Ford Fusion: Charging System - General Information / Charging System. Diagnosis and Testing

Ford Fusion 2013–2020 Service Manual / Electrical / Battery and Charging System / Charging System - General Information / Charging System. Diagnosis and Testing

Inspection and Verification

Verify the customer concern by operating the charging system.

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

Check the battery for loose, damaged or corroded connections.
Check the generator for loose, damaged or corroded connections.
Check engine and battery grounds for loose, damaged or corroded connections.
Check high current BJB for loose or corroded connections.
Verify fuses or fusible links.
Inspect wiring, terminals and connectors.

Inspect the FEAD system. For 1.5L EcoBoost,
REFER to: Accessory Drive (303-05A Accessory Drive - 1.5L EcoBoost (118kW/160PS) – I4, Diagnosis and Testing).
For 2.0L EcoBoost, REFER to: Accessory Drive (303-05B Accessory Drive - 2.0L EcoBoost (184kW/250PS) – MI4, Diagnosis and Testing).
For 2.5L Duratec, REFER to: Accessory Drive (303-05C Accessory Drive - 2.5L Duratec (125kW/170PS), Diagnosis and Testing).
For 2.7L EcoBoost, REFER to: Accessory Drive (303-05D Accessory Drive - 2.7L EcoBoost (238kW/324PS), Diagnosis and Testing).

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

Check for abnormal ignition-off current drain(s).
REFER to: Battery Drain Check (414-01 Battery, Mounting and Cables, General Procedures).

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

Using the diagnostic scan tool, retrieve all Diagnostic Trouble Codes (DTCs). Refer to the appropriate DTC Chart in this section.

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).

PCM DTC Chart

DTC	Description	Action
P0562	System Voltage Low	GO to Pinpoint Test B
P0563	System Voltage High	GO to Pinpoint Test A
P0620	Generator Control Circuit	GO to Pinpoint Test H
P0625	Generator Field Terminal Circuit Low	GO to Pinpoint Test I
P0626	Generator Field Terminal Circuit High	GO to Pinpoint Test I
P065B	Generator Control Circuit Range/performance	GO to Pinpoint Test H
P0A5A	Generator Current Sensor Circuit Range/Performance	GO to Pinpoint Test G
P0A5B	Generator Current Sensor Circuit Low	GO to Pinpoint Test G
P0A5C	Generator Current Sensor Circuit High	GO to Pinpoint Test G
P1397	System Voltage Out Of Self-Test Range	If combined with P0562, GO to Pinpoint Test B If combined with P0563, GO to Pinpoint Test A
All Other DTCs	—	For 1.5L EcoBoost, For 2.0L EcoBoost, REFER to: Electronic Engine Controls (303-14B Electronic Engine Controls - 2.0L EcoBoost (184kW/250PS) – MI4, Diagnosis and Testing). For 2.5L Duratec, REFER to: Electronic Engine Controls (303-14C Electronic Engine Controls - 2.5L Duratec (125kW/170PS), Diagnosis and Testing). For 2.7L EcoBoost, REFER to: Electronic Engine Controls (303-14D Electronic Engine Controls - 2.7L EcoBoost (238kW/324PS), Diagnosis and Testing).

BCM DTC Chart

NOTE: Diagnose all PCM Diagnostic Trouble Codes (DTCs) first.

DTC	Description	Action
B11DB:02	Battery Monitoring Module "A", General Signal Failure	GO to Pinpoint Test F
B11DB:08	Battery Monitoring Module "A", Bus Signal / Message Failure	GO to Pinpoint Test F
B11DB:11	Battery Monitoring Module "A", Circuit Short To Ground	GO to Pinpoint Test F
B11DB:49	Battery Monitoring Module "A", Internal Electronic Failure	CLEAR the Diagnostic Trouble Codes (DTCs). REPEAT the BCM self test. If Diagnostic Trouble Codes (DTCs) B11DB:49 is retrieved, INSTALL new Battery Monitoring Sensor. REFER to: Battery Monitoring Sensor (414-01 Battery, Mounting and Cables, Removal and Installation).
B11DB:55	Battery Monitoring Module "A", Not Configured	CHECK the vehicle service history for recent service actions related to this module. This DTC sets due to incomplete or incorrect PMI procedures. INSTALL As-Built data from Professional Technician Society (PTS) following diagnostic scan tool instructions under Module Programming>As-Built.
B11DB:9A	Battery Monitoring Module "A", Component or System Operating Conditions	GO to Pinpoint Test F
B130C:12	Load Shed Control Circuit Short To Battery	GO to Pinpoint Test E
B130C:14	Load Shed Control Circuit Short To Ground or Open	GO to Pinpoint Test E
B1438:03	Battery Current Sensor, FM / PWM Failure	GO to Pinpoint Test E
B1489:11	Battery Monitoring System (BMS) Sensor Power Circuit Short To Ground	GO to Pinpoint Test F
U1007:31	Lost Communication With Battery Monitoring Sensor "A": No Signal	GO to Pinpoint Test F
All Other DTCs	—	REFER to: Body Control Module (BCM) (419-10 Multifunction Electronic Modules, Diagnosis and Testing).

Symptom Chart(s)

Symptom Chart: Charging System

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).

Symptom Chart

Condition	Possible Sources	Actions
System voltage high	Refer to the Pinpoint Test	GO to Pinpoint Test A
System voltage low or battery is discharged	Refer to the Pinpoint Test	GO to Pinpoint Test B
The generator is noisy	Refer to the Pinpoint Test	GO to Pinpoint Test C
Radio interference	Refer to the Pinpoint Test	GO to Pinpoint Test D
Charging system warning indicator is never or always on	Wiring, terminals or connectors IPC Generator PCM	RETRIEVE Diagnostic Trouble Codes (DTCs) from all modules. If any Diagnostic Trouble Codes (DTCs) are found, Refer to DTC Chart in this section. If no Diagnostic Trouble Codes (DTCs) are found, REFER to: Instrumentation, Message Center and Warning Chimes (413-01 Instrumentation, Message Center and Warning Chimes, Diagnosis and Testing).
Load Shed Message Displays in IPC message center and/or centerstack infotainment display	Refer to the Pinpoint Test	GO to Pinpoint Test J
Battery Saver - System Off displays in centerstack infotainment display	Refer to the Pinpoint Test	GO to Pinpoint Test J

Pinpoint Tests

System Voltage High

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

NOTE: Diagnostic Trouble Code (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

DTC	Description	Fault Trigger Conditions
P0563	System Voltage High	This DTC sets in the PCM when the PCM detects voltage from the charging system greater than 15.9 volts with vehicle speed above 8 km/h (5 mph).
P1397	System Voltage Out of Self-Test Range	If the voltage rises above or drops below the calibrated set point, the PCM sets this DTC. This DTC may also be set if the vehicle has been recently jump started or has had a discharged battery.

Possible Sources

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

Visual Inspection and Diagnostic Pre-checks

Inspect the high current BJB for loose or corroded connections.

PINPOINT TEST A : SYSTEM VOLTAGE HIGH

NOTE: Make sure battery voltage is greater than 12.2 volts prior to and during this pinpoint test.

NOTE: Do not have a battery charger attached during vehicle testing.

A1 PERFORM INSPECTION AND VERIFICATION

Perform Inspection and Verification procedure in this section.

Was an obvious cause for an observed or reported concern found?

Yes

CORRECT the cause as necessary.

GO to A2

A2 RETRIEVE THE PCM (POWERTRAIN CONTROL MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)

Ignition ON.

Using a diagnostic scan tool, perform the PCM self-test.

Is DTC P0620, P0625 or P0626 present?

Yes

For DTC P0620, GO to Pinpoint Test H
For Diagnostic Trouble Codes (DTCs) P0625 and P0626, GO to Pinpoint Test I

GO to A3

A3 COMPARE THE GENERATOR VOLTAGE DESIRED (GENVDSD) PID (PARAMETER IDENTIFICATION) WITH BATTERY VOLTAGE

With the engine running at idle, measure and record:

Positive Lead Measurement / Action Negative Lead

Using a diagnostic scan tool, view the PCM PID GENVDSD.

Is the recorded battery voltage within ±0.5 volt of the PID?

Yes

GO to A6

GO to A4

A4 MEASURE THE "A" SENSE VOLTAGE

Ignition OFF.

Disconnect Generator C1558A (2.0L EcoBoost or 2.5L Duratec).

Disconnect Generator C102A (All other engines).

Ignition ON.

Measure and record:

Positive Lead Measurement / Action Negative Lead

For the 2.0L EcoBoost or 2.5L Duratec, measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1558A-3 Ground

For all other engines, measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C102A-3 Ground

Is the "A" sense voltage equal to the recorded battery voltage?

Yes

GO to A5

No	VERIFY high current BJB fuse 55 (10A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams manual to identify the possible causes of the circuit short.

A5 "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 of this section. 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 cannot be loaded correctly using an LED-style test lamp.

Ignition ON.

Measure and record:

Positive Lead Measurement / Action Negative Lead

For the 2.0L EcoBoost or 2.5L Duratec, install a test lamp between:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1558A-3 Ground

For all other engines, install a test lamp between:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C102A-3 Ground

For the 2.0L EcoBoost or 2.5L Duratec, measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1558A-3 Ground

For all other engines, measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C102A-3 Ground

Is the "A" sense voltage within ±0.5 volt of the recorded battery voltage?

Yes

GO to A6

No	VERIFY the BJB fuse F55 (10A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams manual to identify the possible causes of the circuit short.

A6 CHECK FOR INTERMITTENT IN THE REGULATOR CIRCUIT

Connect Generator C1558A (2.0L EcoBoost or 2.5L Duratec).

Connect Generator C102A (For all other engines).

Start the engine.

With the engine running at idle, headlamps on and heater blower on high, measure:

Positive Lead Measurement / Action Negative Lead

Perform a wiggle test on the generator wiring and following connections while measuring voltage:
- Generator C1558A (2.0L EcoBoost or 2.5L Duratec)
- Generator C102A (All other engines)
- Inline C146

Does battery voltage change more than 0.5 volt?

Yes

INSPECT and REPAIR any corrosion in the generator B+ circuit or positive battery cable and C1558A (2.0L EcoBoost or 2.5L Duratec) or C102A (all other engines) connections.

GO to A7

A7 CHECK THE VOLTAGE DROP IN THE VEHICLE GROUNDS

Connect Generator C1558A (2.0L EcoBoost or 2.5L Duratec).

Connect Generator C102A (For all other engines).

Start the engine.

With the engine running at idle, headlamps on and heater blower on high, measure:

Positive Lead Measurement / Action Negative Lead

Generator case

Is the voltage drop less than 0.5 volt?

Yes

GO to A8

No	INSPECT and REPAIR the engine ground, generator ground or the battery ground for corrosion.

A8 MONITOR THE GENERATOR COMMAND (GENCMD), GENERATOR MONITOR (GENMON) AND GENERATOR VOLTAGE DESIRED (GENVDSD) PIDS

Ignition OFF.

Disconnect Generator C1558A (2.0L EcoBoost or 2.5L Duratec).

Disconnect Generator C102A (All other engines).

For the 2.0L EcoBoost or 2.5L Duratec, connect a fused jumper wire:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1558A-1 C1558A-2

For all other engines, connect a fused jumper wire:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C102A-1 C102A-2

Start the engine.

Using a diagnostic scan tool, view PCM Parameter Identifications (PIDs).

Using the active command, set the PID GENVDSD to 14 volts.

Monitor the PCM Parameter Identifications (PIDs) GENMON and GENVDSD.

Do the Parameter Identifications (PIDs) read within 5% of each other?

Yes

GO to A9

GO to A12

A9 COMPARE THE PCM (POWERTRAIN CONTROL MODULE) SUPPLY VOLTAGE (VPWR) PID (PARAMETER IDENTIFICATION) TO BATTERY VOLTAGE

With the engine running at idle, measure and record:

Positive Lead Measurement / Action Negative Lead

Using a diagnostic scan tool, view PCM Parameter Identifications (PIDs).

Monitor the PCM PID VPWR.

Does the PID accurately display battery voltage within ±0.5 volt of the recorded battery voltage?

Yes

The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. ADDRESS the root cause of any connector or pin issues.

GO to A10

A10 CHECK PCM (POWERTRAIN CONTROL MODULE) SUPPLY VOLTAGE CIRCUITS

Ignition OFF.

Disconnect BJB PCM power relay.

Disconnect PCM C1915B (1.5L EcoBoost).

Disconnect PCM C1381B (2.0L EcoBoost).

Disconnect PCM C1551B (2.5L Duratec).

Disconnect PCM C1231B (2.7L EcoBoost).

Connect a fused jumper wire:

Positive Lead Measurement / Action Negative Lead

BJB PCM Relay pin 3 BJB PCM Relay pin 5

Measure and record:

Positive Lead Measurement / Action Negative Lead

NOTE: The following step will load test the circuit. A headlamp bulb would be an effective load. To avoid connector terminal damage, use the Flex Probe Kit for connector connections. Connect the load to a suitable ground connection.

For the 1.5L EcoBoost, connect the load to each circuit and measure:
Click to display connectors

Positive Lead	Measurement / Action	Negative Lead
C1915B-101		Ground
C1915B-102		Ground
C1915B-103		Ground

For the 2.0L EcoBoost, connect the load to each circuit and measure:
Click to display connectors

Positive Lead	Measurement / Action	Negative Lead
C1381B-101		Ground
C1381B-102		Ground
C1381B-103		Ground

For the 2.5L Duratec, connect the load to each circuit and measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1551B-97 Ground

C1551B-99 Ground

For the 2.7L EcoBoost, connect the load to each circuit and measure:
Click to display connectors

Positive Lead	Measurement / Action	Negative Lead
C1231B-101		Ground
C1231B-102		Ground
C1231B-103		Ground

Are the voltages within 0.5 volt of the recorded battery voltage?

Yes

REMOVE the fused jumper wire. GO to A11

No	REPAIR the affected circuit(s).

A11 CHECK PCM (POWERTRAIN CONTROL MODULE) GROUND FOR HIGH RESISTANCE

NOTE: The following step will load test the circuit. A headlamp bulb would be an effective load. To avoid connector terminal damage, use the Flex Probe Kit for connector connections.

Connect the load to a suitable 12 volt power connection.

For the 1.5L EcoBoost, connect the load to each circuit and measure:
Click to display connectors

Positive Lead	Measurement / Action	Negative Lead
C1915B-96		Ground
C1915B-97		Ground
C1915B-98		Ground
C1915B-99		Ground

For the 2.0L EcoBoost, connect the load to each circuit and measure:
Click to display connectors

Positive Lead	Measurement / Action	Negative Lead
C1381B-96		Ground
C1381B-97		Ground
C1381B-98		Ground
C1381B-99		Ground

For the 2.5L Duratec, connect the load to each circuit and measure:
Click to display connectors

Positive Lead	Measurement / Action	Negative Lead
C1551B-5		Ground
C1551B-100		Ground
C1551B-102		Ground
C1551B-103		Ground

For the 2.7L EcoBoost, connect the load to each circuit and measure:
Click to display connectors

Positive Lead	Measurement / Action	Negative Lead
C1231B-96		Ground
C1231B-97		Ground
C1231B-98		Ground
C1231B-99		Ground

Is the voltage drop less than 0.5 volt?

Yes

GO to A12

No	REPAIR the affected circuit(s).

A12 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION

Ignition OFF.

Disconnect and inspect all PCM connectors.

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

Reconnect the PCM connectors. Make sure they seat and latch correctly.

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

Is the concern still present?

Yes

CHECK OASIS for any applicable Technical Service Bulletins (TSBs). If a TSB exists for this concern, DISCONTINUE this test and FOLLOW the TSB instructions. If no Technical Service Bulletins (TSBs) address this concern,
Ford Fusion. Charging System. Diagnosis and Testing

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No	The system is operating correctly at this time. The concern may have been caused by module connections. ADDRESS the root cause of any connector or pin issues.

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 battery B+ cable. The PCM monitors this B+ voltage through PCM VPWR or FPPWR circuits. If the charging system voltage drops 1.5 volts or more below the generator voltage desired (GENVDSD), the DTC sets and the charging system MIL illuminates after 30 seconds.

Diagnostic Trouble Code (DTC) Fault Trigger Conditions

DTC	Description	Fault Trigger Conditions
P0562	System Voltage Low	If voltage drops 1.5 volts or more below the generator voltage desired (calculated by the PCM), this DTC sets after 30 seconds.
P1397	System Voltage Out of Self-Test Range	If the voltage rises above or drops below the calibrated set point, the PCM sets this DTC . This DTC may also be set if the vehicle has been recently jump started or has had a discharged battery.

Possible Sources

Battery
Fuses or fusible links
Generator
PCM
High current BJB
Wiring, terminals or connectors

Visual Inspection and Diagnostic Pre-checks

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

PINPOINT TEST B : SYSTEM VOLTAGE LOW OR BATTERY IS DISCHARGED

NOTE: Make sure battery voltage is greater than 12.2 volts prior to and during this pinpoint test.

NOTE: Do not have a battery charger attached during vehicle testing.

B1 PERFORM INSPECTION AND VERIFICATION

Perform Inspection and Verification procedure in this section.

Was an obvious cause for an observed or reported concern found?

Yes

CORRECT the cause as necessary.

GO to B2

B2 RETRIEVE DIAGNOSTIC TROUBLE CODES (DTCS)

Using a diagnostic scan tool, perform the PCM self-test.

Is DTC P0620, P0625 or P0626 present?

Yes

For DTC P0620, GO to Pinpoint Test H
For Diagnostic Trouble Codes (DTCs) P0625 and P0626, GO to Pinpoint Test I

GO to B3

B3 CHECK THE GENERATOR CONNECTIONS

Ignition OFF.

Disconnect all of the generator connectors and inspect for:
- 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

Reconnect the generator connectors. Make sure they seat and latch correctly.

Measure and record:

Positive Lead Measurement / Action Negative Lead

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C102C-1 Ground

Is the voltage within 0.5 volt of the recorded battery voltage?

Yes

GO to B4

TIGHTEN or INSTALL a new generator B+ nut as needed. For 1.5L EcoBoost,
REFER to: Generator - 1.5L EcoBoost (118kW/160PS) – I4 (414-02 Generator and Regulator, Removal and Installation).
For 2.0L EcoBoost, REFER to: Generator - 2.0L EcoBoost (184kW/250PS) – MI4 (414-02 Generator and Regulator, Removal and Installation).
For 2.5L Duratec REFER to: Generator - 2.5L Duratec (125kW/170PS) (414-02 Generator and Regulator, Removal and Installation).
For 2.7L EcoBoost REFER to: Generator - 2.7L EcoBoost (238kW/324PS) (414-02 Generator and Regulator, Removal and Installation).
VERIFY high current BJB MEGA 8 fuse (275A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams manual to identify the possible causes of the circuit short.

B4 CHECK THE VOLTAGE DROP IN THE GENERATOR B+ CIRCUIT

Start the engine.

With the engine running at idle, headlamps on and blower on high, measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C102C-1

Perform a wiggle test of the generator wiring and connections while measuring voltage drop.

Is the voltage drop less than 0.5 volt?

Yes

GO to B5

No	INSPECT and REPAIR any corrosion in the generator B+ circuit or positive battery cable connections.

B5 CHECK THE VOLTAGE DROP IN THE VEHICLE GROUNDS

With the engine running at idle, headlamps on and heater blower on high, measure:

Positive Lead Measurement / Action Negative Lead

Generator case

Is the voltage drop less than 0.5 volt?

Yes

GO to B6

No	INSPECT and REPAIR the engine ground, generator ground or the battery ground for corrosion.

B6 MONITOR THE GENERATOR VOLTAGE DESIRED (GENVDSD) PID (PARAMETER IDENTIFICATION) WHILE COMMANDED

Using a diagnostic scan tool, view the PCM GENVDSD PID.

Using a diagnostic scan tool active command, set the PCM PID GENVDSD to 14 volts.

With the engine running at idle, measure battery and record:

Positive Lead Measurement / Action Negative Lead

Is the recorded battery voltage within ±0.5 volt of the PID?

Yes

GO to B7

GO to B16

B7 COMPARE THE PCM (POWERTRAIN CONTROL MODULE) SUPPLY VOLTAGE (VPWR) PID (PARAMETER IDENTIFICATION) TO BATTERY VOLTAGE

With the engine running at idle, headlamps on and blower on high, measure and record:

Positive Lead Measurement / Action Negative Lead

Using a diagnostic scan tool, view the PCM PID VPWR.

Does the PID accurately display battery voltage within ±0.5 volt of the recorded battery voltage?

Yes

GO to B8

No	REPAIR high resistance or loose connections in the affected PCM power circuit(s).

B8 COMPARE THE PCM (POWERTRAIN CONTROL MODULE) VOLTAGE SUPPLY CIRCUITS

Ignition OFF.

Disconnect BJB PCM power relay.

Disconnect PCM C1915B (1.5L EcoBoost).

Disconnect PCM C1381B (2.0L EcoBoost).

Disconnect PCM C1551B (2.5L Duratec).

Disconnect PCM C1231B (2.7L EcoBoost).

Connect a fused jumper wire:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

BJB PCM power relay pin 3 BJB PCM power relay pin 5

Measure and record:

Positive Lead Measurement / Action Negative Lead

NOTE: The following step will load test the circuit. A headlamp bulb would be an effective load. To avoid connector terminal damage, use the Flex Probe Kit for connector connections. Connect the load to a suitable ground connection.

Ignition ON.

For the 1.5L EcoBoost, connect the load to each circuit and measure:
Click to display connectors

Positive Lead	Measurement / Action	Negative Lead
C1915B-101		Ground
C1915B-102		Ground
C1915B-103		Ground

For the 2.0L EcoBoost, connect the load to each circuit and measure:
Click to display connectors

Positive Lead	Measurement / Action	Negative Lead
C1381B-101		Ground
C1381B-102		Ground
C1381B-103		Ground

For the 2.5L Duratec, connect the load to each circuit and measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1551B-97 Ground

C1551B-99 Ground

For the 2.7L EcoBoost, connect the load to each circuit and measure:
Click to display connectors

Positive Lead	Measurement / Action	Negative Lead
C1231B-101		Ground
C1231B-102		Ground
C1231B-103		Ground

Are the voltages within 0.5 volt of the recorded battery voltage?

Yes

REMOVE the fused jumper wire and INSTALL BJB PCM power relay. GO to B9

No	REPAIR the affected circuit(s).

B9 CHECK PCM (POWERTRAIN CONTROL MODULE) GROUND FOR HIGH RESISTANCE

NOTE: The following step will load test the circuit. A headlamp bulb would be an effective load. To avoid connector terminal damage, use the Flex Probe Kit for connector connections.

Ignition OFF.

Remove Fused jumper wire.

Connect the load to a suitable 12 volt power connection.

For the 1.5L EcoBoost, connect the load to each circuit and measure:
Click to display connectors

Positive Lead	Measurement / Action	Negative Lead
C1915B-96		Ground
C1915B-97		Ground
C1915B-98		Ground
C1915B-99		Ground

For the 2.0L EcoBoost, connect the load to each circuit and measure:
Click to display connectors

Positive Lead	Measurement / Action	Negative Lead
C1381B-96		Ground
C1381B-97		Ground
C1381B-98		Ground
C1381B-99		Ground

For the 2.5L Duratec, connect the load to each circuit and measure:
Click to display connectors

Positive Lead	Measurement / Action	Negative Lead
C1551B-5		Ground
C1551B-100		Ground
C1551B-102		Ground
C1551B-103		Ground

For the 2.7L EcoBoost, connect the load to each circuit and measure:
Click to display connectors

Positive Lead	Measurement / Action	Negative Lead
C1231B-96		Ground
C1231B-97		Ground
C1231B-98		Ground
C1231B-99		Ground

Is the voltage drop less than 0.5 volt?

Yes

GO to B10

No	REPAIR the affected circuit(s).

B10 COMPARE THE BCM VOLTAGE SUPPLY CIRCUITS

Ignition OFF.

Disconnect all of the BCM connectors.

Measure and record:

Positive Lead Measurement / Action Negative Lead

NOTE: The following step will load test the circuit. A headlamp bulb would be an effective load. To avoid connector terminal damage, use the Flex Probe Kit for connector connections. Connect the load to a suitable ground connection.

Connect the load to each circuit and measure:
Click to display connectors

Positive Lead	Measurement / Action	Negative Lead
C2280A-1		Ground
C2280B-17		Ground
C2280C-21		Ground
C2280C-22		Ground

Are the voltages within 0.5 volt of the recorded battery voltage?

Yes

GO to B11

No	REPAIR the affected circuit(s).

B11 CHECK BCM GROUND FOR HIGH RESISTANCE

NOTE: The following step will load test the circuit. A headlamp bulb would be an effective load. To avoid connector terminal damage, use the Flex Probe Kit for connector connections.

Connect the load to a suitable 12 volt power connection.

Connect the load to each circuit and measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C2280F-6 Ground

C2280F-7 Ground

Is the voltage drop less than 0.5 volt?

Yes

GO to B12

No	REPAIR the affected circuit(s).

B12 MONITOR THE SUPPLY VOLTAGE (VPWR) PID (PARAMETER IDENTIFICATION)

Start the engine.

Measure and record:

Positive Lead Measurement / Action Negative Lead

Using a diagnostic scan tool, view PCM PID VPWR and record.

Momentarily accelerate the engine to Wide Open Throttle (WOT) and release. Repeat this step 4-5 times while continuing to monitor the PID .

Does the PID stay within 0.5 volt of the recorded battery voltage when the engine Revolutions Per Minute (RPM) are increased?

Yes

With 2.5L Duratec GO to B13
For all other engines, the system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. INSPECT and REPAIR any connector or pin issues found. If no connector or pin issues are found, Perform the battery drain test.
REFER to: Battery Drain Check (414-01 Battery, Mounting and Cables, General Procedures).

GO to B16

B13 CHECK THE INJPWR_M PID (PARAMETER IDENTIFICATION)

Using a diagnostic scan tool, view PCM Parameter Identifications (PIDs).

Monitor the PCM PID INJPWR_M

Does the PID read greater than 0.5 volts ?

Yes

GO to B14

No	VERIFY BJB fuse F29 (5A) is OK. If OK, REFER to the Wiring Diagrams and REPAIR the circuit open. If not OK, REFER to the Wiring Diagrams manual to identify the possible causes of the circuit short.

B14 COMPARE THE INJPWR_M PID (PARAMETER IDENTIFICATION) TO BATTERY VOLTAGE

With the engine still running at idle, measure and record the battery voltage at the battery.

Monitor the PCM PID INJPWR_M.

Does the PID accurately display battery voltage within ±0.5 volt of the recorded battery voltage?

Yes

GO to B17

GO to B15

B15 CHECK BJB (BATTERY JUNCTION BOX) FUEL PUMP RELAY

Ignition OFF.

Swap the BJB fuel pump relay with a known good relay.

Start the engine.

With the engine running at idle, measure and record the battery voltage at the battery.

Monitor the PCM PID INJPWR_M.

Does the PID accurately display battery voltage within ±0.5 volt of the recorded battery voltage?

Yes

REPLACE the BJB fuel pump relay.

No	REFER to the Wiring Diagrams and REPAIR circuit CBB29 for high resistance.

B16 CHECK GENERATOR CLUTCH OPERATION

Ignition OFF.

Perform the generator clutch component test. GO to Pinpoint Test K

Is the generator clutch OK?

Yes

INSTALL a new generator. For 1.5L EcoBoost,
REFER to: Generator - 1.5L EcoBoost (118kW/160PS) – I4 (414-02 Generator and Regulator, Removal and Installation).
For 2.0L EcoBoost, REFER to: Generator - 2.0L EcoBoost (184kW/250PS) – MI4 (414-02 Generator and Regulator, Removal and Installation).
For 2.5L Duratec, REFER to: Generator - 2.5L Duratec (125kW/170PS) (414-02 Generator and Regulator, Removal and Installation).
For 2.7L EcoBoost, REFER to: Generator - 2.7L EcoBoost (238kW/324PS) (414-02 Generator and Regulator, Removal and Installation).

No	INSTALL a new generator clutch. REFER to: Generator Pulley (414-02 Generator and Regulator, Removal and Installation).

B17 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION

Ignition OFF.

Disconnect and inspect all PCM connectors.

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

Reconnect the PCM connectors. Make sure they seat and latch correctly.

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

Is the concern still present?

Yes

Click here to access Guided Routine (PCM). Ford Fusion. Charging System. Diagnosis and Testing

Internet Explorer version 11 or greater is required to perform this Pinpoint Test.
CLEAR all Diagnostic Trouble Codes (DTCs) in all modules.

No	The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. ADDRESS the root cause of any connector or pin issues.

Generator Noise or Mechanical Performance

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.

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.

PINPOINT TEST C : GENERATOR NOISE OR MECHANICAL PERFORMANCE

C1 CHECK FOR ACCESSORY DRIVE BELT NOISE AND LOOSE MOUNTING BRACKETS

Ignition OFF.

Check the FEAD belt and tensioner for damage and correct installation. For 1.5L EcoBoost,
REFER to: Accessory Drive (303-05A Accessory Drive - 1.5L EcoBoost (118kW/160PS) – I4, Diagnosis and Testing).
For 2.0L EcoBoost REFER to: Accessory Drive (303-05B Accessory Drive - 2.0L EcoBoost (184kW/250PS) – MI4, Diagnosis and Testing).
For 2.5L Duratec REFER to: Accessory Drive (303-05C Accessory Drive - 2.5L Duratec (125kW/170PS), Diagnosis and Testing).
For 2.7L EcoBoost REFER to: Accessory Drive (303-05D Accessory Drive - 2.7L EcoBoost (238kW/324PS), Diagnosis and Testing).

Is the accessory drive OK?

Yes

GO to C2

No	REPAIR as necessary.

C2 CHECK THE GENERATOR MOUNTING

Check the generator mounting for loose bolts or misalignment.

Is the generator mounted correctly?

Yes

GO to C3

No	REPAIR as necessary.

C3 CHECK THE GENERATOR FOR NOISE

Start the engine.

With the engine running, 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?

Yes

GO to C4

No	REFER to: Engine (303-00 Engine System - General Information, Diagnosis and Testing). to diagnose the source of the engine noise.

C4 CHECK GENERATOR CLUTCH OPERATION

Ignition OFF.

Perform the generator clutch component test. GO to Pinpoint Test K

Is the generator clutch OK?

Yes

No	INSTALL a new generator clutch. REFER to: Generator Pulley (414-02 Generator and Regulator, Removal and Installation).

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) Audio Control Module (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
In-vehicle entertainment system
Wiring, terminals or connectors

Visual Inspection and Diagnostic Pre-checks

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

PINPOINT TEST D : RADIO INTERFERENCE

D1 VERIFY THE GENERATOR IS THE SOURCE OF THE AUDIO SYSTEM INTERFERENCE

Start the engine.

Allow the engine to idle.

Tune the audio system to a station where interference is present.

Ignition OFF.

Disconnect Generator C102C .

Start the engine.

Allow the engine to idle.

Is the interference present with the generator disconnected?

Yes

REFER to: Information and Entertainment System (415-00 Information and Entertainment System - General Information) .
(Sony Sound) or REFER to: Information and Entertainment System (415-00 Information and Entertainment System - General Information) .
(Base), or REFER to: Information and Entertainment System (415-00 Information and Entertainment System - General Information) .
(Premium)

Battery Current Sensor Faults

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

Normal Operation and Fault Conditions

For information on the battery current sensor,
REFER to: Charging System - System Operation and Component Description (414-00 Charging System - General Information, Description and Operation).

Diagnostic Trouble Code (DTC) Fault Trigger Conditions

DTC	Description	Fault Trigger Conditions
B130C:12	Load Shed Control Circuit Short To Battery	This DTC sets in the BCM when the BCM senses a short in the battery current sensor control circuit.
B130C:14	Load Shed Control Circuit Short To Ground or Open	This DTC sets in the BCM when the BCM senses an open or ground in the battery current sensor control circuit.
B1438:03	Battery Current Sensor, FM (Frequency Modulated) / PWM (Pulse Width Modulated) Failure	This DTC sets in the BCM when the BCM does not indicate current from the battery current sensor.

Possible Sources

Battery current sensor
Wiring, terminals or connectors

Visual Inspection and Diagnostic Pre-checks

Inspect the battery current sensor
Inspect the battery current sensor connector

PINPOINT TEST E : BATTERY CURRENT SENSOR FAULTS

NOTE: Make sure battery voltage is greater than 12.2 volts prior to and during this pinpoint test.

NOTE: Do not have a battery charger attached during vehicle testing.

E1 CHECK THE BATTERY CURRENT SENSOR CONNECTION

Inspect the battery current sensor for the following:
- physical damage
- corrosion
- disconnected electrical connector
- battery ground cable routed through the battery current sensor
- debris between the battery current sensor and the battery ground cable

Are any of these conditions found during inspection?

Yes

REPAIR as necessary. GO to E13

GO to E2

E2 CHECK THE BATTERY CURRENT SENSOR REFERENCE VOLTAGE CIRCUIT

Ignition OFF.

Disconnect Battery current sensor C1646 .

Ignition ON.

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1646-1 Ground

Is the voltage between 4.8 and 5.2 volts?

Yes

GO to E6

No	If the voltage is less than 4.8 volts, GO to E4 If the voltage is greater than 5.2 volts, GO to E3

E3 CHECK THE BATTERY CURRENT SENSOR REFERENCE VOLTAGE CIRCUIT FOR A SHORT TO VOLTAGE

Ignition OFF.

Disconnect BCM C2280C .

Using the Terminal Release Kit, release and temporarily remove BCM C2280C-3.

Connect BCM C2280C .

Ignition ON.

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1646-1 Ground

Is any voltage present?

Yes

REPAIR the circuit.

No	INSTALL C2280C-3 and GO to E14

E4 CHECK THE BATTERY CURRENT SENSOR REFERENCE VOLTAGE CIRCUIT FOR A SHORT TO GROUND

Ignition OFF.

Disconnect BCM C2280C .

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1646-1 Ground

Is the resistance greater than 10,000 ohms?

Yes

GO to E5

No	REPAIR the circuit.

E5 CHECK THE BATTERY CURRENT SENSOR REFERENCE VOLTAGE CIRCUIT FOR AN OPEN

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1646-1 C2280C-3

Is the resistance less than 3 ohms?

Yes

GO to E13

No	REPAIR the circuit.

E6 CHECK THE BATTERY CURRENT SENSOR SIGNAL RETURN CIRCUIT

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1646-1 C1646-2

Is the voltage between 4.8 and 5.2 volts?

Yes

GO to E9

GO to E7

E7 CHECK THE BATTERY CURRENT SENSOR SIGNAL RETURN CIRCUIT FOR VOLTAGE

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1646-2 Ground

Is any voltage present?

Yes

REPAIR the circuit.

GO to E8

E8 CHECK THE BATTERY CURRENT SENSOR SIGNAL RETURN CIRCUIT FOR AN OPEN

Ignition OFF.

Disconnect BCM C2280C .

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1646-2 C2280C-19

Is the resistance less than 3 ohms?

Yes

GO to E13

No	REPAIR the circuit.

E9 CHECK THE BATTERY CURRENT SENSOR FEEDBACK CIRCUIT FOR A SHORT TO VOLTAGE

Disconnect BCM C2280C .

Ignition ON.

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1646-3 Ground

Is any voltage present?

Yes

REPAIR the circuit.

GO to E10

E10 CHECK THE BATTERY CURRENT SENSOR FEEDBACK CIRCUIT FOR A SHORT TO GROUND

Ignition OFF.

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1646-3 Ground

Is the resistance greater than 10,000 ohms?

Yes

GO to E11

No	REPAIR the circuit.

E11 CHECK THE BATTERY CURRENT SENSOR FEEDBACK CIRCUIT FOR AN OPEN

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1646-3 C2280C-8

Is the resistance less than 3 ohms?

Yes

GO to E12

No	REPAIR the circuit.

E12 CHECK THE BATTERY CURRENT SENSOR FEEDBACK CIRCUIT FOR A SHORT TO THE SIGNAL RETURN OR REFERENCE CIRCUIT

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1646-3 C1646-1

C1646-3 C1646-2

Are the resistances greater than 10,000 ohms?

Yes

GO to E13

No	REPAIR the affected circuit.

E13 CHECK THE BATTERY CURRENT SENSOR CONNECTION

Ignition OFF.

Disconnect Battery Current Sensor C1646, if necessary.

Inspect the battery current sensor connector for:
- 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

Connect Battery Current Sensor C1646 .

Connect BCM C2280C .

Ignition ON.

Using a diagnostic scan tool, clear all Diagnostic Trouble Codes (DTCs) in all modules.

Using a diagnostic scan tool, perform the BCM self-test.

Did the DTC return?

Yes

REPAIR as necessary or INSTALL a new battery current sensor.
REFER to: Battery Current Sensor (414-01 Battery, Mounting and Cables, Removal and Installation).
CLEAR the Diagnostic Trouble Codes (DTCs). REPEAT the self-test. If the DTC returns, GO to E14

No	The system is operating correctly at this time. The concern may have been caused by module connections. ADDRESS the root cause of any connector or pin issues.

E14 CHECK FOR CORRECT BCM (BODY CONTROL MODULE) OPERATION

Ignition OFF.

Disconnect and inspect all BCM connectors.

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

Reconnect the BCM connectors. Make sure they seat and latch correctly.

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

Is the concern still present?

Yes

Click here to access Guided Routine (BCM). Ford Fusion. Charging System. Diagnosis and Testing

Internet Explorer version 11 or greater is required to perform this Pinpoint Test.
CLEAR all Diagnostic Trouble Codes (DTCs) in all modules.

No	The system is operating correctly at this time. The concern may have been caused by module connections. ADDRESS the root cause of any connector or pin issues.

Battery Monitoring Sensor Faults

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

Normal Operation and Fault Conditions

The BCM monitors the battery state of charge using the battery monitoring sensor attached to the negative battery cable. Battery voltage is hardwired to the battery monitoring sensor and data is transferred from the battery monitoring sensor to the BCM via a LIN circuit.

Diagnostic Trouble Code (DTC) Fault Trigger Conditions

DTC	Description	Fault Trigger Conditions
B11DB:02	Battery Monitoring Module "A", General Signal Failure	This DTC sets if the BCM receives corrupted data from the battery monitoring sensor over the LIN.
B11DB:08	Battery Monitoring Module "A", Bus Signal / Message Failure	This DTC sets if the BCM receives corrupted data from the battery monitoring sensor over the LIN.
B11DB:11	Battery Monitoring Module "A", Circuit Short To Ground	This DTC sets if the BCM detects low voltage on the battery monitoring sensor LIN.
B11DB:9A	Battery Monitoring Module "A", Component or System Operating Conditions	This DTC sets if the BCM receives corrupted data from the battery monitoring sensor over the LIN.
B1489:11	Battery Monitoring System (BMS) Sensor Power Circuit Short To Ground	This DTC sets if the BCM receives no data from the battery monitoring sensor over the LIN.
U1007:31	Lost Communication With Battery Monitoring Sensor "A": No Sub Type Information	This DTC sets if the BCM does not detect communication through the LIN circuit. This can be a result of an open or short in the LIN circuit or the voltage supply circuit.

Possible Sources

Battery monitoring sensor
Wiring, terminals or connectors

Visual Inspection and Diagnostic Pre-checks

Inspect the battery monitoring sensor
Inspect the battery monitoring sensor connector

PINPOINT TEST F : BATTERY MONITORING SENSOR FAULTS

NOTE: Make sure battery voltage is greater than 12.2 volts prior to and during this pinpoint test.

NOTE: Do not have a battery charger attached during vehicle testing.

F1 CHECK ELECTRICAL CONNECTOR CONDITION

Disconnect Battery Monitoring Sensor C1689 .

Check the Battery Monitoring Sensor electrical connections for security, damage and corrosion.

Check the battery cable connections.

Connect Battery Monitoring Sensor C1689 .

Are all connectors clean and connected properly?

Yes

GO to F2

No	REPAIR any corrosion in the battery cable connections. REPAIR any damaged, bent or pushed-out pins.

F2 RETRIEVE BCM (BODY CONTROL MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)

Ignition ON.

Using a diagnostic scan tool, clear all Diagnostic Trouble Codes (DTCs) in all modules.

Using a diagnostic scan tool, perform the BCM self-test.

Did the DTC return?

Yes

GO to F3

No	For any PCM or BCM Diagnostic Trouble Codes (DTCs) refer to DTC charts in this section. The concern may have been caused by a loose or corroded connector. ADDRESS the root cause of any connector or pin issues.

F3 CHECK THE BATTERY MONITORING SENSOR VOLTAGE

Ignition OFF.

Disconnect Battery Monitoring Sensor C1689 .

Measure and record:

Positive Lead Measurement / Action Negative Lead

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1689-2 Ground

Is the voltage within 0.5 volt of the recorded battery voltage?

Yes

GO to F4

No	REPAIR the circuit.

F4 CHECK THE BATTERY MONITORING SENSOR LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR A SHORT TO VOLTAGE

Disconnect BCM C2280C .

Ignition ON.

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1689-1 Ground

Is any voltage present?

Yes

REPAIR the circuit.

GO to F5

F5 CHECK THE BATTERY MONITORING SENSOR LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR A SHORT TO GROUND

Ignition OFF.

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1689-1 Ground

Is the resistance greater than 10,000 ohms?

Yes

GO to F6

No	REPAIR the circuit.

F6 CHECK THE BATTERY MONITORING SENSOR LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR AN OPEN

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1689-1 C2280C-4

Is the resistance less than 3 ohms?

Yes

INSTALL a new Battery monitoring sensor.
REFER to: Battery Monitoring Sensor (414-01 Battery, Mounting and Cables, Removal and Installation).

No	REPAIR the circuit. GO to F7

F7 CLEAR DIAGNOSTIC TROUBLE CODES (DTCS)

Connect Battery Monitoring Sensor C1689 .

Connect BCM C2280C .

Ignition ON.

Using a diagnostic scan tool, clear all Diagnostic Trouble Codes (DTCs) in all modules.

Enter the following diagnostic mode: BCM self-test.

Is DTC B11DB:02, B11DB:08, B11DB:11, B11DB:49, or B11DB:9A present?

Yes

GO to F8

No	For all other BCM Diagnostic Trouble Codes (DTCs) refer to DTC charts in this section.

F8 CHECK FOR CORRECT BCM (BODY CONTROL MODULE) OPERATION

Ignition OFF.

Disconnect and inspect all BCM connectors.

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

Reconnect the BCM connectors. Make sure they seat and latch correctly.

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

Is the concern still present?

Yes

Click here to access Guided Routine (BCM). Ford Fusion. Charging System. Diagnosis and Testing

Internet Explorer version 11 or greater is required to perform this Pinpoint Test.
CLEAR all Diagnostic Trouble Codes (DTCs) in all modules.

No	The system is operating correctly at this time. The concern may have been caused by module connections. ADDRESS the root cause of any connector or pin issues.

Generator Current Sensor Faults

Refer to Wiring Diagrams Cell 13 for schematic and connector information.

Normal Operation and Fault Conditions

The generator current sensor is a Hall-effect sensor attached to the generator B+ cable. It is supplied a 5 volt reference and ground from the PCM. The PCM reads the generator current sensor feedback voltage to determine how much current is flowing through the generator B+ cable.

Diagnostic Trouble Code (DTC) Fault Trigger Conditions

DTC	Description	Fault Trigger Conditions
P0A5A	Generator Current Sensor Circuit Range/Performance	Sets in the PCM when the PCM does not detect current through the generator current sensor and there are no generator current sensor circuit Diagnostic Trouble Codes (DTCs) set.
P0A5B	Generator Current Sensor Circuit Low	Sets in the PCM when the PCM senses lower than expected voltage on the generator current sensor feedback circuit, indicating an open or a short directly to ground.
P0A5C	Generator Current Sensor Circuit High	Sets in the PCM when the PCM senses higher than expected voltage on the generator current sensor feedback circuit, indicating a short directly to voltage.

Possible Sources

Generator current sensor
PCM
Wiring, terminals or connectors

Visual Inspection and Diagnostic Pre-checks

Inspect the generator current sensor.
Inspect the generator current sensor connector

PINPOINT TEST G : GENERATOR CURRENT SENSOR FAULTS

NOTE: Make sure battery voltage is greater than 12.2 volts prior to and during this pinpoint test.

NOTE: Do not have a battery charger attached during vehicle testing.

G1 RETRIEVE DIAGNOSTIC TROUBLE CODES (DTCS)

Ignition ON.

Using a diagnostic scan tool, perform the PCM self-test

Is DTC P0562 present?

Yes

GO to Pinpoint Test B

No	For DTC P0A5A, GO to G2 For DTC P0A5B, GO to G3 For DTC P0A5C, GO to G6

G2 CHECK THE GENERATOR CURRENT SENSOR

Ignition OFF.

Inspect the generator current sensor for the following:
- physical damage
- corrosion
- disconnected electrical connector
- generator B+ cable routed through the generator current sensor
- debris between the generator current sensor and the generator B+ cable

Are any of these conditions found during inspection?

Yes

REPAIR as necessary or INSTALL a new generator current sensor.
REFER to: Generator Current Sensor (414-01 Battery, Mounting and Cables, Removal and Installation).

GO to G9

G3 CHECK THE GENERATOR CURRENT SENSOR REFERENCE VOLTAGE CIRCUIT FOR AN OPEN

Ignition OFF.

Disconnect Generator current sensor C1645 .

Ignition ON.

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1645-1 Ground

Is the voltage between 4.8 and 5.2 volts?

Yes

GO to G4

No	If the voltage is less than 4.8 volts, REPAIR the circuit for an open or high resistance. If the voltage is greater than 5.2 volts, REPAIR the circuit for a short to voltage.

G4 CHECK THE GENERATOR CURRENT SENSOR SIGNAL RETURN CIRCUIT FOR AN OPEN

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1645-1 C1645-2

Is the voltage between 4.8 and 5.2 volts?

Yes

GO to G5

No	REPAIR the circuit for an open or high resistance.

G5 CHECK THE GENERATOR CURRENT SENSOR FEEDBACK CIRCUIT FOR A SHORT TO GROUND

Ignition OFF.

Disconnect PCM C1915B (1.5L EcoBoost).

Disconnect PCM C1381B (2.0L EcoBoost).

Disconnect PCM C1551B (2.5L Duratec).

Disconnect PCM C1231B (2.7L EcoBoost).

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1645-3 Ground

Is the resistance greater than 10,000 ohms?

Yes

GO to G6

No	REPAIR the circuit.

G6 CHECK THE GENERATOR CURRENT SENSOR FEEDBACK CIRCUIT FOR A SHORT TO VOLTAGE

Ignition OFF.

Disconnect PCM C1915B (1.5L EcoBoost).

Disconnect PCM C1381B (2.0L EcoBoost).

Disconnect PCM C1551B (2.5L Duratec).

Disconnect PCM C1231B (2.7L EcoBoost).

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1645-3 Ground

Is any voltage present?

Yes

REPAIR the circuit.

GO to G7

G7 CHECK THE GENERATOR CURRENT SENSOR FEEDBACK CIRCUIT FOR A SHORT TO THE SIGNAL RETURN OR VOLTAGE REFERENCE CIRCUIT

Ignition OFF.

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1645 -3 C1645-1

C1645 -3 C1645-2

Are the resistances greater than 10,000 ohms?

Yes

GO to G8

No	REPAIR the affected circuit.

G8 CHECK THE GENERATOR CURRENT SENSOR FEEDBACK CIRCUIT FOR AN OPEN

For the 1.5L EcoBoost, measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1915B-94 C1645-3

For the 2.0L EcoBoost, measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1381B-94 C1645-3

For the 2.5L Duratec, measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1551B-45 C1645-3

For the 2.7L EcoBoost, measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1231B-94 C1645-3

Is the resistance less than 3 ohms?

Yes

GO to G9

No	REPAIR the circuit.

G9 CHECK THE GENERATOR CURRENT SENSOR CONNECTION

Ignition OFF.

Disconnect Generator current sensor C1645 .

Inspect the generator current sensor connector for the following:
- 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

Connect and correctly seat the generator current sensor connector.

Ignition ON.

Using a diagnostic scan tool, clear all Diagnostic Trouble Codes (DTCs) in all modules.

Using a diagnostic scan tool, perform the PCM self-test

Did the DTC return?

Yes

REPAIR as necessary or INSTALL a new generator current sensor.
REFER to: Generator Current Sensor (414-01 Battery, Mounting and Cables, Removal and Installation).
CLEAR the Diagnostic Trouble Codes (DTCs). REPEAT the self-test. If the DTC returns, GO to G10

No	The system is operating correctly at this time. The concern may have been caused by an intermittently loose or corroded connector. ADDRESS the root cause of any connector or pin issues.

G10 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION

Ignition OFF.

Disconnect and inspect all PCM connectors.

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

Reconnect the PCM connectors. Make sure they seat and latch correctly.

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

Is the concern still present?

Yes

Click here to access Guided Routine (PCM). Ford Fusion. Charging System. Diagnosis and Testing

Internet Explorer version 11 or greater is required to perform this Pinpoint Test.
CLEAR all Diagnostic Trouble Codes (DTCs) in all modules.

No	The system is operating correctly at this time. The concern may have been caused by module connections. ADDRESS the root cause of any connector or pin issues.

P0620, P065B

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

Normal Operation and Fault Conditions

The PCM monitors the generator output via the generator monitor (GENMON) circuit. The PCM uses the generator command (GENCOM) circuit to command the generator to either increase or decrease output. If the GENCOM circuit (generator control circuit) or the "A" sense circuit are open or shorted to ground, the PCM will not be able to control the generator output. When the engine speed is greater than 2,000 rpm, the generator defaults to a steady voltage output of 13.5 volts and the PCM sends a request to the IPC to illuminate the charging system warning indicator. A GENCOM circuit fault can be confirmed by viewing the PCM PID generator command line fault (GENCMD_LF) (YES status indicator fault).

Diagnostic Trouble Code (DTC) Fault Trigger Conditions

DTC	Description	Fault Trigger Conditions
P0620	Generator Control Circuit	The PCM sets this DTC if the GENCOM circuit, "A" sense circuit, or B+ circuit is open or shorted to ground.
P065B	Generator Control Circuit Range/performance	The PCM sets this DTC when the generator reports an internal regulator failure.

Possible Sources

Fuses or Fusible Links
Generator
Generator clutch.
PCM
Wiring, terminals or connectors

Visual Inspection and Diagnostic Pre-checks

Inspect the high current BJB for loose or corroded connections.
Inspect the generator clutch.

PINPOINT TEST H : P0620, P065B

NOTE: Make sure battery voltage is greater than 12.2 volts prior to and during this pinpoint test.

NOTE: Do not have a battery charger attached during vehicle testing.

H1 PERFORM INSPECTION AND VERIFICATION

Perform Inspection and Verification procedure in this section.

Was an obvious cause for an observed or reported concern found?

Yes

CORRECT the cause as necessary.

GO to H2

H2 CHECK THE GENERATOR CONNECTIONS

Ignition OFF.

Disconnect all of the generator connectors and inspect for:
- 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

Reconnect the generator connectors. Make sure they seat and latch correctly.

Measure and record:

Positive Lead Measurement / Action Negative Lead

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C102C-1 Ground

Is the voltage within 0.5 volt of the recorded battery voltage?

Yes

GO to H3

TIGHTEN or INSTALL a new generator B+ nut as needed. For 1.5L EcoBoost,
REFER to: Generator - 1.5L EcoBoost (118kW/160PS) – I4 (414-02 Generator and Regulator, Removal and Installation).
For 2.0L EcoBoost, REFER to: Generator - 2.0L EcoBoost (184kW/250PS) – MI4 (414-02 Generator and Regulator, Removal and Installation).
For 2.5L Duratec, REFER to: Generator - 2.5L Duratec (125kW/170PS) (414-02 Generator and Regulator, Removal and Installation).
For 2.7L EcoBoost, REFER to: Generator - 2.7L EcoBoost (238kW/324PS) (414-02 Generator and Regulator, Removal and Installation).
VERIFY high current BJB MEGA 8 fuse (275A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams manual to identify the possible causes of the circuit short.

H3 CHECK THE VOLTAGE DROP IN THE GENERATOR B+ CIRCUIT

Start the engine.

With the engine running at idle, headlamps on and blower on high, measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C102C-1

Perform a wiggle test of the generator wiring and connections while measuring voltage drop.

Is the voltage drop less than 0.5 volt?

Yes

GO to H4

No	INSPECT and REPAIR any corrosion in the generator B+ circuit or positive battery cable connections.

H4 "A" SENSE CIRCUIT LOAD TEST

Ignition OFF.

Disconnect Generator C1558A (2.0L EcoBoost or 2.5L Duratec) .

Disconnect Generator C102A (All other engines).

Ignition ON.

Measure and record:

Positive Lead Measurement / Action Negative Lead

For the 2.0L EcoBoost or 2.5L Duratec, install a test lamp between:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1558A-3 Ground

For all other engines, install a test lamp between:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C102A-3 Ground

Perform a wiggle test on the generator wiring while measuring voltage.

For the 2.0L EcoBoost or 2.5L Duratec, perform a wiggle test on the generator wiring and measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1558A-3 Ground

For all other engines, perform a wiggle test on the generator wiring and measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C102A-3 Ground

Is the "A" sense voltage within ±0.5 volt of the recorded battery voltage?

Yes

GO to H5

No	VERIFY high current BJB fuse 55 (10A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams manual to identify the possible causes of the circuit short.

H5 CHECK THE GENERATOR COMMAND CIRCUIT FOR A SHORT TO VOLTAGE

Ignition OFF.

Disconnect PCM C1915B (1.5L EcoBoost).

Disconnect PCM C1381B (2.0L EcoBoost).

Disconnect PCM C1551B (2.5L Duratec).

Disconnect PCM C1231B (2.7L EcoBoost).

Ignition ON.

For the 2.0L EcoBoost or 2.5L Duratec, perform a wiggle test on the generator wiring and measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1558A-2 Ground

For all other engines, perform a wiggle test on the generator wiring and measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C102A-2 Ground

Is any voltage present?

Yes

REPAIR the circuit.

GO to H6

H6 CHECK THE GENERATOR COMMAND CIRCUIT FOR A SHORT TO GROUND

Ignition OFF.

For the 2.0L EcoBoost or 2.5L Duratec, perform a wiggle test on the generator wiring and measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1558A-2 Ground

For all other engines, perform a wiggle test on the generator wiring and measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C102A-2 Ground

Is the resistance greater than 10,000 ohms?

Yes

GO to H7

No	REPAIR the circuit.

H7 CHECK THE GENERATOR COMMAND CIRCUIT FOR AN OPEN

For the 1.5L EcoBoost, perform a wiggle test on the generator wiring and measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1915B-59 C102A-2

For the 2.0L EcoBoost, perform a wiggle test on the generator wiring and measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1381B-59 C1558A-2

For the 2.5L Duratec, perform a wiggle test on the generator wiring and measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1551B-64 C1558A-2

For the 2.7L EcoBoost, perform a wiggle test on the generator wiring and measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1231B-59 C102A-2

Is the resistance less than 3 ohms?

Yes

GO to H8

No	REPAIR the circuit.

H8 COMPARE THE GENERATOR MONITOR (GENMON) AND GENERATOR COMMAND (GENCMD) PIDS

Ignition OFF.

Connect BJB fuse 7 (20A).

Connect PCM C1915B (1.5L EcoBoost).

Connect PCM C1381B (2.0L EcoBoost).

Connect PCM C1551B (2.5L Duratec).

Connect PCM C1231B (2.7L EcoBoost).

For the 2.0L EcoBoost or 2.5L Duratec, connect a fused jumper wire:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1558A-1 C1558A-2

For all other engines, connect a fused jumper wire:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C102A-1 C102A-2

Start the engine.

Using a diagnostic scan tool, view PCM Parameter Identifications (PIDs).

Monitor the PCM Parameter Identifications (PIDs) GENMON and GENCMD.

Perform a wiggle test of the generator wiring and connections.

Do the Parameter Identifications (PIDs) read within 5% of each other?

Yes

REMOVE the fused jumper wire. GO to H10

No	REMOVE the fused jumper wire. GO to H9

H9 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION

Ignition OFF.

Disconnect and inspect all PCM connectors.

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

Reconnect the PCM connectors. Make sure they seat and latch correctly.

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

Is the concern still present?

Yes

Click here to access Guided Routine (PCM). Ford Fusion. Charging System. Diagnosis and Testing

Internet Explorer version 11 or greater is required to perform this Pinpoint Test.
CLEAR all Diagnostic Trouble Codes (DTCs) in all modules.

No	The system is operating correctly at this time. The concern may have been caused by module connections. ADDRESS the root cause of any connector or pin issues.

H10 CHECK GENERATOR CLUTCH OPERATION

Ignition OFF.

Perform the generator clutch component test. GO to Pinpoint Test K

Is the generator clutch OK?

Yes

No	INSTALL a new generator clutch. REFER to: Generator Pulley (414-02 Generator and Regulator, Removal and Installation).

DTC P0625 or P0626

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

Normal Operation and Fault Conditions

The PCM monitors the generator output via the generator monitor (GENMON) circuit (generator field terminal circuit). If the PCM cannot read the GENMON circuit due to an open or short to ground, when the engine speed is greater than 2,000 rpm, the generator defaults to a steady voltage of 13.5 volts and the PCM sends a request to the IPC to illuminate the charging system warning indicator. A GENMON duty cycle of 3% or less indicates a short to ground fault is present and results in DTC P0625 setting in the PCM . A GENMON duty cycle of 98% or more indicates an open or short to voltage fault is present and results in DTC P0626 setting in the PCM.

Diagnostic Trouble Code (DTC) Fault Trigger Conditions

DTC	Description	Fault Trigger Conditions
P0625	Generator Field Terminal Circuit Low	The PCM sets this DTC if the GENMON circuit is shorted to ground, the "A" sense circuit is open or the B+ circuit is open. This DTC also sets by a faulted PCM or generator.
P0626	Generator Field Terminal Circuit High	The PCM sets this DTC if the GENMON circuit is open or shorted to power. This DTC can also be set by a faulted PCM or generator.

Possible Sources

Battery
Fuses or Fusible Links
Generator
Generator clutch.
PCM
Wiring, terminals or connectors

Visual Inspection and Diagnostic Pre-checks

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

PINPOINT TEST I : DTC P0625 OR P0626

I1 PERFORM INSPECTION AND VERIFICATION

Perform Inspection and Verification procedure in this section.

Was an obvious cause for an observed or reported concern found?

Yes

CORRECT the cause as necessary.

No	CHARGE or INSTALL a new battery as necessary. REFER to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).

I2 CHECK THE GENERATOR CONNECTIONS

Ignition OFF.

Disconnect all of the generator connectors and inspect for:
- 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

Reconnect the generator connectors. Make sure they seat and latch correctly.

Measure and record:

Positive Lead Measurement / Action Negative Lead

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C102C-1 Ground

Is the voltage within 0.5 volt of the recorded battery voltage?

Yes

GO to I3

TIGHTEN or INSTALL a new generator B+ nut as needed. For 1.5L EcoBoost,
REFER to: Generator - 1.5L EcoBoost (118kW/160PS) – I4 (414-02 Generator and Regulator, Removal and Installation).
For 2.0L EcoBoost, REFER to: Generator - 2.0L EcoBoost (184kW/250PS) – MI4 (414-02 Generator and Regulator, Removal and Installation).
For 2.5L Duratec, REFER to: Generator - 2.5L Duratec (125kW/170PS) (414-02 Generator and Regulator, Removal and Installation).
For 2.7L EcoBoost, REFER to: Generator - 2.7L EcoBoost (238kW/324PS) (414-02 Generator and Regulator, Removal and Installation).
VERIFY high current BJB MEGA 8 fuse (275A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams manual to identify the possible causes of the circuit short.

I3 CHECK THE VOLTAGE DROP IN THE GENERATOR B+ CIRCUIT

Start the engine.

With the engine running at idle, headlamps on and blower on high, measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C102C-1

Perform a wiggle test of the generator wiring and connections while measuring voltage drop.

Is the voltage drop less than 0.5 volt?

Yes

For DTC P0625, GO to I4
For DTC P0626, GO to I5

No	INSPECT and REPAIR any corrosion in the generator B+ circuit or positive battery cable connections.

I4 "A" SENSE CIRCUIT LOAD TEST

Ignition OFF.

Disconnect Generator C1558A (2.0L EcoBoost or 2.5L Duratec).

Disconnect Generator C102A (All other engines).

Ignition ON.

Measure and record:

Positive Lead Measurement / Action Negative Lead

For the 2.0L EcoBoost or 2.5L Duratec, install a test lamp between:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1558A-3 Ground

For all other engines, install a test lamp between:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C102A-3 Ground

For the 2.0L EcoBoost or 2.5L Duratec, perform a wiggle test on the generator wiring and measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1558A-3 Ground

For all other engines, perform a wiggle test on the generator wiring and measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C102A-3 Ground

Is the "A" sense voltage within ±0.5 volt of the recorded battery voltage?

Yes

GO to I5

No	VERIFY high current BJB fuse 55 (10A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams manual to identify the possible causes of the circuit short.

I5 CHECK THE GENERATOR MONITOR CIRCUIT FOR A SHORT TO VOLTAGE

Ignition OFF.

Disconnect PCM C1915B (1.5L EcoBoost).

Disconnect PCM C1381B (2.0L EcoBoost).

Disconnect PCM C1551B (2.5L Duratec).

Disconnect PCM C1231B (2.7L EcoBoost).

Ignition ON.

For the 2.0L EcoBoost or 2.5L Duratec, perform a wiggle test on the generator wiring and measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1558A-1 Ground

For all other engines, perform a wiggle test on the generator wiring and measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C102A-1 Ground

Is any voltage present?

Yes

REPAIR the circuit.

GO to I6

I6 CHECK THE GENERATOR MONITOR CIRCUIT FOR A SHORT TO GROUND

Ignition OFF.

For the 2.0L EcoBoost or 2.5L Duratec, perform a wiggle test on the generator wiring and measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1558A-1 Ground

For all other engines, perform a wiggle test on the generator wiring and measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C102A-1 Ground

Is the resistance greater than 10,000 ohms?

Yes

GO to I7

No	REPAIR the circuit.

I7 CHECK THE GENERATOR MONITOR CIRCUIT FOR AN OPEN

For the 1.5L EcoBoost, perform a wiggle test on the generator wiring and measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1915B-26 C102A-1

For the 2.0L EcoBoost, perform a wiggle test on the generator wiring and measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1381B-26 C1558A-1

For the 2.5L Duratec, perform a wiggle test on the generator wiring and measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1551B-26 C1558A-1

For the 2.7L EcoBoost, perform a wiggle test on the generator wiring and measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1231B-26 C102A-1

Is the resistance less than 3 ohms?

Yes

GO to I8

No	REPAIR the circuit.

I8 CHECK THE GENERATOR B+ INTERNAL RESISTANCE

NOTE: Failure to disconnect the battery will result in false resistance readings. Disconnect the battery.
REFER to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

Disconnect Generator C102C .

Measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

Generator B+ Terminal Generator case

Is the resistance greater than 25K ohms?

Yes

GO to I9

GO to I12

I9 CHECK THE RESISTANCE OF THE VOLTAGE REGULATOR INTERNAL CIRCUITS

Measure:
Click to display connectors

Positive Lead	Measurement / Action	Negative Lead
Generator pin 1 (Component Side)		Generator case
Generator pin 2 (Component Side)		Generator case
Generator pin 3 (Component Side)		Generator case

Are the resistances greater than 10,000 ohms?

Yes

GO to I10

GO to I12

I10 COMPARE THE GENMON AND THE GENCMD PIDS

Connect PCM C1915B (1.5L EcoBoost).

Connect PCM C1381B (2.0L EcoBoost).

Connect PCM C1551B (2.5L Duratec).

Connect PCM C1231B (2.7L EcoBoost).

For the 2.0L EcoBoost or 2.5L Duratec, connect a fused jumper wire:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C1558A-1 C1558A-2

For all other engines, connect a fused jumper wire:
Click to display connectors

Positive Lead Measurement / Action Negative Lead

C102A-1 C102A-2

Start the engine.

Using a diagnostic scan tool, view PCM Parameter Identifications (PIDs).

Using the active command, set the PID GENVDSD to 14 volts.

Monitor the PCM Parameter Identifications (PIDs) GENMON and GENCMD.

Perform a wiggle test of the generator wiring and connections.

Do the Parameter Identifications (PIDs) read within 5% of each other?

Yes

REMOVE the fused jumper wire. GO to I12

No	REMOVE the fused jumper wire. GO to I11

I11 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION

Ignition OFF.

Disconnect and inspect all PCM connectors.

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

Reconnect the PCM connectors. Make sure they seat and latch correctly.

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

Is the concern still present?

Yes

Click here to access Guided Routine (PCM). Ford Fusion. Charging System. Diagnosis and Testing

Internet Explorer version 11 or greater is required to perform this Pinpoint Test.
CLEAR all Diagnostic Trouble Codes (DTCs) in all modules.

No	The system is operating correctly at this time. The concern may have been caused by module connections. ADDRESS the root cause of any connector or pin issues.

I12 CHECK GENERATOR CLUTCH OPERATION

Ignition OFF.

Perform the generator clutch component test. GO to Pinpoint Test K

Is the generator clutch OK?

Yes

No	INSTALL a new generator clutch. REFER to: Generator Pulley (414-02 Generator and Regulator, Removal and Installation).

Load Shed Message Displays in Message Center

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

Normal Operation and Fault Conditions

When the engine is off and the key is in on or accessory mode, and the BCM determines the battery state of charge is below 50%, or 45 minutes have elapsed, a load shed message is sent over the CAN. This message turns off the audio/navigation system to save the remaining battery charge. Under this condition the a load shed message will be displayed to notify the driver that battery protection actions are active:

System Off to Save Battery Turn Ignition Off displays on the FCDIM (without touchscreen controls)
SYSTEM OFF TO SAVE BATTERY PLEASE TURN IGNITION OFF OR START ENGINE displays on the FDIM (with touchscreen controls)
Battery Saver - System Off displays on the FDIM (with Sync)

These messages displaying may be normal operation and not indicate a fault. Refer to the Owner Literature and
REFER to: Charging System - System Operation and Component Description (414-00 Charging System - General Information, Description and Operation).
Load shed messages displaying with the engine running or only on the FCDIM or the FDIM (with touchscreen controls) indicates the audio system has detected a fault.

Possible Sources

Normal operation
Audio system
Battery
BCM
Fuses or Fusible Links
Generator
Wiring, terminals or connectors

Visual Inspection and Diagnostic Pre-checks

Inspect the high current BJB for loose or corroded connections.
Inspect the battery for loose or corroded connections.
Inspect the generator for loose or corroded connections.
Inspect the BJB for loose or corroded connections.
Inspect the high current BJB for loose or corroded connections.
Inspect C146 for loose or corroded connections.
Inspect battery and engine grounds for loose or corroded connections.

PINPOINT TEST J : LOAD SHED MESSAGE DISPLAYS IN MESSAGE CENTER

J1 PERFORM INSPECTION AND VERIFICATION

Perform Inspection and Verification procedure in this section.

Was an obvious cause for an observed or reported concern found?

Yes

CORRECT the cause as necessary.

GO to J2

J2 VERIFY THE CUSTOMER CONCERN

Verify the customer concern by operating the charging system.

Did the customer indicate battery saver message only appeared in the centerstack with the engine running?

Yes

Without touch screen or Sony audio,
REFER to: Information and Entertainment System (415-00 Information and Entertainment System - General Information) .
With touch screen, REFER to: Information and Entertainment System (415-00 Information and Entertainment System - General Information) .
With Sony Audio, REFER to: Information and Entertainment System (415-00 Information and Entertainment System - General Information) .

GO to J3

J3 VERIFY THE NETWORK

Ignition ON.

Using a diagnostic scan tool, perform the Network Test.

Did the APIM, BCM, and PCM pass the Network Test?

Yes

GO to J4

No	REFER to: Communications Network (418-00 Module Communications Network, Diagnosis and Testing).

J4 PERFORM PCM (POWERTRAIN CONTROL MODULE) SELF TEST

Ignition ON.

Using a diagnostic scan tool, perform the PCM self-test.

Were any battery or charging system related Diagnostic Trouble Codes (DTCs) retrieved?

Yes

REFER to PCM DTC chart in this section.

GO to J5

J5 RETRIEVE ALL CONTINUOUS MEMORY DIAGNOSTIC TROUBLE CODES (CMDTCS)

Ignition ON.

Using a diagnostic scan tool, retrieve all Continuous Memory Diagnostic Trouble Codes (CMDTCs).

Were any battery or charging system related Diagnostic Trouble Codes (DTCs) retrieved?

Yes

For BCM Diagnostic Trouble Codes (DTCs) refer to BCM DTC chart in this section.
For APIM or ACM Diagnostic Trouble Codes (DTCs), Refer to the appropriate section in Group 415 for the procedure.
For other battery or charging system related Diagnostic Trouble Codes (DTCs),
REFER to: Diagnostic Trouble Code Charts (100-00 General Information, Diagnosis and Testing).

GO to J6

J6 CHECK BCM (BODY CONTROL MODULE) BAT_ST_CHRG PID (PARAMETER IDENTIFICATION)

Ignition ON.

Using a diagnostic scan tool, view the BCM Parameter Identifications (PIDs).

Monitor the BCM BAT_ST_CHRG PID.

Does the PID indicate 50% or more?

Yes

GO to J8

GO to J7

J7 RELEARN BATTERY STATE OF CHARGE

NOTE: The battery state of charge is too low and needs to be relearned. Refer to the Description and Operation in this section for more information on battery state of charge.

Remove all accessories from the lighter, all power outlets and DC/AC inverter.

NOTE: The key should not be left in the vehicle but should be left in a secure location away from the vehicle such as a lock box. Allow vehicle to sit undisturbed for at least 6 hours.

Ignition ON.

Using a diagnostic scan tool, view the BCM Parameter Identifications (PIDs).

Monitor the BCM BAT_ST_CHRG PID.

Does the PID indicate 50% or more?

Yes

The concern may have been caused by too low of a battery state of charge. REVIEW Energy Management operation with customer and return vehicle to customer.

GO to J8

J8 VERIFY INLINE CONNECTOR

Inspect inline connector C146 for secure connection.

Disconnect Inline connector C146 .

Inspect for:
- 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

Were any concerns present?

Yes

CORRECT the cause as necessary.

GO to J9

J9 CHECK FOR CORRECT BCM (BODY CONTROL MODULE) OPERATION

Ignition OFF.

Disconnect and inspect all BCM connectors.

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

Reconnect the BCM connectors. Make sure they seat and latch correctly.

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

Is the concern still present?

Yes

Click here to access Guided Routine (BCM). Ford Fusion. Charging System. Diagnosis and Testing

Internet Explorer version 11 or greater is required to perform this Pinpoint Test.
CLEAR all Diagnostic Trouble Codes (DTCs) in all modules.

No	The system is operating correctly at this time. The concern may have been caused by module connections. ADDRESS the root cause of any connector or pin issues.

Generator Clutch Component Test

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

Normal Operation and Fault Conditions

The generator clutch allows the generator rotor to continue to rotate when the engine or FEAD system slows. The clutch should slip freely and smoothly in a clockwise direction. It should not rotate freely in the counterclockwise direction. A loose FEAD belt or a weak or binding tensioner can cause the pulley to overheat.
REFER to: Charging System - System Operation and Component Description (414-00 Charging System - General Information, Description and Operation).

PINPOINT TEST K : GENERATOR CLUTCH COMPONENT TEST

K1 INSPECT THE GENERATOR CLUTCH

Remove the generator. For 1.5L EcoBoost,
REFER to: Generator - 1.5L EcoBoost (118kW/160PS) – I4 (414-02 Generator and Regulator, Removal and Installation).
For 2.0L EcoBoost, REFER to: Generator - 2.0L EcoBoost (184kW/250PS) – MI4 (414-02 Generator and Regulator, Removal and Installation).
For 2.5L Duratec, REFER to: Generator - 2.5L Duratec (125kW/170PS) (414-02 Generator and Regulator, Removal and Installation).
For 2.7L EcoBoost, REFER to: Generator - 2.7L EcoBoost (238kW/324PS) (414-02 Generator and Regulator, Removal and Installation).

Inspect the generator clutch for heat damage.

Is there evidence of heat damage?

Yes

INSTALL a new generator clutch.
REFER to: Generator Pulley (414-02 Generator and Regulator, Removal and Installation).
INSPECT the FEAD system. For 1.5L EcoBoost,
REFER to: Accessory Drive (303-05A Accessory Drive - 1.5L EcoBoost (118kW/160PS) – I4, Diagnosis and Testing).
For 2.0L EcoBoost, REFER to: Accessory Drive (303-05B Accessory Drive - 2.0L EcoBoost (184kW/250PS) – MI4, Diagnosis and Testing).
For 2.5L Duratec, REFER to: Accessory Drive (303-05C Accessory Drive - 2.5L Duratec (125kW/170PS), Diagnosis and Testing).
For 2.7L EcoBoost, REFER to: Accessory Drive (303-05D Accessory Drive - 2.7L EcoBoost (238kW/324PS), Diagnosis and Testing).

GO to K2

K2 CHECK THE GENERATOR CLUTCH FOR SMOOTH ROTATION

Using a small screwdriver or similar tool, insert the tool through the rubber button on the center of the pulley cap and pry off the cap. Discard the cap. A new cap must be installed.

Using a 17 mm hex tool bit (such as a Snap-on® SAM17E2 or equivalent) and socket wrench, insert the 17 mm hex tool bit into the end of the clutch shaft.

While holding the clutch pulley firmly by hand, turn the clutch shaft clockwise. The clutch shaft should rotate smoothly and freely.

Does the clutch shaft rotation feel rough or seized?

Yes

INSTALL a new generator clutch.
REFER to: Generator Pulley (414-02 Generator and Regulator, Removal and Installation).

GO to K3

K3 CHECK FOR REVERSE ROTATION RESISTANCE

While holding the clutch pulley firmly by hand, turn the clutch shaft counterclockwise.

Is there some resistance (a spring feel)?

Yes

GO to K4

No	INSTALL a new generator clutch. REFER to: Generator Pulley (414-02 Generator and Regulator, Removal and Installation).

K4 CHECK FOR REVERSE ROTATION

While holding the clutch pulley firmly by hand, turn the clutch shaft counterclockwise.

Does the clutch shaft rotate freely?

Yes

INSTALL a new generator clutch.
REFER to: Generator Pulley (414-02 Generator and Regulator, Removal and Installation).

Charging System - System Operation and Component Description. Description and Operation

System Operation System Diagram Network Message Chart Module Network Input Messages — Body Control Module (BCM) Broadcast Message Originating Module Message Purpose Alternator fault PCM The PCM has detected a fault in the generator or generator circuits...

Battery, Mounting and Cables

Other information:

Ford Fusion 2013–2020 Service Manual: Radio Transceiver Module (RTM). Removal and Installation

Removal NOTICE: Use care to not crease the headliner during removal and installation or damage to the headliner can occur. NOTE: Removal steps in this procedure may contain installation details. WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in section 100-00 General Information. Failure to follow this instruction may result ..

Ford Fusion 2013–2020 Owners Manual: About This Manual

Thank you for choosing Ford. We recommend that you take some time to get to know your vehicle by reading this manual. The more that you know about your vehicle, the greater the safety and pleasure you will get from driving it. WARNING: Driving while distracted can result in loss of vehicle control, crash and injury. We strongly recommend that you use extreme caution when using any device ..

Understanding Your Tire Pressure Monitoring System

Ford Fusion. Understanding Your Tire Pressure Monitoring System

The tire pressure monitoring system measures pressure in your road tires and sends the tire pressure readings to your vehicle. You can view the tire pressure readings through the information display. The low tire pressure warning light will turn on if the tire pressure is significantly low. Once the light is illuminated, your tires are under-inflated and need to be inflated to the manufacturer’s recommended tire pressure. Even if the light turns on and a short time later turns off, your tire pressure still needs to be checked.

Ford Fusion: Charging System - General Information / Charging System. Diagnosis and Testing

Charging System - System Operation and Component Description. Description and Operation

Battery, Mounting and Cables

Other information:

Ford Fusion 2013–2020 Service Manual: Radio Transceiver Module (RTM). Removal and Installation

Ford Fusion 2013–2020 Owners Manual: About This Manual

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Understanding Your Tire Pressure Monitoring System