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Smart Charge Alternator

This technical service bulletin discusses common problems with Smart Charge alternators, such as those used in Ford Focus vehicles. These alternators communicate with the powertrain control module to vary charging output based on factors like temperature and load. Issues often stem from faulty wiring between the alternator's three-pin plug and the vehicle due to chafed or broken wires inside the nylon sleeving over time. Mechanics are advised to inspect the wiring loom visually and test it for continuity or broken conductors if the alternator warning light is on or it stops charging. A repair harness is available from PowerMax for Ford 6G alternator wiring looms.

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205 views1 page

Smart Charge Alternator

This technical service bulletin discusses common problems with Smart Charge alternators, such as those used in Ford Focus vehicles. These alternators communicate with the powertrain control module to vary charging output based on factors like temperature and load. Issues often stem from faulty wiring between the alternator's three-pin plug and the vehicle due to chafed or broken wires inside the nylon sleeving over time. Mechanics are advised to inspect the wiring loom visually and test it for continuity or broken conductors if the alternator warning light is on or it stops charging. A repair harness is available from PowerMax for Ford 6G alternator wiring looms.

Uploaded by

vladccc
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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September 2019

PowerMax A/S
Industrivej 50
DK ‐6740 Bramming
+45 38411100
Technical Service Bulletin
Smart Charge Alternator problems
There are a few things that a mechanic should know when diagnosing and testing
Smart Charge Alternators.

Smart Charge alternators in vehicles like Ford Focus. These vehicles use “Smart Charge” system.
This system uses two‐way communication between the Powertrain Control Module (PCM) and the
alternator to vary the charging output depending on factors such as temperature, battery state,
load, etc.

The alternator plug has three connections, one for PCM to alternator commands, one for
command acknowledgement signals from the alternator back to the PCM and the third is a battery
voltage sensor.

The alternator has an integrated voltage regulator that will, in theory, continue to operate
conventionally should communication with the PCM be lost.
Although these alternators do sometimes fail, a very common problem is with the actual wiring
loom from the three‐pin plug.

Check for chaffed or broken wires when replacing the alternator

Some vehicle manufacturers e.g. Ford uses thin wall cable, which is housed inside nylon
convoluted sleeving. Over time, and with engine vibration, the insulation on the cables can
become chaffed by the inside of the sleeving, leading to broken or corroded conductors. This will
cause the warning lamp to illuminate and the alternator may or may not stop charging. The loom
can be tested for continuity with a meter but should also be visually inspected carefully and
replaced or repaired if faults are found. A quick test is to measure voltage on the two outside
terminals, one will have battery voltage, the other, with ignition on, will have between 5 and 9V.

PowerMax offers a Repair Harness for Ford 6G Alternators, with part number 81130000

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