1991 1999 ford explorer chilton User Manual
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Unbolt the battery (B+) lead from the back of the alternator ... Label and disengage all of the wiring connectors from the alternator. To disconnect push-on type terminals, disengage the lock tab and pull straight off. 3. Remove the alternator bolts, then remove the alternator from the engine 4. ... then remove the alternator mounting bolts Remove the alternator from its mounting bracket To install: HOW TO USE THIS BOOK 222 REMOVAL & INSTALLATION
Position the alternator on the engine. 5. Install the alternator mounting bolts. On 3.8L and 5.0L engines, tighten the upper bolt to 16-21 ft. lbs. (21-29 Nm) and the lower bolt to 30-40 ft. lbs. (40-55 Nm). On 4.6L engines, tighten both bolts to 15-22 ft. lbs. (20-30 Nm). 6. On 4.6L engines, install the alternator mounting bracket and bolts. Tighten the bolts to 71-106 inch lbs. (8-12 Nm). 7. Install the accessory drive belt. Ensure that the drive belt is properly installed on the pulleys before starting the engine. 8. Attach all engine wiring harness connectors to the alternator. 9. Connect the negative battery cable. 10. Voltage Regulator REMOVAL & INSTALLATION 1991-95 models with non-integral type regulator The regulator is attached to the alternator by 4 Torx® head screws Click to enlarge HOW TO USE THIS BOOK Voltage Regulator 223
Disconnect the negative battery cable. 1. Remove 4 Torx® head screws holding the voltage regulator to the alternator rear housing. Remove the regulator, with the brush and terminal holder attached. 2. Hold the regulator in one hand and pry off the cap covering the Aterminal screw head with a small prybar. 3. Holding the regulator in one hand, break off the tab covering the A screw to expose the brush holder retaining screws Click to enlarge Remove 2 Torx® head screws retaining the regulator to the brush holder. Separate the regulator from the brush holder. 4. HOW TO USE THIS BOOK 224 REMOVAL & INSTALLATION
To install: Install the brush holder on the regulator with 2 retaining screws. Tighten the screws to 25-35 inch lbs. (2.8-4.0 Nm). 5. Exploded view of the voltage regulator and brush holder assembly Click to enlarge Install the cap on the head of the Aterminal screw. 6. Depress the brushes into the holder and hold the brushes in position by inserting a standard size paper clip, or equivalent tool, through both the location hole in the regulator and through the holes in the brushes. 7. Install the regulator/brush holder assembly and remove the paper clip. Install the attaching screws and tighten to 20-30 inch lbs. (2.3-3.4 Nm). 8. Connect the negative battery cable. 9. 1995-99 models with integral type regulator The internal voltage regulator used on alternators used with these vehicles is not removable or, in any other way, serviceable. If the voltage regulator is found to be defective, a new alternator must be installed. HOW TO USE THIS BOOK REMOVAL & INSTALLATION 225
Example of the integral type regulator atlernator Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. HOW TO USE THIS BOOK 226 REMOVAL & INSTALLATION
STARTING SYSTEM General Information The starting system is designed to rotate the engine at a speed fast enough for the engine to start. The starting system is comprised of the following components: Permanent magnet gear-reduction starter motor with a solenoid-actuated drive · Battery · Remote control starter switch (part of the ignition switch) · Park/Neutral Position (PNP) or Manual Lever Position (MLP) switch (on 1994 automatic transmission models) or Transmission Range (TR) sensor (on 1995-99 automatic transmission models) · Clutch Pedal Position (CPP) switch (on manual transmission models) · Starter relay · Heavy circuit wiring · Exploded view of the coil type starterClick to enlarge STARTING SYSTEM 227
Exploded view of the permanent magnet type starter Click to enlarge Heavy cables, connectors and switches are utilized by the starting system because of the large amount of amperage this system is required to handle while cranking the engine. For premium starter motor function, the resistance in the starting system must be kept to an absolute minimum. A discharged or faulty battery, loose or corroded connections, or partially broken cables will result in slower-than-normal cranking speeds. The amount of damage evident may even prevent the starter motor from rotating the engine at all. Vehicles equipped with a manual transmission are equipped with a Clutch Pedal Position (CPP) switch in the starter circuit, which is designed to prevent the starter motor from operating unless the clutch pedal is depressed. Vehicles equipped with automatic transmissions are equipped with either a Park/Neutral Position (PNP) switch, a Manual Lever Position (MLP) switch or a Transmission Range (TR) sensor in the starter circuit. These switches prevent the starter motor from functioning unless the transmission range selector lever is in Neutral (N) or Park (P). HOW TO USE THIS BOOK 228 General Information
The starter motor is a 12 volt assembly, which has the starter solenoid mounted on the drive end-housing. The starter solenoid energizes when the relay contacts are closed. When the solenoid energizes, the starter drive engages with the flywheel ring gear, rotating the crankshaft and starting the engine. An overrunning clutch in the starter drive assembly protects the starter motor from excessive speed when the engine starts. Starter TESTING Use the charts to help locate and diagnose starting system problems. Remember that the starter uses large amounts of current during operation, so use all appropriate precautions during testing. Starter system inspection chartClick to enlarge HOW TO USE THIS BOOK Starter 229
Starter system evaluation procedure chart Click to enlarge REMOVAL & INSTALLATION Disconnect the negative battery cable. 1. Raise the front of the vehicle and install jackstands beneath the frame. Firmly apply the parking brake and place blocks in back of the rear wheels. 2. HOW TO USE THIS BOOK 230 TESTING
Disconnect all wires connected to the starter, including this ground wire on the starter moutnting bolt stud Tag and disconnect the wiring at the starter. 3. WARNING When detaching the hardshell connector at the S-terminal, grasp the plastic shell to pull it off. Do not pull on the wire itself. Ensure to pull the connector straight off to prevent damage to the connector and S-terminal. If any part of the connector is damaged, replace the damaged component. Some starters use a self-threading bolt to hold the starter cableHOW TO USE THIS BOOK REMOVAL & INSTALLATION 231