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Tuesday, March 13, 2012

How to Replace Alternator on Ford E series?

The ford E series Alternator replacing Procedure:----


Alternator
REMOVAL & INSTALLATION
TESTING
 details are mentioned below: ------

4.6L, 5.4L & 6.8L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Disconnect the negative battery cable.
  3. Remove the air intake assembly.
  4. Rotate the accessory drive belt tensioner clockwise (vehicles with A/C) or counterclockwise (vehicles without A/C) and reposition the accessory drive belt aside.
  5. Disconnect the alternator electrical connectors.
  6. Position the alternator B+ protective cover aside, remove the B+ terminal nut and position the B+ terminal aside.
  7. Remove the four mounting bolts and the alternator bracket.
  8. Remove the two mounting bolts and the alternator.
  9. Installation is the reverse order of removal. Tighten the alternator mounting bolts to 18 ft. lbs. (25 Nm) and bracket mounting bolts to 89 inch lbs. (10 Nm). 

    image
    Fig. Exploded view of the alternator mounting-Gasoline Engines
Diesel Engines
Dual Alternators
Specific to:
Ford E-350 Super Duty 2008-2009
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Disconnect the negative battery cable.
  3. Remove the bolt and position the ground strap aside.
  4. Remove the two bolts and position the power steering fluid reservoir bracket aside.
  5. Remove the three bolts and position the cowl wiring harness aside.
  6. Remove the three bracket screws from the Charge Air Cooler (CAC) tube bracket.
  7. Remove the two stud nuts and the CAC tube bracket.
  8. Loosen the two clamps and remove the CAC tube.
  9. Rotate the secondary accessory drive belt tensioner clockwise and position the accessory drive belt aside.
  10. Disconnect the alternator electrical connector.
  11. Position the alternator B+ protective cover aside, remove the B+ terminal nut and position the B+ terminal aside.
  12. Remove the 3 bolts and the alternator.
  13. Installation is the reverse order of removal. Tighten the alternator mounting bolts to 35 ft. lbs. (47 Nm).
Single Alternator
Specific to:
Ford E-350 Super Duty 2008-2009
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Disconnect the negative battery cable.
  3. Remove the bolt and position the Manifold Absolute Pressure (MAP) sensor aside.
  4. Remove the bolt and position the ground strap aside.
  5. Remove the two bolts and position the power steering fluid reservoir bracket aside.
  6. Remove the three bolts and position the cowl wiring harness aside.
  7. Remove the three bracket screws from the Charge Air Cooler (CAC) tube bracket.
  8. Remove the two stud nuts and the CAC tube bracket.
  9. Loosen the two clamps and remove the CAC tube.
  10. Rotate the accessory drive belt tensioner clockwise and position the accessory drive belt aside.
  11. Remove the nut from the alternator stud bolt and position the transmission level indicator tube bracket aside.
  12. Disconnect the alternator electrical connector.
  13. Position the alternator B+ protective cover aside, remove the B+ terminal nut and position the B+ terminal aside.
  14. Remove the 3 bolts, the ground strap and the alternator.
  15. Installation is the reverse order of removal. Tighten the alternator mounting bolts to 35 ft. lbs. (47 Nm).

Testing



Dual Alternators
Specific to:
Ford E-350 Super Duty 2008-2009
  1. Before servicing the vehicle, refer to the Precautions Section.
    WARNING
    To prevent damage to the alternator, do not make jumper wire connections except as directed. Do not allow any metal object to come in contact with the housing and the internal diode cooling fins with the key on or off. A short circuit will result and burn out the diodes.


    NOTE
    The battery posts and cable clamps must be clean and tight for accurate meter indications. Refer to the battery tester manual for complete directions on checking out the charging system.
  2. Turn off all lamps and electrical components.
  3. Place the vehicle in NEUTRAL and apply the parking brake.
  4. Carry out the Load Test and No-Load Test according to the following component tests:
Alternator On-Vehicle Test-Load Test
Specific to:
Ford E-250 2008-2009
Ford E-350 Super Duty 2008-2009
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Switch the tester to the ammeter function.
  3. Connect the positive and negative leads of the tester to the corresponding battery terminals.
  4. Connect the current probe to the alternator B+ output lead, circuit 36 (YE/WH).
    NOTE
    Make sure to disconnect the alternator that is not being tested.
  5. With the engine running at 2,000 rpm, adjust the tester load bank to determine the output of the alternator. The alternator output should be at least 87 amps.
  6. With the engine running, turn the A/C on, (if equipped) the blower motor on HIGH and the headlamps on high beam.
  7. Increase the engine speed to approximately 2,000 rpm. The voltage should increase a minimum of 0.5 volt above the base voltage. Backprobe the I circuit at the alternator connector (connector plugged in) and measure the I circuit voltage. If the voltage is less than 2 volts, install a new alternator. If the voltage does not increase as specified, carry out the Alternator On-Vehicle Tests-No-Load Test, in this section. If the voltage increases as specified, the charging system is operating normally. Proceed to the following battery tests.
Alternator On-Vehicle Test-No-Load Test
Specific to:
Ford E-250 2008-2009
Ford E-350 Super Duty 2008-2009
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Switch the tester to the voltmeter function.
  3. Connect the voltmeter positive lead to the alternator B+ terminal and the negative lead to ground.
  4. Turn all electrical accessories off.
  5. With the engine running at 2,000 rpm, check the alternator output voltage. The voltage should be between 13.0 and 15.5 volts.
Single Alternator
Specific to:
Ford E-150 2008-2009
Ford E-250 2008-2009
Ford E-350 Super Duty 2008-2009

WARNING
To prevent damage to the alternator, do not make jumper wire connections except as directed. Do not allow any metal object to come in contact with the housing and the internal diode cooling fins with the key on or off. A short circuit will result and burn out the diodes.


NOTE
The battery posts and cable clamps must be clean and tight for accurate meter indications. Refer to the tester manual for complete directions for testing the charging system.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Turn off all lamps and electrical components.
  3. Place the transmission in NEUTRAL and apply the parking brake.
  4. Carry out the Load Test and No-Load Test according to the following component tests:
Alternator On-Vehicle Tests-Load Test
Specific to:
Ford E-150 2008-2009
Ford E-250 2008-2009
Ford E-350 Super Duty 2008-2009
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Switch the tester to the ammeter function.
  3. Connect the positive and negative leads of the battery tester to the corresponding battery terminals.
  4. Connect the current probe to the alternator B+ output terminal, circuit 36 (YE/WH).
  5. With the engine running at 2,000 rpm, adjust the tester load bank to determine the output of the alternator. The alternator output should be at least 87 amps.
  6. With the engine running, turn the A/C on, the blower motor on high speed and the headlamps on high beam.
  7. Increase the engine speed to approximately 2,000 rpm. The voltage should increase a minimum of 0.5 volt above the base voltage. If the voltage does not increase as specified, carry out the Alternator On-Vehicle Tests-No Load Test, in this section. If the voltage increases as specified, the charging system is operating normally.
Alternator On-Vehicle Tests-No-Load Test
Specific to:
Ford E-150 2008-2009
Ford E-250 2008-2009
Ford E-350 Super Duty 2008-2009
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Switch the tester to the voltmeter function.
  3. Connect the voltmeter positive lead to the alternator B+ terminal and the negative lead to ground.
  4. Turn all electrical accessories off.
  5. With the engine running at 2,000 rpm, check the alternator output voltage. The voltage should be between 13.0 and 15.0 volts.

This details will help.
Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html


Posted by Hemant somaiya at 3:21 PM
Labels: alternator location diagram on ford e series vans, how to replace ford van alternator, replacing ford E series Alternator, testing ford e series van alternator

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