Inspection and Diagnostic Pre-checks

• Inspect the FEAD belt.
• Inspect for loose bolts/brackets.
• Inspect the generator/pulley.

Radio Interference

Refer to Wiring Diagrams Cell 12 for schematic and connector information.

Normal Operation and Fault Conditions

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

NOTE: If the Original Equipment Manufacturer (OEM) ACM has been replaced with an aftermarket unit, the vehicle may not pass this test. Return the vehicle to Original Equipment Manufacturer (OEM) condition before following this pinpoint test.

NOTE: If the engine is operated at greater than 2,000 Revolutions Per Minute (RPM) momentarily, the generator self-excites. Make sure when the generator is disconnected the engine rpm stays below 2,000 Revolutions Per Minute (RPM). If it rises above 2,000 Revolutions Per Minute (RPM), turn the ignition to the OFF position and start the test over again.

NOTE: Inspect for any aftermarket 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.

Possible Sources

• Generator
• Wiring, terminals or connectors
• In-vehicle entertainment system

Visual Inspection and Diagnostic Pre-checks

• Inspect the generator.
• Inspect the in-vehicle entertainment system.

U012D, U042E

Refer to Wiring Diagrams Cell 12 for schematic and connector information.

Normal Operation and Fault Conditions

The charging system supplies voltage to the battery and the vehicle electrical system through the battery B+ cable. The PCM monitors the generator output through a dedicated LIN communication circuit. The generator uses this LIN circuit to communicate the desired voltage setpoint from the PCM to the internal voltage regulator. The generator also uses this LIN circuit to communicate the generator load and error conditions to the PCM .

  Diagnostic Trouble Code (DTC) Fault Trigger Conditions

Possible Sources

• Generator
• Wiring, terminals or connectors

Visual Inspection and Diagnostic Pre-checks

• Inspect high current BJB MEGA fuse 1 (450A).
• Inspect high current BJB for loose or corroded connections.

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