2003 FORD MUSTANG check engine

PINPOINT TEST S: THE SERVICE ENGINE SOON INDICATOR IS
NEVER/ALWAYS ON side and ground.
z Key in ON position.
z Does the ABS indicator illuminate? No
GO to
R3 .
R3 CHECK CIRCUIT 603 (DG) FOR AN OPEN
z
Key in OFF position.
z Disconnect: Instrument Cluster C220b.
z Measure the resistance between the instrument cluster
C220b pin 15, circuit 603 (DG), harness side and the anti-
lock brake control module C135 pin 16, circuit 603 (DG),
harness side.
z Is the resistance less than 5 ohms? Yes
GO to
R4 .
No
REPAIR the circuit. TEST
the system for normal
operation. R4 CHECK FOR CORRECT INSTRUMENT CLUSTER
OPERATION z
Disconnect all instrument cluster connectors.
z Check for:
zcorrosion
z pushed- out pins
z Connect all instrument cluster connectors and make sure
they seat correctly.
z Operate the system and verify the concern is still present.
z Is the concern still present? Yes
INSTALL a new instrument
cluster. REFER to
Instrument Cluster
in this
section. TEST the system
for normal operation.
No
The system is operating
correctly at this time.
Concern may have been
caused by a loose or
corroded connector.
CLEAR the DTCs.
REPEAT the self- test. Test Step Result / Action to Take
S1 CARRY OUT THE INSTRUMENT Klj . 35 ba
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PINPOINT TEST T: THE TURN/HAZARD INDICATOR IS
NEVER/ALWAYS ON CLUSTER SERVICE ENGINE SOON
INDICATOR ACTIVE COMMAND
z
Connect the diagnostic tool.
z Key in ON position.
z Enter the following diagnostic mode
on the diagnostic tool: Instrument
Cluster Active Command.
z Trigger the instrument cluster active
command MIL.
z Did the SERVICE ENGINE SOON
indicator illuminate? Yes
REFER to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual.
No
GO to
S2 .
S2 CHECK FOR CORRECT
INSTRUMENT CLUSTER OPERATION z
Disconnect all instrument cluster
connectors.
z Check for:
zcorrosion
z pushed- out pins
z Connect all instrument cluster
connectors and make sure they seat
correctly.
z Operate the system and verify the
concern is still present.
z Is the concern still present? Yes
INSTALL a new instrument cluster. REFER to
Instrument Cluster
in this section. TEST the
system for normal operation.
No
The system is operating correctly at this time.
Concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT
the self- test. Test Step Result / Action to
Take T1 CHECK THE TURN SIGNAL AND HAZARD LAMPS OPERATION
CAUTION: Use the correct probe adapter(s) when making
measurements. Failure to use the correct probe adapter(s) may
damage the connector.
z Key in ON position.
z Operate the left and right turn signals.
z Operate the hazard lamps.
z Do the turn signals and hazard lamps operate correctly? Yes
GO to
T2 .
No
REFER to Section 417 - 01 .
T2 CHECK THE CIRCUIT IN QUESTION —
CIRCUIT 2 (WH/LB) (RH)
OR CIRCUIT 3 (LG/WH) (LH) z
Key in OFF position.
z Disconnect: Instrument Cluster C220a (RH) or C220b (LH).
z Key in ON position.
z Measure the voltage between the instrument cluster C220a pin 3,
circuit 3 (LG/WH), harness side and ground, while the steering
column multifunction switch is placed in the left turn position (LH); or
between the instrument cluster C220b pin 3, circuit 2 (WH/LB),
harness side and ground, while the steering column multifunction
switch is placed in the right turn position (RH). Yes
GO to
T3 .
No
REPAIR the circuit
(s) in question.
TEST the system for
normal operation. Klj . 36 ba
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provide ventilation.
WARNING: 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.
1. Verify the customer concern by operating the engine to duplicate the concern.
2. Inspect the charging system (battery, generator cable, harness connectors, connections) to determine if any obvious mechanical or electrical concerns exist. If found, repair as necessary
and test the system for normal operation. Refer to the following tables:
3. Check the operation of the charging system warning indicator lamp (instrument cluster). Normal operation is as follows:
zWith the ignition switch OFF, the charging system warning indicator should be OFF.
z With the ignition switch in RUN and the engine off, the charging system warning indicator
light should be on.
z With the engine running, the charging system warning indicator light should be off.
4. Verify the battery is being charged. Carry out the Battery— Load Test. Refer to Component
Tests in this section.
5. If the customer concern is verified after the initial inspection, refer to the Symptom Chart to determine which tests to carry out.
Symptom Chart Visual Inspection Chart
Mechanical Electrical
z
Battery case, posts, hold- down clamp, cables and
connections
z Generator drive (serpentine) belt for condition and
tension. Refer to Section 303 - 05 .
z Generator pulley z
Battery junction box (BJB)
fuse 20 (20A)
z Fuse links
z Circuitry
z Battery charge warning
indicator
z Cables
Normal Charging System Voltages Ignition
Switch
Position A Circuit
36
(YE/WH) I Circuit
904
(LG/RD) Generator B+
Circuit 38 (BK/OG) Battery Engine to
battery
ground Charging
System Warning Indicator
Operation OFF 12V 0V 12V 12V 0V Off
RUN-
engine off 12V 1-
3V 12V 12V 0V Illuminated
RUN-
engine
running 13-
15V 13-
15V 13-
15V 13-15V 0V Off Klj . 3 ba
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LOW
PINPOINT TEST B: THE CHARGING SYSTEM WARNING INDICATOR
IS ON WITH THE ENGINE RUNNING (THE BATTERY VOLTAGE
DOES NOT INCREASE)
Test Step Result / Action to Take
A1 CHECK BATTERY CONDITION
z
Carry out the Battery— Condition Test to determine if
the battery can hold a charge and is OK for use.
Refer to Section 414 - 01 .
z Is the battery OK? Yes
GO to
A2 .
No
INSTALL a new battery. REFER
to Section 414 - 01 . TEST the
system for normal operation. A2 CHECK THE GENERATOR OUTPUT
z
Carry out the On- Vehicle Generator Load/No Load
Test. Refer to Component Tests in this section.
z Is the generator OK? Yes
GO to
A3 .
No
GO to Pinpoint Test B .
A3 CHECK FOR CURRENT DRAINS
z
Carry out the Battery— Drain Test. Refer to
Component Tests in this section.
z Are there any excessive current drains? Yes
REPAIR as necessary. TEST the
system for normal operation.
No
GO to
A4 .
A4 CHECK FOR CURRENT DRAINS WHICH SHUT OFF
WHEN THE BATTERY IS DISCONNECTED z
Carry out the Battery— Electronic Drains Which Shut
Off When the Battery Cable is Disconnected Test.
Refer to Component Tests in this section.
z Are there any current drains which shut off when
the battery is disconnected? Yes
REPAIR as necessary. TEST the
system for normal operation.
No
GO to
Pinpoint Test B .
Test Step Result / Action to
Take B1 CHECK GENERATOR B+ CIRCUIT 38 (BK/OG)
z
Disconnect: Generator B+ C102b.
z Measure the voltage between the generator C102b, circuit 38
(BK/OG), component side and ground. Yes
GO to
B2 .
No
REPAIR the circuit.
TEST the system for
normal operation. Klj . 5 ba
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z
Is the voltage equal to battery positive voltage (B+)? B2 CHECK GENERATOR A CIRCUIT 36 (YE/WH)
z
Disconnect: Generator C102c (4.6L 4V) or C102a (3.8L or 4.6L
2V).
z Measure the voltage between the generator C102c (4.6L 4V) or
C102a (3.8L or 4.6L 2V) pin 3, circuit 36 (YE/WH), harness side
and ground.
z Is the voltage equal to battery positive voltage (B+)? Yes
GO to
B3 .
No
REPAIR the circuit.
TEST the system for
normal operation. B3 CHECK I CIRCUIT 904 (LG/RD) FOR AN OPEN
z
Key in ON position.
z With the ignition switch in the RUN position and the engine off,
measure the voltage between the generator C102c (4.6L 4V) or
C102a (3.8L or 4.6L 2V) pin 1, circuit 904 (LG/RD), harness side
and ground.
z Is the voltage equal to battery positive voltage (B+)? Yes
GO to
B4 .
No
REPAIR the circuit.
TEST the system for
normal operation. B4 CHECK FOR VOLTAGE DROP IN B+ CIRCUIT 38 (YE/WH)
z
Key in START position.
z With the engine at 2,000 rpm, measure the voltage drop between
the generator C102b, circuit 38 (BK/OG), component side and
positive battery terminal. Yes
INSTALL a new
generator. REFER to
Section 414
- 02 .
TEST the system for
normal operation.
No Klj . 6 ba
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PINPOINT TEST C: THE SYSTEM OVERCHARGES (THE BATTERY
VOLTAGE IS GREATER THAN 15.5 VOLTS)
PINPOINT TEST D: THE CHARGING SYSTEM WARNING INDICATOR
IS ON WITH THE ENGINE RUNNING AND THE BATTERY z
Is the voltage drop less than 0.5 volt? REPAIR high
resistance in the B+
circuit 38 (BK/OG).
TEST the system for
normal operation.
Test Step Result / Action to Take
C1 CHECK FOR VOLTAGE DROP IN A CIRCUIT 36 (YE/WH)
z
Disconnect: Generator C102c (4.6L 4V) or C102a (3.8L or 4.6L
2V).
z Key in ON position.
z Measure the voltage drop between the generator C102c (4.6L
4V) or C102a (3.8L or 4.6L 2V) pin 3, circuit 36 (YE/WH),
harness side and positive battery terminal.
z Is the voltage drop less than 0.5 volt? Yes
GO to
C2 .
No
REPAIR the high
resistance in A circuit 36
(YE/WH). TEST the
system for normal
operation. C2 CHECK GENERATOR AND BATTERY GROUND
CONNECTIONS z
Key in OFF position.
z Check the ground connections between the voltage regulator
and the generator and the engine, and the battery and the
engine.
z Are all ground connections clean and tight? Yes
INSTALL a new
generator. REFER to
Section 414
- 02 . TEST
the system for normal
operation.
No
REPAIR ground
connections as
necessary. TEST the
system for normal
operation. Klj . 7 ba
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INCREASES VOLTAGE
PINPOINT TEST E: THE CHARGING SYSTEM WARNING INDICATOR
IS OFF WITH THE IGNITION SWITCH IN THE RUN POSITION AND
THE ENGINE OFF
PINPOINT TEST F: THE CHARGING SYSTEM WARNING INDICATOR
LAMP FLICKERS OR IS INTERMITTENT
Test Step Result / Action to Take
D1 CHECK I CIRCUIT 904 (LG/RD) FOR A
SHORT TO GROUND z
Disconnect: Generator C102c (4.6L 4V) or
C102a (3.8L or 4.6L 2V).
z Key in ON position.
z With the ignition switch in the RUN position,
check the charging system warning
indicator.
z Is the charging system warning indicator
illuminated? Yes
REPAIR circuit 904 (LG/RD) for a short to
ground. TEST the system for normal
operation.
No
INSTALL a new generator. REFER to
Section 414
- 02 . TEST the system for
normal operation. Test Step Result / Action to
Take E1 CHECK THE CHARGING SYSTEM WARNING INDICATOR
LAMP z
Disconnect: Generator C102c (4.6L 4V) or C102a (3.8L or 4.6L
2V).
z With the engine off, connect a fused (15A) jumper wire between
the generator C102c (4.6L 4V) or C102a (3.8L or 4.6L 2V) pin 1,
circuit 904 (LG/RD), harness side and ground.
z Key in ON position.
z Is the charging system warning indicator lamp illuminated? Yes
INSTALL a new
generator. REFER to
Section 414
- 02 . TEST
the system for normal
operation.
No
REFER to Section 413 - 01 for diagnosis
and testing of the
instrument cluster. Test Step Result / Action to
Take F1 CHECK FOR LOOSE CONNECTIONS
z
Check all generator, battery, and power distribution connections
for looseness, corrosion, loose or bent terminals, or loose eyelets.
z Are all connections clean and tight? Yes
GO to
F2 .
No Klj . 8 ba
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PINPOINT TEST G: THE GENERATOR IS NOISY REPAIR as
necessary. TEST the
system for normal
operation.
F2 CHECK FUSE
z
Key in START position.
z With the engine running, check battery junction box (BJB) fuse 20
(20A) in circuit 36 (YE/WH) for looseness by wiggling the fuse and
noting the charging system warning indicator lamp operation.
z Does the charging system warning indicator lamp flicker? Yes
REPAIR loose fuse
connections as
necessary. TEST the
system for normal
operation.
No
GO to
F3 .
F3 CHECK A CIRCUIT 36 (YE/WH) CONNECTIONS
z
Key in OFF position.
z Connect a fused jumper wire between the generator C102c, (4.6L
4V) or C102a (3.8L or 4.6L 2V) pin 3, circuit 36 (YE/WH), harness
side and the positive battery terminal.
z Key in START position.
z With the engine running, note the charging system warning
indicator operation.
z Does the charging system warning indicator lamp flicker? Yes
REFER to
Section 414 - 02 . TEST the
system for normal
operation.
No
REPAIR loose
connection(s) in
circuits. TEST the
system for normal
operation. Test Step Result / Action to Take
G1 CHECK FOR ACCESSORY DRIVE NOISE
z
Check the accessory drive belt for damage and
correct installation. Check the accessory
mounting brackets and generator pulley for
looseness or misalignment.
z Is the accessory drive OK? Yes
GO to
G2 .
No
REPAIR as necessary. REFER to
Section 303 - 05 for diagnosis and testing
of the accessory drive system. TEST the
system for normal operation. G2 CHECK GENERATOR MOUNTING
z
Check the generator mounting for loose bolts
or misalignment.
z Is the generator mounted correctly? Yes
GO to
G3 .
No
REPAIR as necessary. TEST the system
for normal operation. G3 CHECK GENERATOR FOR ELECTRICAL Klj . 9 ba
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