AutoZone 2011 Ford Fiesta SES 1.6L SFI DOHC 4cyl | Repair Guides | Engine Electrical | Charging System | Alternator | AutoZone.com

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    2011 Ford Fiesta SES 1.6L SFI DOHC 4cyl

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    Toyota Celica, Corolla, ECHO & MR2 1999-05

    Alternator

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    Diagnosis & Testing



    A voltmeter and ammeter are necessary for testing.

    1. Make sure the battery terminals are not loose or corroded. Check the fusible link for continuity.
    2.  
    3. Inspect the drive belt for excessive wear. Check the drive belt tension. If necessary adjust the drive belt.
    4.  
    5. Check the fusible link, H-fuses, M-fuses, and fuses for continuity.
    6.  
    7. Visually check alternator wiring and listen for abnormal noises.
    8.  
    9. Check that the discharge warning light comes ON when the ignition switch is turned ON . Start the engine. Check that the warning light goes out.
    10.  
    11. Check the charging circuit WITHOUT A LOAD.
      1. Disconnect the wire from terminal B of the alternator and attach it to the negative lead of the ammeter.
      2.  
      3. Connect the positive lead of the ammeter to terminal B of the alternator.
      4.  
      5. Connect the positive lead of the voltmeter to terminal B of the alternator.
      6.  
      7. Ground the negative lead of the voltmeter.
      8.  
      9. To check the charging circuit, run the engine from idle to 2000 rpms and check the reading on the ammeter and voltmeter. Standard amperage is 10 amps or less. Standard voltage is as follows:

        77°F (25°C)-14.0-15.0 volts
         
        239°F (115°C)-13.5-14.3 volts
         

      10.  
      11. If the voltmeter reading is more than standard voltage, replace the voltage regulator. If the voltmeter reading is less than standard, check the alternator.
      12.  

    12.  



    Click image to see an enlarged view

    Fig. Connections of components when checking the charging circuit without a load

    1. Check the charging circuit WITH A LOAD.
      1. With the engine running at 2000 rpm, turn on high beams and heater fan to HI.
      2.  
      3. Check the standard amperage, it should be 30 amps or more. If the ammeter is less than standard, replace the alternator.
      4.  

    2.  
    3. Replace the necessary parts. Recheck the charging system.
    4.  

    If a battery is fully charged, sometimes the indication will be less than 30 amps.

    Alternator 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.
      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.

    8.  

    Alternator No-Load Test
    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.  
    3. Turn off all electrical loads (radio, blower motor, wipers, etc.)
    4.  
    5. Start the engine and increase engine speed to approximately 1500 rpm.
    6.  
    7. 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.
    8.  
    9. 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.

    10.  
    11. If the voltage is within specifications, proceed to the next test.
    12.  

    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.  

    Precautions



    To prevent damage to the alternator and regulator, the following precautionary measures must be taken when working with the electrical system.



    NEVER reverse the battery connections. Always check the battery polarity visually. This is to be done before any connections are made to ensure that all of the connections correspond to the battery ground polarity of the car.
     
    Booster batteries must be connected properly. Make sure the positive cable of the booster battery is connected to the positive terminal of the battery which is getting the boost.
     
    Disconnect the battery cables before using a fast charger; the charger has a tendency to force current through the diodes in the opposite direction for which they were designed.
     
    NEVER use a fast charger as a booster for starting the car.
     
    NEVER disconnect the voltage regulator while the engine is running, unless as noted for testing purposes.
     
    Do NOT ground the alternator output terminal.
     
    Do NOT operate the alternator on an open circuit with the field energized.
     
    Do NOT attempt to polarize the alternator.
     
    Disconnect the battery cables and remove the alternator before using an electric arc welder on the car.
     
    Protect the alternator from excessive moisture. If the engine is to be steam cleaned, cover or remove the alternator.
     

    Removal & Installation



    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Remove or disconnect the following:

      Negative battery cable
       
      Drive belt
       
      Wiring
       
      On 2ZZ-GE, 2 bolts and bracket
       
      Alternator
       

    4.  

    To install:

    1. Install or connect the following:

      Alternator
       
      Torque the larger bolt-40 ft. lbs. (54 Nm); smaller bolt-18 ft. lbs. (25 Nm)
       
      On 2ZZ-GE, 2 bolts and bracket. Torque to 21 ft. lbs (29 Nm).
       
      Drive belt
       
      Wiring
       
      Negative battery cable

      Click image to see an enlarged view

      Fig. Alternator with 2 mounting bolts

       

    2.  

    1. Before servicing the vehicle, refer to the Precautions section.
      NOTE
      It may be necessary to remove the gravel shield and work from underneath the car in order to gain access to the alternator retaining bolts.

    2.  
    3. Remove or disconnect the following:

      Negative battery cable
       
      Wiring from the alternator
       
      Drive belt
       
      Alternator
       

    4.  

    To install:

    1. Install or connect the following:

      Alternator. Torque the smaller bolt to 18 ft. lbs. (25 Nm) and the larger bolt to 40 ft. lbs. (54 Nm).
       
      Alternator connector and wiring
       
      Drive belt
       
      Negative battery cable
       

    2.  

    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Remove or disconnect the following:

      Negative battery cable
       
      Wire clamp from the rectifier
       
      Alternator harness
       
      2 bolts
       
      Alternator
       

    4.  

    To install:

    1. Install or connect the following:

      Alternator and hand tighten the bolts
       
      Drive belt and adjust if necessary. Torque the 14 mm bolt to 14 ft. lbs. (18 Nm) and the 17 mm bolt to 40 ft. lbs. (54 Nm).
       
      Alternator connector and clamp
       
      Alternator electrical wiring
       
      Negative battery cable
       

    2.  

    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Remove or disconnect the following:

      Negative battery cable
       
      Accessory drive belt
       
      Right motor mount
       
      Wire harness clamp
       
      Alternator wiring harness
       
      Alternator mounting bolts
       
      Alternator

      Click image to see an enlarged view

      Fig. MR2 alternator mounting exploded view

       

    4.  

    To install:

    1. Install or connect the following:

      Alternator. Tighten the upper mounting bolt to 18 ft. lbs. (25 Nm) and the lower mounting bolt to 40 ft. lbs. (54 Nm).
       
      Alternator wiring harness 3
       
      Wire harness clamp
       
      Right motor mount. Tighten the bolts to 38 ft. lbs. (52 Nm).
       
      Accessory drive belt
       
      Negative battery cable
       

    2.  

    GT-S
    1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    2.  
    3. Remove or disconnect the following:
      NOTE
      On some models it is necessary to remove the fuse/relay block located near the alternator.



      Negative battery cable
       



      Drive belt
       
      Wiring
       
      Alternator
       

    4.  

    To install:

    1. Install or connect the following:

      Alternator
       
      Drive belt. Torque the pivot bolt and adjusting bolts: 5S-FE: Pivot bolt-40 ft. lbs. (54 Nm); Adjusting bolt-14 ft. lbs. (19 Nm).
       
      Wiring
       
      Negative battery cable
       

    2.  

     
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