Friday, March 9, 2012

How to replace Alternator on Ford and mercury?

The procedure is similar for both Ford Taurus and Mercury Sable.


Alternator
REMOVAL & INSTALLATION
TESTING


Removal & Installation



  1. Disconnect the battery.
  2. Remove the generator B+ nut and terminal.
  3. Disconnect the generator electrical connector and position the engine wiring harness aside.
  4. Position the upper radiator hose aside and remove the upper radiator hose cradle.
  5. Remove the 5 pin-type retainers from the wire harness across the top of the radiator and position the harness aside.
  6. Rotate the accessory drive belt tensioner and position the accessory drive belt aside.
  7. Remove the upper generator nut and stud.
  8. Loosen the lower generator bolt.
  9. Remove the generator.
  10. To install, reverse the removal procedure.
  11. Tighten lower generator bolt to 35 ft. lbs. (47 Nm).
  12. Tighten upper generator nut to 35 ft. lbs. (47 Nm).
  13. Tighten upper generator stud to 71 inch lbs. (8 Nm).
  14. Tighten the generator B+ nut and terminal to 106 inch lbs. (12 Nm).

Testing



Load Test
Specific to:
Ford Taurus 2008-2009
Mercury Sable 2008-2009
  1. With the engine running, turn on the blower motor and the high beams ( or other electrical accessories to place a load on the charging system).
  2. Increase and hold engine speed to 2000 rpm.
  3. Measure the voltage reading at the battery.
  4. The voltage should increase at least 0.5 volts from the voltage test. If the voltage does not meet specifications, the charging system is malfunctioning.
    NOTE
    Usually under and overcharging is caused by a defective alternator, or its related parts (regulator), and replacement will fix the problem; however, faulty wiring and other problems can cause the charging system to malfunction. Further testing will reveal the exact component failure. Many automotive parts stores have alternator bench testers available for use by customers. An alternator bench test is the most definitive way to determine the condition of your alternator.
No Load Test
Specific to:
Ford Taurus 2008-2009
Mercury Sable 2008-2009
  1. Connect a tachometer to the engine.
    CAUTION
    Ensure that the transmission is in Park and the emergency brake is set. Blocking a wheel is optional and an added safety measure.
  2. Turn off all electrical loads (radio, blower motor, wipers, etc.)
  3. Start the engine and increase engine speed to approximately 1500 rpm.
  4. Measure the voltage reading at the battery with the engine holding a steady 1500 rpm. Voltage should have raised at least 0.5 volts, but no more than 2.5 volts.
  5. If the voltage does not go up more than 0.5 volts, the alternator is not charging. If the voltage goes up more than 2.5 volts, the alternator is overcharging.
    NOTE
    Usually under and overcharging is caused by a defective alternator, or its related parts (regulator), and replacement will fix the problem; however, faulty wiring and other problems can cause the charging system to malfunction. Further testing, which is not covered by this book, will reveal the exact component failure. Many automotive parts stores have alternator bench testers available for use by customers. An alternator bench test is the most definitive way to determine the condition of your alternator.
  6. If the voltage is within specifications, proceed to the next test.
Voltage Test
Specific to:
Ford Taurus 2008-2009
Mercury Sable 2008-2009
  1. Make sure the engine is OFF , and turn the headlights on for 15-20 seconds to remove any surface charge from the battery.
  2. Using a DVOM set to volts DC, probe across the battery terminals.
  3. Measure the battery voltage.
  4. Write down the voltage reading and proceed to the next test.

This details will help.
Thanks.





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