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to replace a alternator on a 05 ford escape, what all has to be removed in order to pull it out and replace with new

Submitted by sabu on Sun, 08/02/2009 - 08:17

Diagnosis &

Submitted by Tim West on Sun, 08/02/2009 - 08:23.


Diagnosis & Testing



Alternator Load Test

  1. With the engine running, turn the A/C on, the blower motor on high speed and the headlamps on high beam.
    2.  
  2. Increase the engine speed to approximately 2,000 rpm. The voltage should increase a minimum of 0.5 volt above the base voltage.




    1. If the voltage does not increase as specified, carry out the Alternator On-Vehicle Tests in this section.
      2.  
    2. If the voltage increases as specified, the charging system is operating normally.
       

      3.  


    3.  


Alternator On-Vehicle Tests


WARNING
To prevent damage to the generator, do not make the jumper wire connections except as directed.




WARNING
Do not allow any metal object to come in contact with the housing and the internal diode cooling fins with key on or off. A short circuit will result and burn out the diodes.




NOTE
Battery posts and cable clamps must be clean and tight for accurate meter indications.




NOTE
Refer to the battery tester manual for complete directions for testing the charging system.



  1. Turn off all lamps and electrical components.
    2.  
  2. Place the transmission range selector lever in NEUTRAL and apply the parking brake.
    3.  

  3. Carry out the Load Test and No-Load Test according to the following component tests:
     

    4.  


Load Test

  1. Switch the battery tester to the ammeter function.
    2.  
  2. Connect the positive and negative leads of the battery tester to the corresponding battery terminals.

    3.  
  3. Connect the current probe to the generator B+ output terminal, circuit 36 (YE/WH).
    4.  
  4. With the engine running, turn the A/C on, the blower motor on high speed and the headlamps on high beam.
    5.  
  5. Increase the engine speed to approximately 2,000 rpm. The voltage should increase a minimum of 0.5 volt above the base voltage.
    6.  
  6. If the voltage does not increase as specified, carry out the Alternator On-Vehicle Tests. For additional information, refer to Alternator On-Vehicle Tests - No Load Test in this section.
    7.  
  7. If the voltage increases as specified, the charging system is operating normally.
    8.  
  8. Adjust the tester load bank to determine the output of the generator. Alternator output should be at least 58 amps.



    Click image to see an enlarged view

    Fig. Alternator amperage output graph

    9.  


No Load Test

  1. Switch the battery tester to the voltmeter function.

    2.  
  2. Connect the voltmeter positive lead to the generator B+ output terminal, circuit 36 (YE/WH) and the negative lead to ground.
    3.  
  3. Turn all electrical accessories off.
    4.  
  4. With the engine running at 2,000 rpm, check the generator output voltage. The voltage should be between 13.0 and 15.0 volts.

    5.  


Battery - Electronic Drains Which Shut Off When The Battery Cable Is Disconnected

  1. Repeat the steps of the battery drain testing.
    2.  
  2. Make sure all doors are closed and accessories are off. Without starting the engine, turn the ignition switch to RUN for a moment and then OFF. Wait a few minutes for the illuminated entry lamps to turn off if equipped.
    3.  
  3. Connect the ammeter and read the amperage draw.
    4.  
  4. The current reading (current drain) should be less than 50 mA (0.05 amp). If the current drain exceeds 50 mA (0.05 amp) after a few minutes, and if this drain did not show in previous tests, the drain is most likely caused by an inoperative electronic component. As in previous tests, remove the fuses from the battery/central junction box one at a time to locate the problem circuit.
     
    5.  


Current Drain Test


NOTE

No production vehicle should have more than a 50 mA (0.050 amp) continuous draw.


Check for current drains on the battery in excess of 50 milliampere (0.050 amp) with all the electrical accessories off and the vehicle at rest. Current drains can be tested with the following procedure:



CAUTION
Do not attempt this test on a lead-acid battery that has recently been recharged. Explosive gases can cause personal injury.




WARNING
To prevent damage to the meter, do not crank the engine or operate accessories that draw more than 10A.




NOTE
Many modules draw 10 mA (0.010 amp) or more continuously.




NOTE
Use an in-line ammeter between the battery positive or negative post and its respective cable.




NOTE
Typically, a drain of approximately one amp can be attributed to an engine compartment lamp, glove compartment lamp, or luggage compartment lamp staying on continually. Other component failures or wiring shorts may be located by selectively pulling fuses to pinpoint the location of the current drain. When the current drain is found, the meter reading will fall to an acceptable level. If the drain is still not located after checking all the fuses, it may be due to the generator.




NOTE
To accurately test the drain on a battery, an in-line digital ammeter must be used. Use of a test lamp or voltmeter is not an accurate method due to the number of electronic modules.



  1. Make sure the junction box/fuse panels are accessible without turning on interior and underhood lights.
    2.  
  2. Drive the vehicle at least five minutes and over 48 km/h (30 mph) to turn on and exercise the vehicle systems.
    3.  
  3. Allow the vehicle to sit with the key off for at least 40 minutes to allow modules to time out/power down.
    4.  
  4. Connect a fused jumper wire between the negative battery cable and the negative battery post to prevent modules from resetting and to catch capacitive drains.
    5.  

  5. Disconnect the negative battery cable from the post without breaking the connection of the jumper wire.

    NOTE
    It is very important that continuity is not broken between the battery and the negative battery cable when connecting the meter. If this happens, the entire procedure must be repeated.


    6.  
  6. Connect the tester between the negative battery cable and the post. The meter must be capable of reading milliampere and should have a 10 amp capability.


    NOTE
    If the meter settings need to be switched or the test leads need to be moved to another jack, the jumper wire must be reinstalled to avoid breaking continuity.


    7.  
  7. Remove the jumper wire.

    NOTE
    Amperage draw will vary from vehicle to vehicle depending on the equipment package. Compare to a comparable vehicle for reference.




    NOTE
    No production vehicle should have more than a 50 mA (0.050 amp) draw.


    8.  
  8. If the draw is found to be excessive, pull fuses from the battery/central junction box one at a time and note the current drop. Do not reinstall the fuses until you are finished testing.
     
    9.  


Removal & Installation



2.0L Engine

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



    Negative battery cable

     

    Drive belt

     

    Alternator electrical connectors and loosen the upper alternator bolt while moving the alternator to the rear of the engine

     

    Alternator. Torque the lower bolt to 35 ft. lbs. (48Nm). Torque the upper bolt to 18 ft. lbs. (25 Nm).

     


    3.  


To install:

  1. Install or connect the following:



    Alternator with the upper bolt in the alternator before installation. Torque the bolts to 18 ft. lbs. (25 Nm).

     

    Alternator electrical connectors

     

    Drive belt

     

    Negative battery cable

     


    2.  


2.3L Engine

  1. Before servicing the vehicle, refer to the Precautions Section.

    2.  
  2. Disconnect the 12v battery.

    NOTE
    For the Escape Hybrid, when the battery is disconnected and connected, the brake pedal needs to be calibrated. After the battery has been connected, with the vehicle in park, turn the key to the ON position. Press the brake pedal firmly, then fully release to calibrate the brake pedal.


    3.  
  3. Remove the front end accessory drive belt tensioner. Rotate the front end accessory drive belt tensioner counter-clockwise to loosen tension on the front end accessory drive belt.
    4.  
  4. Remove the front end accessory drive belt.
    5.  
  5. Remove the alternator B+ terminal.
    6.  
  6. Remove the alternator electrical connector.
    7.  
  7. Remove the alternator lower air duct bolt.
    8.  
  8. Remove the alternator lower air duct. Press the locking tab to release the lower air duct from the upper air duct.
    9.  
  9. Remove the pin-type retainer.

    10.  
  10. Remove the alternator shield .
    11.  
  11. Remove the alternator stud nut.
    12.  
  12. Remove the alternator stud.
    13.  
  13. Remove the alternator bolts.
    14.  
  14. Remove the alternator.



    Click image to see an enlarged view

    Fig. Alternator mounting-2.3L Engine

    15.  
  15. To install, reverse the removal procedure. Observe the following torques:



    Alternator mounting bolts: 35 ft. lbs. (47 Nm)

     

    Alternator stud: 18 ft. lbs. (24 Nm)

     

    Stud nut: 35 ft. lbs. (47 Nm)

     

    Shield nut: 15 ft. lbs. (20 Nm)

     

    Lower air duct bolt: 35 inch lbs. (4 Nm)

     


    16.  


3.0L Engine

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



    Negative battery cable

     

    Right side intermediate axle shaft

     

    Right side splash shield and retainers

     

    Drive belt

     

    Alternator electrical connectors

     

    Alternator. Torque the mounting and adjusting bolts to 35 ft. lbs. (48Nm).



    Click image to see an enlarged view

    Fig. Alternator mounting-3.0L engine

     


    3.  


To install:

  1. Install or connect the following:




    Alternator. Torque the bolts to 35 ft. lbs. (48 Nm).

     

    Alternator electrical connectors

     

    Drive belt

     

    Negative battery cable

     


    2.  


Hybrid

  1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
  2. Disconnect the 12v battery.


    NOTE
    When the battery is disconnected and connected, the brake pedal needs to be calibrated. After the battery has been connected, with the vehicle in park, turn the key to the ON position. Press the brake pedal firmly, then fully release to calibrate the brake pedal.


    3.  
  3. Remove the front end accessory drive belt tensioner. Rotate the front end accessory drive belt tensioner counter-clockwise to loosen tension on the front end accessory drive belt.
    4.  
  4. Remove the front end accessory drive belt.
    5.  
  5. Remove the alternator B+ terminal.
    6.  
  6. Remove the alternator electrical connector.
    7.  
  7. Remove the alternator lower air duct bolt.

    8.  
  8. Remove the alternator lower air duct. Press the locking tab to release the lower air duct from the upper air duct.
    9.  
  9. Remove the pin-type retainer.
    10.  
  10. Remove the alternator shield .
    11.  
  11. Remove the alternator stud nut.
    12.  
  12. Remove the alternator stud.
    13.  
  13. Remove the alternator bolts.
    14.  
  14. Remove the alternator.




    Click image to see an enlarged view

    Fig. Alternator mounting-2.3L Engine

    15.  
  15. To install, reverse the removal procedure. Observe the following torques:




    Alternator mounting bolts: 35 ft. lbs. (47 Nm)

     

    Alternator stud: 18 ft. lbs. (24 Nm)

     

    Stud nut: 35 ft. lbs. (47 Nm)

     

    Shield nut: 15 ft. lbs. (20 Nm)

     

    Lower air duct bolt: 35 inch lbs. (4 Nm)

     

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