Ford Escape: Charging System - General Information / Diagnosis and Testing - Charging System - 1.5L EcoBoost (132kW/180PS) – I3 (Y1)

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.

DTC Fault Trigger Conditions

Possible Sources

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

Visual Inspection and Pre-checks

• Inspect GND G107, G106 and G109 for loose, damaged or corroded connections.
• Inspect the high current BJB for loose, damaged or corroded connections.

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.

• Perform Inspection and Verification procedure in this section.

• Start the engine.

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

• Monitor the PCM GENVDSD PID .

• With the engine still running at idle, measure and record:

  Positive Lead	Measurement / Action	Negative Lead

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

• With the engine still running at idle, headlamps on and heater blower on high, measure the voltage drop between generator case and the battery negative terminal

• Measure and record:

  Positive Lead	Measurement / Action	Negative Lead
  Generator case

• 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 still running at idle, measure battery and record:

  Positive Lead	Measurement / Action	Negative Lead

• Increase the engine rpm until the generator starts to generate output.

• With the engine running, measure and record:

  Positive Lead	Measurement / Action	Negative Lead
  		Ground

• 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.

• Turn the headlamps and heater blower off.

• Ignition OFF.

• Disconnect PCM C175B .

• Connect a 5 amp fused jumper wire between the following:
  Click to display connectors
  

  Positive Lead	Measurement / Action	Negative Lead
  PCMRC (PCM Relay Control) C175B-25		Ground

• KOEO

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

  Positive Lead	Measurement / Action	Negative Lead
  C175B-100		Ground
  C175B-101		Ground
  C175B-102		Ground

• 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.

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 TSB 's address this concern,    VIN required to access Guided Routine (PCM) .

Normal Operation and Fault Conditions

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

DTC Fault Trigger Conditions

Possible Sources

• Battery
• Fuses or fusible links
• Generator
• PCM
• Wiring, terminals or connectors

Visual Inspection and Pre-checks

• Inspect the FEAD system. REFER to 303-05.
• Inspect for abnormal ignition-off current drain(s).
• Inspect the battery.
• Inspect the high current BJB for loose, damaged or corroded connections.
• Verify high current BJB fuse MEGA (225A).

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.

• Perform Inspection and Verification procedure in this section.

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

• 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
  C1104A-1		Ground

• 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
  C1104A-1

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

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

  Positive Lead	Measurement / Action	Negative Lead
  Generator case

• 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 still running at idle, measure battery and record:

  Positive Lead	Measurement / Action	Negative Lead

• With the engine still 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.

• Ignition OFF.

• Disconnect PCM C175B .

• Connect a 5 amp fused jumper wire between the following:
  Click to display connectors
  

  Positive Lead	Measurement / Action	Negative Lead
  PCMRC (PCM Relay Control) C175B-25		Ground

• KOEO

• For 1.5L EcoBoost, measure and record:
  Click to display connectors
  

  Positive Lead	Measurement / Action	Negative Lead
  C175B-100		Ground
  C175B-101		Ground
  C175B-102		Ground

• NOTE: Measure battery voltage at the battery. With the engine still running at idle, turn off all accessory loads, measure and record:

  Positive Lead	Measurement / Action	Negative Lead

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

• With the engine still running at idle, turn headlamps ON and blower on HIGH.

• Measure and record:

  Positive Lead	Measurement / Action	Negative Lead

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

• NOTE: Measure battery voltage at the battery. With the engine still running at idle, turn off all accessory loads.

• 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 .

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

• Monitor the PCM PID INJPWR_M

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

• Monitor the PCM PID INJPWR_M.

• 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.

• 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.

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,    VIN required to access Guided Routine (PCM)

Normal Operation and Fault Conditions

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

DTC Fault Trigger Conditions

Possible Sources

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

Visual Inspection and Pre-checks

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

• Ignition OFF.

• Check the FEAD belt and tensioner for damage and correct installation. REFER to: Accessory Drive (303-05, Diagnosis and Testing).

• Check the generator mounting for loose bolts or misalignment.

• 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.

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.

Normal Operation and Fault Conditions

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

Possible Sources

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

Visual Inspection and Pre-checks

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

• Start the engine.

• Allow the engine to idle.

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

• Ignition OFF.

• Disconnect Generator C1104A .

• Start the engine.

• Allow the engine to idle.

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.

DTC Fault Trigger Conditions

Possible Sources

• Battery monitoring sensor
• BCM
• Generator clutch (if equipped)
• Wiring, terminals or connectors

Visual Inspection and Pre-checks

• Inspect the battery monitoring sensor.
• Inspect the battery monitoring sensor connector.

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.

• 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 .

• 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.

• 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
  C1646-2		Ground

• Ignition ON.

• Measure:
  Click to display connectors
  

  Positive Lead	Measurement / Action	Negative Lead
  C1689-1		Ground

• Ignition OFF.

• Disconnect BCM C2280E .

• Measure:
  Click to display connectors
  

  Positive Lead	Measurement / Action	Negative Lead
  C1689-1		Ground

• Measure:
  Click to display connectors
  

  Positive Lead	Measurement / Action	Negative Lead
  C1689-1		C2280E-45

• 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.

Normal Operation and Fault Conditions

The charging system supplies voltage to the battery and the vehicle electrical system through the battery B+ cable. The PCM monitors the generator output through a LIN communication circuit shared with the automatic grill shutters (AGS). The PCM uses this LIN circuit to communicate the desired voltage setpoint to the generator internal voltage regulator. The generator also uses this to communicate the generator load and error conditions to the PCM .

DTC Fault Trigger Conditions

Possible Sources

• Active grille shutters
• Generator
• PCM
• Wiring, terminals or connectors

Visual Inspection and Pre-checks

• Inspect high current BJB for loose, damaged or corroded connections.
• Inspect the FEAD belt.

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.

• While looking through the grille opening, inspect the vehicle for the presence of grille shutters.
  REFER to: Active Grille Shutter (501-02 Front End Body Panels, Removal and Installation).
  

• Ignition OFF.

• Disconnect Grille Shutter Actuator C1651 .

• Ignition ON.

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

• Measure and record:

  Positive Lead	Measurement / Action	Negative Lead

• Measure:
  Click to display connectors
  

  Positive Lead	Measurement / Action	Negative Lead
  C1104A-1		Ground

• Ignition OFF.

• Disconnect Generator C1104B .

• Disconnect PCM C175B .

• Measure:
  Click to display connectors
  

  Positive Lead	Measurement / Action	Negative Lead
  C1104B-1		Ground

• Ignition OFF.

• Measure:
  Click to display connectors
  

  Positive Lead	Measurement / Action	Negative Lead
  C1104B-1		Ground

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

  Positive Lead	Measurement / Action	Negative Lead
  C1104B-1		C175B-47
  C1104B-1		C1651-2

• 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.

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,    VIN required to access Guided Routine (PCM)

Normal Operation and Fault Conditions

DTC Fault Trigger Conditions

Possible Sources

• PCM

• Ignition ON.

• Using a diagnostic scan tool, clear the Diagnostic Trouble Codes (DTCs).

• Wait 10 seconds.

• Using a diagnostic scan tool, perform the PCM self-test and DIAGNOSE any cooling fan Diagnostic Trouble Codes (DTCs).

Normal Operation and Fault Conditions

DTC Fault Trigger Conditions

Possible Sources

• BCM

• Ignition ON.

• Using a diagnostic scan tool, clear the Diagnostic Trouble Codes (DTCs).

• Wait 10 seconds.

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

Normal Operation and Fault Conditions

CHECK the vehicle service history for recent service actions related to this module.

DTC Fault Trigger Conditions

Possible Sources

• Incomplete or incorrect PMI procedures.

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

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 - 1.5L EcoBoost (132kW/180PS) – I3 (Y1) - System Operation and Component Description (414-00 Charging System - General Information, Description and Operation).

Possible Sources

Visual Inspection and Pre-checks

• Remove the generator.
  REFER to: Generator - 1.5L EcoBoost (132kW/180PS) – I3 (Y1), Vehicles Built From: 2-October-2020 (414-02 Generator and Regulator, Removal and Installation).
  

• Inspect the generator clutch for heat damage.

• 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.

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

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

DTC Fault Trigger Conditions

Possible Sources

• Battery Monitoring Sensor.

• Ignition ON.

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

Normal Operation and Fault Conditions

RETRIEVE DTC from all modules. If any DTC s are found, Refer to DTC Chart in this section. If no DTC s are found,REFER to: Instrumentation, Message Center and Warning Chimes (413-01 Instrumentation, Message Center and Warning Chimes, Diagnosis and Testing).
REFER to: Instrumentation, Message Center and Warning Chimes - Vehicles With: Head Up Display (HUD) (413-01 Instrumentation, Message Center and Warning Chimes, Diagnosis and Testing).

Possible Sources

• Wiring, terminals or connectors
• IPC procedures.
• Generator