Ford Falcon. Manual — part 354

414-02-9

Alternator and Regulator

414-02-9

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST C : THE CHARGING SYSTEM WARNING INDICATOR IS ON WITH THE ENGINE

RUNNING (THE BATTERY VOLTAGE INCREASES)

Test Step

Result / Action to Take

C1

CHECK CONNECTOR C161

Make sure that connector C161 is correctly mated to the alternator

Yes

and making contact.

Go to C2

Is the connection OK?

No

REPAIR connector C161 as necessary.
Test the system for normal operation.

C2

CHECK THE ALTERNATOR OUTPUT VOLTAGE

With the engine running at 2000 rpm, measure the voltage output at

Yes

the alternator B+ terminal.

REPLACE voltage regulator.
Test the system for normal operation.

Is the voltage output less than 16 volts?

No

Go to H1

PINPOINT TEST D : THE CHARGING SYSTEM WARNING INDICATOR IS OFF WITH THE IGNITION

SWITCH IN THE RUN POSITION AND THE ENGINE OFF (THE BATTERY VOLTAGE INCREASES)

Test Step

Result / Action to Take

D1

CHECK THE CHARGING SYSTEM WARNING

INDICATOR OPERATION

Key in ON position.

Yes

Go to D2

Disconnect The alternator connector C161.

No

Ground the alternator connector C161 I circuit with the ignition switch

REPAIR connector C161, I Circuit 904 (GY/R)

in the RUN position and the engine OFF.

as necessary.

Ensure connector C390 is correctly assembled.

Test the system for normal operation.

Is the warning indicator ON?

D2

CHECK THE ALTERNATOR

Connect C161 connector.

Yes

REPLACE the alternator.

Observe the warning indicator.

Test the system for normal operation.

Is the warning indicator ON?

No

REPLACE the voltage regulator.
Test the system for normal operation.

PINPOINT TEST E : THE CHARGING SYSTEM WARNING OPERATES CORRECTLY BUT THE BATTERY

VOLTAGE DOES NOT INCREASE.

Test Step

Result / Action to Take

E1

CHECK CIRCUIT 36 (Y/W)

Key in ON position.

Yes

Go to E2

Measure the voltage between the B+ terminal on the alternator Circuit
36 (Y/W).

No

REPAIR Circuit 36 (Y/W) as necessary.

Is the voltage equal to battery positive voltage (B+)?

Test the system for normal operation.

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414-02-10

Alternator and Regulator

414-02-10

DIAGNOSIS AND TESTING (Continued)

Test Step

Result / Action to Take

E2

CHECK THE ALTERNATOR CONNECTORS

Check the battery terminals and alternator connectors C161 &

Yes

C390for corrosion and tightness.

Perform the Alternator On-Vehicle Tests;
REFER to Component Tests in this section.

Are all the connectors clean and tight?

No

REPAIR the connectors as necessary.
Test the system for normal operation.

PINPOINT TEST F : THE BATTERY IS DEAD OR WILL NOT STAY CHARGED OR LOW BATTERY OR

ALTERNATOR VOLTAGE

Test Step

Result / Action to Take

F1

CHECK THE BATTERY DRAIN

Key in OFF position.

Yes

PERFORM Battery - Drain Testing.

Make sure that all interior and exterior lamps and switches are off.

REFER to Component Tests in this section.

Check the battery drain.

No

Is the drain greater than 0.5 amps?

Go to F2

F2

CHECK THE ALTERNATOR OUTPUT

Check the alternator output. Perform Alternator On-Vehicle Tests;

Yes

refer to Component Tests in this section.

Go to F3

Is the alternator OK?

No

REPLACE the alternator.
Test the system for normal operation.

F3

CHECK THE BATTERY CONDITION

Check the battery capacity. with the Midtronic handheld battery tester.

Yes

Go to F4

Is the battery OK?

No

REPLACE the battery.
Test the system for normal operation.

F4

CHECK OTHER ELECTRICAL SYSTEMS FOR DRAINS

Check the drains from electronic modules. Perform the test for

Yes

Battery-Electronic Drains Which Shut Off When the Battery Cable is

RECHARGE the battery.

Disconnected; refer to Component Tests in this section.

Test the system for normal operation.

Are the electronic modules OK?

No

REPLACE the module or REPAIR the circuit
causing the electrical drain as necessary.
Test the system for normal operation.

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414-02-11

Alternator and Regulator

414-02-11

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST G : THE SYSTEM OVERCHARGES (BATTERY VOLTAGE IS GREATER THAN 15.5

VOLTS)

Test Step

Result / Action to Take

G1

CHECK FOR A VOLTAGE DROP

Key in ON position.

Yes

Go to G2

Check for voltage drop from the battery positive post and the voltage
regulator ’A’ terminal.

No

REPAIR Circuit 36 (Y/W) for high resistance as

Is the voltage drop less than 0.5 volts?

necessary.
Test the system for normal operation.

G2

CHECK THE BATTERY VOLTAGE

With the engine running, turn off all accessories.

Yes

Go to G3

Increase the engine speed and monitor the voltage at the battery.

No

Does the battery voltage remain less than 15 volts?

Go to G6

G3

CHECK THE ALTERNATOR FOR LOW VOLTAGE

Key in OFF position.

Yes

Go to G5

Measure the voltage at the voltage regulator F terminal.

No

Does the voltage equal battery voltage?

Go to G4

G4

CHECK FOR GROUNDED SLIP RINGS

Key in OFF position.

Yes

REPLACE the alternator.

Disconnect The alternator connector C161.

Test the system for normal operation.

Remove the voltage regulator from the alternator.

No

Measure the resistance from both alternator slip rings to ground.

REPLACE the voltage regulator.
Test the system for normal operation.

Is the resistance greater than 1K ohms?

G5

CHECK THE WARNING SYSTEM INDICATOR

OPERATION

With the engine running, increase the engine speed, check the

Yes

indicator operation and check for a battery voltage increase.

REPAIR circuit 904 (GY/R) as necessary.
Test the system for normal operation.

Does the battery voltage increase above 15 volts or does the
indicator flicker?

No

REPLACE the alternator.
Test the system for normal operation

G6

CHECK THE WARNING SYSTEM INDICATOR

OPERATION

With the engine running, increase the engine speed, check the

Yes

indicator operation and check for a battery voltage increase.

REPAIR circuit 904 (GY/R) as necessary.
Test the system for normal operation.

Does the battery voltage increase above 15 volts or does the
indicator flicker?

No

REPLACE the alternator.
Test the system for normal operation.

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Alternator and Regulator

414-02-12

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST H : BATTERY LEAKAGE OR DAMAGE

Test Step

Result / Action to Take

H1

CHECK FOR ACID LEAKAGE OR DAMAGE

Check for acid damage to the vehicle harnesses and to the body.

Yes

REPAIR the damaged areas as necessary.

Is there acid damage?

No

Go to H2

H2

CHECK THE CHARGING SYSTEM FOR

OVERCHARGING

With the engine running, turn off all the accessories. Increase the

Yes

engine speed and monitor the voltage at the battery.

Go to G1

Does battery voltage increase more than 15 volts?

No

Go to H3

H3

CHECK THE BATTERY MOUNTING

Make sure the battery is properly mounted and level in the battery

Yes

tray.

Go to H4

Is the battery properly mounted?

No

Install the battery.
Test the system for normal operation.

H4

CHECK FOR BATTERY CONTACT

Make sure that there are no fasteners or other parts contacting the

Yes

battery case causing excess pressure.

REMOVE or REPOSITION these items as
necessary.

Is there anything contacting the battery case?

Test the system for normal operation.

No

Go to H5

H5

CHECK THE BATTERY LEAKAGE OR DAMAGE

Check the battery case for damage such as cracks or poor seals.

Yes

The charging system is OK.

Is the battery OK?

Test the system for normal operation.

No

REPLACE the battery.
Test the system for normal operation.

PINPOINT TEST I : THE VOLTAGE GAUGE READS HIGH OR LOW

Test Step

Result / Action to Take

I1

CHECK THE BATTERY VOLTAGE

With the engine running, turn off all accessories. Increase the engine

Yes

speed and monitor the voltage at the battery.

Go to G1

Is the battery voltage more than 15 volts?

No

Go to I2

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