Ford Galaxy / Ford S-MAX. Manual — part 717

Supplementary heater

Instrument cluster

Battery

Charging is controlled by the PCM and the GEM. The PCM communicates with the generator
control module using a LIN connection. The PCM will instruct the generator to increase or
decrease charging voltages in accordance with the requirements of the power supply
systems. In turn the generator control module will inform the PCM of the current output of
the generator.

The generator control module monitors the generator output. If a fault develops in the
generator control module, control circuits or the generator, the PCM will be informed and a
diagnostic trouble code (DTC) will be set.

Using the information received by the PCM from the generator control module, the PCM can
calculate the generator load. The generator load information is transferred to the GEM using
CAN communication. The GEM uses the load information to calculate maximum allowable
current consumption of the climate related systems. The GEM also controls the initiation of
fault warnings to the display information module. The battery charge warning indicator is
turned off by means of an instruction from the GEM using CAN communication.

To reduce the load on the generator to within its working limits and assist with battery
recovery after start up, the GEM will switch non critical systems off and on.

The systems that are controlled by the GEM have typical loads of:

Heated windshield

70 amps

Heated rear screen

25 amps

Heated mirrors

4 amps

Supplementary heating

80 amps

The climate systems have been chosen because they can be switched off for short periods
of time with barely detectable changes in their ultimate function. During this control period,
the function indicators for the system being controlled will remain illuminated. The total load
reduction if all controlled components where switched off would be in the region of 180
amps.

Conversely, the GEM can switch the same components on at any time thereby increasing
engine load. This function is used to assist with the engine warm up process.

Inspection and Verification

WARNINGS:

Batteries contain sulphuric acid. Avoid contact with skin, eyes, or clothing. Also,

shield your eyes when working near batteries to protect against possible splashing of the
acid solution. In case of acid contact with skin or eyes, flush immediately with water for a
minimum of 15 minutes and get prompt medical attention. If acid is swallowed, call a
physician immediately. Failure to follow these instructions may result in personal injury.

Batteries normally produce explosive gases which can cause personal injury.

Therefore, do not allow flames, sparks or lighted substances to come near the battery.
When charging or working near a battery, always shield your face and protect your eyes.
Always provide ventilation. Failure to follow these instructions may result in personal
injury.

1. 1. Verify the customer concern.

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2. 2. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

3. 3. If an obvious cause for an observed or reported concern is found, correct the cause

(if possible) before proceeding to the next step.

4. 4. Check the operation of the charging system warning indicator lamp, located in the

instrument cluster. Normal operation is as follows:

Normal Charging System Voltages

5. 5. If the cause is not visually evident, verify the symptom and refer to the Symptom

Chart.

Symptom Chart

Mechanical

Electrical

Accessory drive belt
Generator
Generator decoupler (if equipped)

Fuse(s)
Wiring harness
Electrical connector(s)
Battery junction box (BJB)
Battery
Battery cables
Charging system warning indicator
PCM
GEM

Ignition Switch

Position

I

Circuit

Generator B+

Circuit

Battery

Engine to

battery

ground

Charging System

Warning Indicator

Operation

Position 0

0V

10-12V

10-12V

0V

OFF

Position II

0V

10-12V

10-12V

0V

Illuminated

Position II with
the engine
running

13-15V 13-15V

13-15V

0V

OFF

Symptom

Possible Sources

Action

The charging system
warning indicator is on
with the engine running
and the battery does not
increase voltage.

Accessory drive

belt.

*

CHECK the condition and installation of the

accessory drive belt. INSTALL a new
accessory drive belt or tensioner as required.
CHECK the system for normal operation.

*

Generator.
Generator

control module.

Generator LIN

communication
system.

PCM.
GEM.

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*

*

*
*

Using the Ford approved diagnostic tool,

RETRIEVE and RECTIFY the charging related
DTCs from the PCM and the GEM. TEST the
system for normal operation.

*

The charging system
warning indicator is on
with the engine running
and the battery increases
voltage.

GEM.
PCM.
Instrument

cluster.

Instrument

cluster CAN bus
system.

Generator.
Generator

control module.

*
*
*

*

*
*

Using the Ford approved diagnostic tool,

RETRIEVE and RECTIFY the charging system
indicator related DTCs from the GEM and the
PCM. TEST the system for normal operation.

*

Component Tests

Generator On-Vehicle Tests - No-Load Test

1. 1. REFER to the

Ford approved diagnostic tool

Generator On-Vehicle Tests - Load Test

1. 1. REFER to the

Ford approved diagnostic tool

Battery Identification

Description

Cold crank amp (CCA) rating

Reserve capacity (RC) rating (minutes)

Battery voltage

Ford part number

FINIS code

EN number (European Norm)

Battery type: Ca = Silver/Calcium; Sb = Lead/Antimony

Generator LIN

communication
system.

*

The charging system
warning indicator is off
with ignition switch in the
RUN position and the
engine off.

GEM.
Instrument

cluster.

Instrument

cluster CAN bus
system.

*
*

*

Using the Ford approved diagnostic tool,

RETRIEVE and RECTIFY the charging system
indicator related DTCs from the GEM. TEST
the system for normal operation.

*

Vehicle electrical systems
inoperative

Battery.

*

CARRY OUT the battery test, REFER to the

Battery Test in Component Tests in this
section.

*

The engine cranks slowly

Battery.

*

CARRY OUT the battery test, REFER to the

Battery Test in Component Tests in this
section.

*

Battery cable(s).
Starter motor.

*
*

REFER to:

Starting System

(303-06A

Starting System - 2.0L Duratec-HE
(107kW/145PS) - MI4/2.0L Duratec-HE Flex
Fuel (107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4, Diagnosis and
Testing).

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Amp hour rating

Battery Surface Charge Removal

Surface charge dissipation unit (SCD²)

Description

Connect black lead to battery - Connect red lead to battery +

Red A indicator illuminates and green B indicator flashes

Wait until green B indicator illuminates

Disconnect from battery

Max 18v

-20°C to +55°C

Red indicator (A)

Green indicator (B)

CAUTION: Prior to testing any battery, the surface discharge must be dissipated. This

includes batteries that are returned disconnected from the vehicle. If the battery is
holding a surface charge, the battery tester will give false readings.
NOTE: The SCD² tool eliminates the need to dissipate the battery's surface charge via the
manual process of loading the battery via the operation of the vehicles electrical systems.
It also removes the variability in the process and makes sure that the actual dissipation of
the surface charge is qualified prior to testing.

1. 1. Remove the battery.

REFER to:

Battery

(414-01 Battery, Mounting and Cables, Removal and Installation).

2. 2. Connect the black lead to the battery negative terminal and the red lead to the

battery positive terminal.

3. 3. The red indicator (A) illuminates and the green indicator (B) flashes.

4. 4. Wait until the green indicator (B) fully illuminates, then disconnect from the

battery.

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