5 Alternators Later...STILL Not Charging?? (Ford Escape V6)

[@1dave301]

In 2002, there was a TSB that said Ford claimed the voltage sense wire was too small of a gauge that would cause erratic charging. We soldered an additional wire in parallel and it solved the "several bad alternators" issue on the car we had.

[@1967250s]

I had a similar problem, my 944 Porsche would run all day, come night, battery was not being charged enough. Eventually found a small connector under the dash for the exciting volt had 2 strands of the wire hanging on, the rest of the (small ) wire broken. A quick splice and never a problem again. The 2 strands was enough current to charge during the day, but not enough at night with lights on.

[@D2O2]

Voltage sense wire "should" have virtually zero current and therefore size shouldn't matter.

[@nickmalone3143]

​@@D2O2should be high impedence on a voltage sensor

[@Discretesignals]

The charging system has two circuits. Gen Com (GENRC)and Gen Mon(GENLI). Gen Com is the PCM commanding the alternator. The PCM pulls the voltage from the regulator low to generate the command signal . Gen Mon is basically the regulator talking to the PCM telling the PCM that it is doing what the PCM is commanding on Gen Com. The regulator pulls the voltage low from the PCM to generate the signal. If you short the Gen Com to the Gen Mon at the connector and look at your GENRC and GENLI data pids the values will be bouncing back and forth because the PCM is seeing itself. That lets you know the PCM and circuits are good. You're only seeing one coil in your voltage waveform, so you could have another coil wacking the PCM and causing a reset. You also need to set your voltage scale higher to see those flyback spikes. They are maxing out at 200 volts. Set to 400V. If they max out above 400V, you have an issue.

[@kendom33]

Great explanation

[@PonkyKong]

ripple current from failed elctrolytic capacitors in the ECM?

[@robertdavis6708]

Makes sense! Had to think about that scale for a second. Thanks.

[@ColeTanner88]

I would've liked to have seen the gen com when the issue occurs. It seems like the alternator was doing what it was told by the PCM so I'd assume when the misfire occurs the PCM is getting hit with higher voltage spikes, not knowing what to do and shutting down the alternator. That's my guess

[@yosefmama1136]

I had a old Dodge Ram D50 (Mitsubishi) that started eating voltage regulators (inside the alternator). First replaced with with guaranteed rebuilt alternator. That one did the same thing, and the next one. The voltage regulators either started overcharging OR no charging. So I pulled out my antiquated mechanic books bought in a secondhand bookstore (much needed because I am NO mechanic, but a fair electronic technician). Best checks led me to the ignition switch. 200 ohms in the RUN position. I believe in the old vehicles the charging indicator in the dash was actually a high current circuit fed from the alternator. With the ignition switch in series (increased by 200 ohms) the alternator was constantly charging at max output and never had a chance to rest and cool down. Hard enough for a non-mechanic like me. Love watching your videos.

[@willgeo2215]

I want to thank you for this video. I had similar issues with my 2007 Escape where the alternator would charge if I installed a freshly charged battery, but the next morning it wouldn't show it was charging and the battery would read 11.5 volts while running. I was about to take it to the Ford dealer for a $900 alternator replacement when I came across your video. I installed NKG plugs and the battery light went out and the alternator is charging normally now. You saved me a ton of money! What caused the battery light to come on in the first place was an engine light that came on after I put fuel injector cleaner into a tank that had about 2 gallons of gas in it (a mistake on my part). It caused the engine to misfire. I filled the tank and the engine light cleared away but the battery light kept coming on.

[@MrJet30]

This man is a straight up Genius!. The troubleshooting and the stuff he solves is remarkable.

[@gmv0553]

I have never met or seen another mechanic attack problems with the approach that you take. Love your videos and always look forward to the next one.

[@MrGerryoc]

I love how you stick with it till it’s fixed awesome😊

[@harrylister804]

Ivan is very good. His approach is the scientific method, you know proving stuff. That takes proper tools. If you want to determine if a mechanic can be trusted to solve a difficult electrical problem, ask to see his tool box. If you see a laptop, a thinktool, DMM, picoscope, lots of funky connectors, then he could be qualified. If you see a bottle of Jack Daniels and lots of air tools, maybe he can do pads and rotors or a control arm.

[@maxwebster7572]

@@harrylister804 Yes this is true but I saw a diagnostic guy that couldn't plug a tire.

[@stevenlatham4397]

You defeat some of the weirdest automotive problems. I wish I didn’t live 1,400 miles away.

[@scientist100]

You don't need to find him. I do these fixes and there are a few solos that do it as well. People from shops will not spend time to fix it right because they move quick to make money. I do it as a hobby like Ivan does so we can afford to spend a bit more time, Ivan still needs to make money but with his KZbin films, he offsets his cash flow.

[@metoon3092]

@@scientist100 film?

[@robarnt6]

I KNOW, scientist.. I love these crazy diag videos. Make some!

[@scientist100]

@@metoon3092 indeed, film...

[@TheWilber09]

I'm sure Ivan charges accordingly. It takes as long as it takes for weird issues.

[@rogerrocco5211]

Every problem has solution but few people are as willing as you to discover it. You deserve all the accolades that you receive! Congratulations for your dedication to success! Bravo!👏

[@Pillers4Momoms]

I swear people will look at you crazy after this case study. Job well done.

[@HollomanUFOLanding]

My only complaint about Ivan's videos is that they're finished too quickly! I could watch them for hours! I love a good detectiove story and there's none better than watching this man and his craft. Thanks, Ivan.

[@PineHollowAutoDiagnostics]

I do love to share the mysteries 😄

[@HollomanUFOLanding]

@@PineHollowAutoDiagnostics hahaa In your case Ivan, it's not "Murder She Wrote' but "Misfire He Fixed!"

[@jdawglawler8833]

Just recovered from smashing my thumb in a car door, I feel your pain!

[@nathanhurst5155]

I noticed that too and saw he had the ole hole drilled into it to relieve the pressure.

[@tomsawyer4776]

I have watched nearly every video you have ever made.....and this is the most unusual I have ever seen. GREAT JOB ! Best diagnostic tech in America.

[@porky7753]

This reminds me of the old days, start off with new plugs and wires and go from there. Great catch Ivan.

[@gnomiefirst9201]

Not a bad place to start (vehicle maintenance history), visual inspection of sp gap way off, there were no recorded misfires (owner did not mention it), misfire repeated while under load. The alternator not charging was the wild card.

[@mikechiodetti4482]

This reminds me of the Ford 2003 and 2004 6.8L V10 engines in the (Los Angeles Dept of Water and Power) F350 1 ton utility vehicles I worked on in the early 2000's. The PCM code was for the Input Shaft Speed Sensor in the front of the transmission. Some of the vehicles came to our Main St shop from other shops. The speed sensor, the connector, wiring and tone ring were all good. After reading an article in IATN about a Chrysler minivan spark plug wire causing a misfire and that caused other electrical problems I decided to check the spark plugs. The vehicles are L.A. DWP City vehicles with LOTS of stop and go driving. ALL 10 plugs were worn down with over a .060 (60 thousandths) gap. 10 new plugs AND 10 new upgraded ign coils, all Motorcraft.......No more ISS code. Many of the 1 ton utility's came to our shop from other shops for the same Code and fix. The trucks would wear out plugs in as little as 35,000 miles. City driving and heavy loads will do that. Most never made it to 100,000 before changing parts. The 5.4L V8 2 valve engines would misfire with worn plugs at 80,000 to 100,000 miles. New plugs and coils and off they'd go. Good one Ivan, hope the neighbor appreciates what you've done!

[@kevincrawford6734]

Noticed the 1mm drill hole in your left thumb Ivan, THE only way to burst a blood blister!! Well done 👍😂

[@PineHollowAutoDiagnostics]

Unfortunately nothing came out...damaged the nail even further haha

[@colinellicott9737]

​@@PineHollowAutoDiagnostics Fifty years ago my Mum (a nurse) used a paper clip heated to red hot over the stove to burn a hole in my big toe's nail to release the blood pressure from a bad contusion. Sterile, quick, easy, but with a distinctive smell ; )

[@GarnConstructionInc]

Its the circus of circuits that have a built in shut down! Nice work Ivan!

[@RupertReynolds1962]

Glad it's fixed! First thing I thought of, when you linked the fault to a misfire, was either 1) misfire rocks engine -> trapped wire shorts or 2) trapped wire shorts -> misfire!

[@cephasrodgers9417]

I suppose this is another reason to make sure that the scheduled maintenance (spark plug replacement) is done as scheduled ;-) Another great video, thanks for sharing

[@jerrymoore7669]

Must be a ford thing. Reminds me of a video Eric o did a few years back. Had a Ford fusion that was turning on a light for an emissions related code. I don't remember the exact one. He did the testing and replaced the part but problem was still there. It would set the light as a certain rpm. He was getting ready to call an ecm. Thinking outside the box, problem occurs at 3000 rpm, what else happens at 3000 rpm. The power steering had a switch that activates at 3000 rpm. The switch was chattering, sending a signal back to the ecm that it could not process. As a result it would turn on the light for the emissions fault. He unplug the switch problem went away.

[@paulstandaert5709]

I remember that episode. It was an EVAP code if I remember correctly. It is also possible that a new ECM would have actually fixed it. That ECM may have had a (failed) circuit within it to deal with this dirty input chatter from the power steering pressure switch. I would have saved that power steering pressure switch and tried it in another vehicle, mostly for curiosity / fun.

[@wazza33racer]

that was an EPIC diagnosis by Eric.......although Keith the wizard from NYC gave him some wise advice "what activates at 3000rpm"?

[@gnomiefirst9201]

I would never guess that a misfire would trip the battery light and not set a misfire in the data. Always appreciate your true detective stories. Well done.

[@Jerroh6]

Woah ! blew my mind twice this week. I just went thru an intermittent coolant leak that would never leak when I was looking at it. Replaced the expansion tank cap and no more leak.

[@hikerJohn]

AMAZING!! We are lucky to have these videos. Not that I'm a mechanic but I just love thinking about mechanical things and solving puzzles. Between you and Automotive Diagnostics & Programming If I were young I would be addicted and what to go into this line of work . . . I would of course have to be good enough at math to take electrical engineering in college. But when I was young I could lean anything I was interested in so I would be motivated to learn math better than I did 55 years ago. I was just a C student in math.

[@victorborges9523]

Regret? I am like the guy you described. I was fully motivated in these fields for automotive. I touched the ceiling professionally. Pierced it, went through it, surpassed the ceiling, won many recognitions, prizes, TV, newspapers, interviews. About 3,000 students later and about half a million vehicles fix later, still not rich. Great life, but not rich. On the other hand, a professional pot smoking customer asked for my help with his boat engine. This kid was from California. Bought three houses in Hawaii, two in NYC and was buying his second in Puerto Rico when I met him. All he did love was smoking marihuana. So he harvested. Sold the leaves for profit. It was the times of Melaleuca oil skyrocketing sales. So, in his mental trip, grabbed a bunch of branches and squeezed it. The rest of this multimillionaire is history. He invented THC. In the conversation he said he was not good in school. All C's.🤔

[@hikerJohn]

@@victorborges9523 I went into Landscaping and did pretty good. It's good work and pays well enough to retire on. If this guy you speak of thinks he invented THC he's smoked a few too may doobies

[@markmaherr]

I work on my own vehicles my entire life, and worked as a mechanic for a while.. but i have been following Eric at south main for years.. thats how i found you. In a video he said where you were coming from. Turns out your about 35 minutes from me. I keep that in my mind, cause i know that if there's ever electrical i cant solve, your not far away 🙏 and you bet, I'll be coming to you.

[@dustcommander100]

Back in the early 2000's, my dad was convinced his Buick's transmission was toast. Turned out to be the plug wires, and he was past the recommended replacement mileage. I think the next couple of cars he had had neither the recommended internal or the issues when they weren't changed. I've heard that on some Fords, bad plugs can damage the engine computer! That would ruin your day!

[@Bryan-Hensley]

A bad rpm sensor in ,I think, the alternator can ruin an automatic transmission in a Ford diesel truck from the late 1990s and early 2000s..

[@Paramount531]

I had an 85 FWD Cadillac Sedan deVille that had bad wires, making the transmission slam shift. I was convinced the trans was done the first time it happened. The bad wires were confirmed by going somewhere really dark, opening the hood and looking for sparks on the wires. The second time it happened I just replaced the wires again.

[@fredsalter1915]

12:00 purple thumb.... been there, done that lol! Great vid, sir ivan!!!!

[@petar443]

What the heck ? First thing i think about is Bernie Thompson at ATS. He had a "2003 Ford T Bird throttle defaulting" and car was going into limp mode because of spike when the AC coil turned off. Always enjoying to watch your videos. You've saved your neighbors for sure ! Many mechanics would go down the rabbit hole. Well done Bernie .. ops i mean Ivan 👍😂

[@ubeenlookingforthis]

I have followed you for some time now. You have taught me that I don't have a chance in hell of fixing any of this stuff, even if I had the $$ for all the equipment, where am I going to get the 10 years of knowledge to put it to good use. My next auto, when the present one dies, will be a 1964-1967 Mustang. It will have a 289 and C4 with a/c and steering. I'll pay a pretty penny for it, but still cheaper than buying a new car at $40-$60K and it will always be worth what I payed for it, no depreciation. I'm totally through with Check engine lights and a level of complexity that is beyond my talents to understand let alone repair. Keep up the good work , I wait for your videos like a kid on the stoop waiting for the ice cream man!

[@johnplump3760]

Years ago I built and tested computers. We did have a "Glitec" that we could not see because the capacitor of th scope remobed it. We could only see it when we used a cutrrent scope. You are very patient and excellent ar diagnosing!!

[@jamilrichardson6953]

the way you diagnose cars is definitely a God given talent. you’ve changed my perspective on diagnostics completely 😅

[@shakey2634]

This is the kind of time consuming diagnostic that dealerships and most independent shops either won’t do or can’t do. So gratifying to watch this. I’ve seen some guys test new, supposed name brand plugs only to find out they are poorly made fakes. Ever had that experience?

[@phildion8010]

You’re the reason I have a scope by the way. Thank you

[@phildion8010]

From Vermont

[@calholli]

I bought one too.. Still haven't needed to use it yet.

[@brianw8963]

Ivan convinced me long ago that a scope is a must have tool, but as I only do this stuff part time on the side , I’m not willing to drop 3K for a 4 channel, which is what I want. Could a guy purchase way lower priced two 2 channel’s and use them in tandem and get all 4 channels on a single screen?

[@calholli]

@@brianw8963 Get a DHO804 .. It can do everything you need. 4 channel. 25M deep memory, 12 bit vertical resolution. (EEvlog has a great hour long review of this thing and you can learn all about it-- it's less than four hundred bucks). This is the one I got.. after months of researching scopes. The only other one I would get is the pico.

[@calholli]

@@brianw8963 I got the dho804 .. watch 'EEvlogs video about it.

[@kerrylewis2581]

This information needs to stay in my memory bank. Great diag and resolution

[@theoldbigmoose]

Great diagnostic skills mate. This is what happens now with sneak circuits, EMI/RFI and all the microprocessors in the cars.

[@michaeltichonuk2176]

My goodness! Well, it speaks volumes of your diagnostic style and skill set!

[@scrappy7571]

So the ignition coils were acting like a emp bomb and disrupting the PCM. Good find!!!

[@jatco84]

Crazy ...Great diagnosis ..and it appears new plugs properly gapped was the cure...Kudos

[@mmichaeldonavon]

Ivan. Once again I'm astonished by the fix! You never seem to amaze me. Thank you.

[@PineHollowAutoDiagnostics]

I didn't believe it either...almost like that weird Subaru lol

[@jthampshire]

Nice work. I actually figured it out early. For electrons to flow across a gap air has to be ionized. If the gap is very wide, voltage has to build higher to make the jump. Add pressure from throttle opening and you can get a no spark situation. That results in a voltage spike on the trigger wire. Now. Why the computer can't tolerate that spike is another story. Great troubleshooting.

[@DuaneDonaldson]

YES, Bernie Thompson training, add redundant grounds to the ignition system and head for ignition specifically to battery for a sure path for the high voltage to return to ground and starter to battery for that system specifically for the same reason plus to help prevent magnetism within the block and trigger wheels specifically during a super high amp draw for the starter initial kick, cheers.

[@simonparkinson1053]

I get LOADS of Ford Focus with the 1.6 litre having a very similar problem. Usually those won't even charge at idle. The alternators on those are LIN controlled. One that came to me had 4 alternators before arrival. On those, it's an ignition lead that goes open at the coil pack end and radiates a massive EMF, scope shows negative 100V or so induced on the LIN signal wire. On some engines, the LIN wire runs at valve cover gasket level so is parallel and relatively close to the ignition leads. Most engine variants, the harness runs half way down the block, but those still get affected by the faulty ignition lead. There's never a misfire complaint though, I've even tried myself and not got a misfire under load. Ignition leads verified by simple continuity test, they're resistive leads so expect 1000-5000 ohms, but an open is a definite open - and an ignition lead set always fixes the charging fault, the original alternator works perfectly

[@billinphoenix255]

Love the videos, you're very methodical and persistent. Thought someone like you would wear the seat belt, here we have "click it or ticket" laws, they can pull you over for that alone. BUT I'm going to give up trying to get you to use them, it's not working. Stay safe out there buddy.

[@j.t.johnston3048]

Awesome build! That's way more elegant than I thought it would be.

[@flatdaddio]

You have had some really weird case studies with coils and plugs. I would never have thought something like this could happen. Very difficult to find. Great job Ivan!!

[@robarnt6]

Well, and the only time this issue might come up is where the owner neglects routine maintenance - making this scenario extremely rare.

[@garyalford9394]

Kind of reminds me of that Subaru with the junk cheap coils !!

[@gsaegerjr]

I had a friends escape with the same symptoms. I tried about 3 different alternators. finally I though go with oem parts so I went to the dealer and was standing at the counter waiting for the parts guy when a ford tech came in for parts and he said let me guess you had an escape and it's over charging. don't tell this place I told you this but go to napa they only seem to be the ones beside oem parts that will work with this car. so I tried it and it actually work.

[@brianmacadam4793]

I've found a electrical rebuild shop for my 50 yr old Lucas alternator. The shop immediately COMPLETELY disassembled and then replaced EVERYTHING. Everything works and has worked for a decade. Find a good shop and let them go to work.

[@volvo09]

I had a rebuilder do an alternator for me once too. It was a rare option high output alternator for an early 90's maxima and it was like $500 for a parts store one!! The shop rebuilt it in a day or two for like $100.

[@robertsmith2956]

My local one didn't survive the covid shutdown, or the machine shop next door to them.

[@on-site4094]

My uncle use to rebuild alternators. Rebuild kits were only. A few bucks Starters he says mechanic change all parts he said we repaired almost everything I said we live in the computer era reduce scrap recycle.

[@volvo09]

@@on-site4094 I got pretty lucky with mine... The stator burned up so it wasn't a quick fix with a voltage regulator or brushes. The shop I used is probably long gone now too.

[@erik_dk842]

@@robertsmith2956 All part of the plan(demic)

[@RJon2006]

One of the coolest diag videos yet. Super wierd. Nicely done, sir. 🇺🇸🇺🇸

[@scottjanoso4475]

Really nice work. Before getting started on repairs you may need to add checking spark plugs along side oil levels. Some of the basics are causing unrelated issues. Glad you didn’t have to swap out another alternator.

[@bills6946]

I could have sworn my gas stove was the problem. Good catch.

[@juanmanuelgil3436]

Amazing diagnostics. I have a 2007 Ford Escape, and you know they do are sensitive about spark plugs being on good condition, 50k is ok for these! 80-100k is pushing it. Also you customer /neighboor was lucky the PCM did not fried the coil drivers, because that is what happens on these years of Ford cars and SUV's, when the spark plug gap is to big, it damages the coil, shorts it out, then fries a driver. Happens on Fusions too which uses a similar PCM to the Ford Escape.

[@billbarney4937]

5 alternators? wow thats crazy. i like rockauto too and get my parts from them also. you have very good diagnostic skills.

[@robiecarmichael9958]

Wow! What a diagnosis’s! But as always you follow the clues, test, and verify. I would be surprised if very many techs would figure this one out. Not surprised you figured it out. Thanks for another great video.

[@tommiller4490]

I had the exact same issue with my 07 Montego. First replacement lasted 6 months, and the next two aftermarkets lasted like no more than a week.I put in " the last one" dealer remanned one from a Ford dealer in Montana about 6 years ago. It's still running. Going through receipts, it looks like I did indeed just happen to replace the sparkplugs when I did the last replacement! Before that I went through Yes they are a PIA to replace!

[@PhillipBailey]

Great catch! Ive had worn plugs take out the PCM drivers for the coils i would imagine due to high primary voltage spikes. Nice place for an alternator for sure...

[@gizmocatz3478]

That was a very interesting case, but as you said that smart charging system it can disable the alternator s soon as a voltage spike is detected. You are the man when it comes to electrical gremlins. I looking forward to the next case.

[@htownblue11]

Incredible scenario and even better diagnosis and theory proven. Well done Ivan. Always learning from you.

[@BlackOpsJuJu]

Nice Case Study for sure Have Never Seen Spark Plugs cause a No Charging Fault But after that many Alternators Figured it had to be something Else Great Diag for Sure

[@wallebo]

Yes, sir. Another amazing video. I had no idea that plugs could cause this. That's why I am here to learn.

[@DirtyWorm12]

It's amazing how easily an ignition spike can cause so much havoc, mainly the 2 wire cop since the driver is inside the ECM. Nice catch, I bet you could've scoped the coils and seen the spikes in the PCM grounds, owers and potentially other circuits

[@robertsmith4954]

I noticed the ABS light was on during your test drive . My 2007 Escape had the tone rings cracked on the front drive axles. I had lest than 25, 000 miles . The rings are very thin. Thanks for the great video's.

[@PineHollowAutoDiagnostics]

Some monkey damaged a rear tone ring during a bearing replacement :(

[@craigtegeler4677]

Good job Ivan! You're the man! I'll just about bet that anything of these sorts of problems like this one are sure to be met with intense scrutinizing!! Maybe I just need to take a ride down where you are at and have you solve some of my gremlins that I have on my 03 Jeep Grand Cherokee! I'm only about 2 hours away from you.

[@davidturner4639]

Wouldn't be surprised if the ignition issue caused the first alternator overcharging problem. Good detective work Ivan.

[@richb419]

Hi Ivan, very good catch! I never have seen a spark plug kill anything but the coil or make noise in the radio, naturally I have never had to work on these computer cars! I did see that the problem was load generated which does point at the ignition system. Rich

[@SS-cc3km]

How did he determine that it was the plugs and not the coils causing the backfeed problem? I think I missed that part in the video. I love this channel, all kinds of weird issues 😂.

[@richb419]

Hi, my spin on it, the plugs needed changing any way and it was missing under load indicating that something in the ignition was faulty. the spark plugs were the cheapest thing to try. the scope showed that the coils seemed to be charging fine. Rich@@SS-cc3km

[@pookatim]

Back in the olden days, I had a Ford that kept overcharging the battery. It drove me nuts trying to figure it out. New regulator didn't help. The battery got so overcharged it actually swelled up! I purchased a new battery and removed the ground cable and that's when I found the issue. The ground cable had a secondary lead coming out of the clamp and it attached to a fender bolt. This secondary lead had a butt connector that allowed one to connect it to the existing ground wire. When I was removing the clamp, the ground wire just fell out of the butt connector. So the problem all along was a bad ground. The bad ground caused the regulator to think the battery was not charged and it would keep allowing the alternator to supply a full charge to the battery.

[@2nickles647]

I've been trying to tell customers to fix the battery cables...nooooo....they are not the problem. It's a bad battery...😅😅😅

[@nevillegoddard4966]

Brilliant diagnosis mate! 😃👍! Gotta think outside the box sometimes with all the electrickery going on under the bonnet of modern cars! Hey your left thumbmail! - OUCH!!!! Car door? Rat trap? Looks like that hurt! D'oh!

[@dima614640]

Yes mind-blowing. But also mind blowing how those coils held up

[@HeyBirt]

Daughter had an Escape that popped up all sorts of odd codes when a couple of the coil packs were failing. Replaced 4 original coil packs (2 had been done by PO) and it was cured. I chased the misfire before the odd codes as computer-controlled cars can do all manner of weird things with secondary ignition problems (and low battery problems.)

[@tsmith578]

The Buick LeSabre ran and drove perfectly fine, one day the check engine light came on with a code for the fuel tank evap system, like you,,,, I do not like to install parts unless I am sure they are needed, After much inspection I could not find anything wrong with the evap system, and and after about three weeks, I was sitting in the car at night with the headlights on, and noticed that the lights were slightly flickering, so upon suspicion I tested the charging system, but could not seem to really find any fault with it, it charged good and the car never had any issues starting or with the functioning of anything. But because of the fact that I had noticed the lights flickering, I decided to replace the alternator, I found a nice looking one from a salvage yard that had remanufactured stickers on it for a really reasonable price and installed it. And the next day the check engine turned off on its own, and the code for the evap system never returned, until like about five years later when it actually developed a rust hole in the evap line.

[@ChrisWilliams-pu8pj]

Ivan, That is what you get with talented technicians!

[@Papa7557]

Great diagnosis on the miss fire that causing the smart charging system to fail.

[@Frank19184]

Wow!! Crazy stuff! Good job on the diagnosis. 👍

[@JadenTravline]

You are the man , this explained in detail the issues i was dealing with , very glad i found your video before doing a horrible alternator install x2 . Spark plugs and coil packs fixed my charging issue !

[@JoseSilveira-newhandleforYT]

You collect weird cases, Ivan! I was still watching, but my first thought was: could it be an intermittent bad ground with engine shaking? Well, you proved me wrong :-) Go figure, bad plugs cause spikes that the electronics don't like - insane! That's why I love the old "dumb" alternators :-)

[@Chris_Lastname]

Never seen that before. Who would have thought spark plug gaps, could kill an alternator feed. You solved another riddle

[@alexanderorozco661]

You have great communication skills. As well your tutorials. Thank you 🥋

[@paulstandaert5709]

This actually makes a good deal of sense. In the most Layman terms, when an inductive load cannot discharge where it is supposed to, it has to discharge somewhere else, and that inductive kick can make its way back to the PCM and set some logic chip bits in prohibitive states and stuff like this happens. It is also possible the PCM has a capacitor or something to deal with this, and that capacitor has failed. After all, its only 18 years old.

[@robertoruiz7069]

I had the same thought,a bad cap somewhere in the system driving the ecm or alt stuff wacky.The plug diagnosis though made me think.Feeling a slight miss fire when it's slight {fishbite} well you need to have learned that from experience.IVAN picked up on it right away.I do remember something about the ford wire years ago.My 1st thing to do,for issues ,is to look at ground wires,for corrosion.It's a habit now!!!haha

[@scottschantz2553]

The value of a good test drive. Great job Ivan!

[@lvsqcsl]

I don't think our Mercury cars have smart charging systems. I am wanting to say on the Panther Platform cars smart charging started in 2006. In all the years I have been driving a car, I have NEVER gone to an auto parts store for a starter or alternator. I recently had the alternator on the 'ol Marquis rebuilt and was told by the tech that there were diodes that were bad. He told me VERY emphatically NOT to get rid of the voltage regulator because you can't get another one. At almost 500,000 miles it still had the original voltage regulator. GREAT VIDEO!

[@dricklorenz9340]

Being that we're only 2 minutes from the end of the video I vote that, YES, it'll be the spark plugs!

[@autodiagyt]

Good ole ignition induced issues. Those are always fun. Like the ford truck I had that would set a programming fault code lol

[@tzvi-goldenberg]

Wow well done. It happened to me once with a Cadillac srx that the customer put Ford plugs in the car, and there it happened to me that the charging was not good and the command to two injectors would stop intermittently and there were even two injectors that broke down... really crazy.

[@Rodewerksahed]

Brilliant technical video. Love it 👍🏻

[@JOHNSUE28]

Thanks!

[@wazza33racer]

Eric at SMA had a vehicle with a faulty,pulsing power steering pressure sensor that caused an induction spike (pulsing DC mimicks AC current) inside the ECU that triggered a fault in another system. I recently got a Great Wall (2.4 petrol) that had a stumble, under part load, between 1500 and 2000rpm. Eliminated TPS,MAP and fuel (pulled great wot and high rpm). Pulled the plugs, no signs of issues, gap was good. Swapped a known good coil pack (4 port single unit) still had an issue. It was clearly an ignition stumble, so I changed the plugs out anyway.........problem solved. Now the vehicle it turns out, had always had a bit of flat spot at those rpm's..........and all of a sudden it developed a bad stumble. New plugs got rid of the stumble, and the long term,minor flat spot.

[@MyRadDesign]

I wonder if a transient was causing the regulator down, which is not duplicated by pulling the monitor line low with a test light. Awesome job with the diagnosis.

[@quicktastic]

I'm not completely shocked. I just had a number of problems resolved on 2.4L Dodge by replacing the plugs. About 150k miles on them and looked it. 3 of the cylinders had misfires and I thought for sure the transmission was shot because it was intermittently shifting hard and always hard when the torque converter engaged. 4 new iridium plugs and the engine runs smooth as silk and the transmission works perfectly. I believe the lack of power was messing up the computer for shifting. I didn't have any battery charging issues though. At least not enough to trigger and codes or starting issues.

[@MrTonyPiscatelle]

That's as crazy as granite gravy.. But !!! You may have seen where the late 1960's Mopar products You could make the radio play without the keys in the ignition. Turn the hazzard light switch on, hold the brake pedal down turn the radio on and it will play on every strike of the hazzard relay/flasher, might have to turn the blinker on also i can't remember back that far. This was an amazing diag Ivan , you da man !

[@chrishill5166]

Another brilliant tutorial. It'll take me a week though to work that one out.

[@jonsingle1614]

Large spark plug gap is great....if the entire ignition system can handle the additional load on the system....as you saw the system could not handle the load and caused a lot of problems....the early GM LS engines originally had a .060 gap...then GM changed the spec to .045....wonder why !??

[@tonep3168]

Brilliant diagnosis Ivan!

[@fritsprive]

I love your video's, but I'm always a bit sad when there is no bonus footage...😢

[@advancedleveldiagnostics]

Wow crazy case study, Thanks for sharing! I don't understand why you lost ignition coil ramps if it was bad spark plugs?

[@AP9311]

Wow spark plugs bring down the alt? Wow, you sure come through weird case studies!! That's fun to do lol. Nice video!!

[@Fishingmaniac1]

Superb diagnosis !

[@DonDegidio]

Hi Ivan, Another excellent round of sleuthing. Who would have thought that spark plugs would have caused an alternator problem. Noticed a blackened thumb nail with a hole. Did you happen to whack your thumb? I've done it a few times and needed to relieve the pressure with a red hot pin to make a hole. What a relief when the blood spurts out.

[@marianodeocampo5569]

Thank you for posting this, I just got into the oscilloscope, I bought a 4425A kit, and have been using my Honda as a test bed to get wave forms and learn Picoscope 7. Anyways I had a Ford Five Hundred that has had 3 alternators put on it, voltages are normal at idle, and spike to 15+ when the engine has rpm’s increased. PCM or another issue under load causing higher voltage spikes in charging value and the battery light would turn on. Makes me think a coil, excessive plug gap, spark plug issue, or PCM issue. I’m gonna look at the car in the next few days and hopefully find that issue with Pico

[@calholli]

I think your smoking gun was that first capture on the test drive.. Where you showed the voltage spikes on the PWM signal from the alt.. You could literally see the spike on the square wave. Pretty crazy. I just wonder if it was actually arching/shorting on the alt wire somewhere in the harness-- or if it was actually back feeding to the PCM through the coil control wire? Very cool capture. (17:50)

[@flinch622]

I am thinking computer buss was pushed so hard trying to fire coils and throw spark across that chasm of a spark plug gap that something else had to lay down, having lost proper bias. Bias is everything to a semiconductors p/n junction. In this instance, alternator control took the hit. I'd have to see board layout and chip diagrams to nail down why. If they used opto-isolators attempting to serve low impedance loads [less than 300k or so], I have seen funny faults in the past: an overcurrent extendig past 30 minutes would fail an output on - wide open, 100%, no reset possible. Anyway, the problem of half baked designs usually revolves around failure to analyze current requirements and associated fault tolerances. Could be weak system analysis by Ford, or could be faulty spec sheets on chips selected.

[@calholli]

@@flinch622 The problem is that the coil charges up and then it wants to arch to ground when it collapses.. But if that ground is too far away for the arch to jump, then it doesn't have anywhere to go, so it winds up back feeding into the ECM.. Most circuits will account for this by adding a diode or even a resistor across it, so that when it collapses, it can just jump to ground across that resistor/ diode.. or however else they choose to filter it. But for spark plugs, they specifically don't add that filter because they want it to jump across the spark plug and no where else. So I can understand why the internal circuits don't have a typical filter to prevent this back feed.. because it might cause misfires sometimes, by allowing your spark to "choose" it's path to ground. So anyway, as long as you run good plugs, it won't ever be a problem. It's still a weird rabbit hole that it leads you down

[@GreyRockOne]

Wow.. Ford, Fix Or Repair Daily.. Nice work Ivan!

[@brianw8963]

I’m getting better at guessing. As soon as You noticed the miss, I was thinking ignition was going to be the problem with the “smart” charging system. Though I thought it was going to be more Chinesium coils, but I was close! To Me, this stuff is GOLDEN. Thanks Ivan . 👍👍🇺🇸

[@nicholaswatson3896]

I had an '06 Volvo with a ford smart charge system and it caused some very strange problems that seemed completely unrelated. The alternator used an over run decoupler pulley that was only manufactured by one US firm at the time. They gave it a life span of 50k but that wasn't reflected in the service schedule. I had BCM faults but no codes until the alternator and pulley were swapped out. it also cured a rough idle I'd always assumed was caused by worn vacuum motor mounts.

[@edwardsilva895]

Remi is reman by BBB in mexico.. worked at their ca warehouse as a truck driver..right at the time they started doing brake calipers in Stockton ca