AutoZone 1960 Ford Falcon 2.4L 1BL 6cyl | Repair Guides | Engine Electrical | Charging System | Alternator | AutoZone.com

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    Ford Taurus/Sable 1996-1999 Repair Guide

    Alternator

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    TESTING



    Voltage Test
    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.  
    3. Using a DVOM set to volts DC, probe across the battery terminals.
    4.  
    5. Measure the battery voltage.
    6.  
    7. Write down the voltage reading and proceed to the next test.
    8.  

    No-Load Test
    1. Connect a tachometer to the engine.
    2.  


    CAUTION
    Ensure that the transmission is in Park and the emergency brake is set. Blocking a wheel is optional and an added safety measure.

    1. Turn off all electrical loads (radio, blower motor, wipers, etc.)
    2.  
    3. Start the engine and increase engine speed to approximately 1500 rpm.
    4.  
    5. 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.
    6.  
    7. 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.
    8.  

    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 guide, 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.

    1. If the voltage is within specifications, proceed to the next test.
    2.  

    Load Test
    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.  
    3. Increase and hold engine speed to 2000 rpm.
    4.  
    5. Measure the voltage reading at the battery.
    6.  
    7. 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.
    8.  

    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 guide, 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.

    REMOVAL & INSTALLATION



    3.0L OHV Engines

    See Figures 1 through 9



    Click image to see an enlarged view

    Fig. Fig. 1: Detach the small electrical connector and...



    Click image to see an enlarged view

    Fig. Fig. 2: ... the regulator connector from the alternator



    Click image to see an enlarged view

    Fig. Fig. 3: Slide the rubber boot back to access the output cable retaining nut



    Click image to see an enlarged view

    Fig. Fig. 4: Remove the retaining nut and remove the cable from the alternator



    Click image to see an enlarged view

    Fig. Fig. 5: Remove the two mounting brace retaining nuts and one bolt and...



    Click image to see an enlarged view

    Fig. Fig. 6: ... remove the mounting brace



    Click image to see an enlarged view

    Fig. Fig. 7: Remove the two alternator retaining bolts and...



    Click image to see an enlarged view

    Fig. Fig. 8: ... remove the alternator from the vehicle

    The alternator is not internally serviceable.

    1. Disconnect the negative battery cable.
    2.  
    3. Unplug the wiring harness electrical connectors from alternator/voltage regulator.
    4.  
    5. Unfasten the alternator output nut (B+) and remove the wire from the stud.
    6.  
    7. Loosen the alternator pivot bolt, then remove the mounting brace bolt from the alternator.
    8.  
    9. Remove the accessory drive belt from the alternator pulley. Refer to General Information & Maintenance of this repair guide for drive belt removal.
    10.  
    11. Unfasten the alternator brace retainers and remove the brace.
    12.  
    13. Unfasten the alternator pivot bolt and remove the alternator from the vehicle.
    14.  



    Click image to see an enlarged view

    Fig. Fig. 9: Exploded view of the alternator mounting-3.0L OHV engines

    To install:
    1. Place the alternator into position.
    2.  
    3. Install the alternator pivot and mounting brace bolts. Do not tighten the bolts until the drive belt is properly tensioned.
    4.  
    5. Place the alternator brace into position. Tighten the brace retaining nut to 15-22 ft. lbs. (20-30 Nm) and the brace bolts to 76-97 inch lbs. (8.5-11 Nm).
    6.  
    7. Install the drive belt over the alternator pulley. Refer to General Information & Maintenance of this repair guide for drive belt installation.
    8.  
    9. Tighten the mounting brace bolt to 15-22 ft. lbs. (20-30 Nm) and the pivot bolt to 30-40 ft. lbs. (40-55 Nm).
    10.  
    11. Attach the wiring harness electrical connector to the alternator/voltage regulator.
    12.  
    13. Place the eyelet of the battery output wire onto the stud and install the nut. Tighten the nut to 62-80 inch lbs. (7-9 Nm).
    14.  
    15. Connect the negative battery cable.
    16.  

    3.0L DOHC Engines

    See Figure 10

    1. Disconnect the negative battery cable.
    2.  
    3. Remove the accessory drive belt. Refer to General Information & Maintenance for this procedure.
    4.  
    5. Disengage the electrical harness connector and output terminal wiring.
    6.  
    7. Remove the engine control sensor nut and position the nut aside.
    8.  
    9. Unfasten the two alternator bolts and one alternator stud bolt.
    10.  
    11. Remove the alternator from the vehicle.
    12.  

    To install:
    1. Place the alternator into position and install the two mounting bolts and bolt stud. Tighten the bolts and stud bolt to 15-22 ft. lbs. (20-30 Nm).
    2.  
    3. Place the engine control sensor in position and install its retaining nut. Tighten the nut to 11-14 ft. lbs. (15-20 Nm).
    4.  
    5. Attach the electrical harness connector and output terminal wiring. Tighten the output wiring terminal retaining nut to 80-106 inch lbs. (9-12 Nm).
    6.  
    7. Install the accessory drive belt. Refer to General Information & Maintenance for this procedure.
    8.  
    9. Connect the negative battery cable.
    10.  



    Click image to see an enlarged view

    Fig. Fig. 10: Exploded view of the alternator mounting-3.0L and DOHC engines (3.4L DOHC engines similar)

    3.4L DOHC Engines

    See Figure 10

    1. Disconnect the negative battery cable.
    2.  
    3. Remove the right side cowl vent screen.
    4.  
    5. Raise the vehicle and support it with jackstands.
    6.  
    7. Remove the right front wheel assembly.
    8.  
    9. Remove the right tie-rod. Refer to Suspension & Steering for this procedure.
    10.  
    11. Remove the accessory drive belt. Refer to General Information & Maintenance for this procedure.
    12.  
    13. Disengage the electrical harness connector and output terminal wiring.
    14.  
    15. Remove the engine control sensor nut and position the nut aside.
    16.  
    17. Unfasten the two alternator bolts and one alternator stud bolt.
    18.  
    19. Remove the alternator from the vehicle.
    20.  

    To install:
    1. Place the alternator into position and install the two mounting bolts and bolt stud. Tighten the bolts and stud bolt to 15-22 ft. lbs. (20-30 Nm).
    2.  
    3. Place the engine control sensor in position and install its retaining nut. Tighten the nut to 11-14 ft. lbs. (15-20 Nm).
    4.  
    5. Attach the electrical harness connector and output terminal wiring. Tighten the output wiring terminal retaining nut to 80-106 inch lbs. (9-12 Nm).
    6.  
    7. Install the accessory drive belt. Refer to General Information & Maintenance for this procedure.
    8.  
    9. Install the right tie-rod. Refer to Suspension & Steering for this procedure.
    10.  
    11. Install the right front wheel assembly and lower the vehicle.
    12.  
    13. Install the right side cowl vent screen.
    14.  
    15. Connect the negative battery cable.
    16.  

     
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