Chapter 1 Routine maintenance and servicing
Chapter 1 Routine maintenance and servicing
Chapter 1 Routine maintenance and servicing
You also want an ePaper? Increase the reach of your titles
YUMPU automatically turns print PDFs into web optimized ePapers that Google loves.
5A•1<strong>Chapter</strong> 5 Part A:Starting <strong>and</strong> charging systemsContentsAlternator - removal <strong>and</strong> refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Alternator brushes <strong>and</strong> voltage regulator - renewal . . . . . . . . . . . . . 7Auxiliary drivebelt check <strong>and</strong> renewal . . . . . . . . . . . . . . .See <strong>Chapter</strong> 1Battery - removal <strong>and</strong> refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Battery - testing <strong>and</strong> charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Battery, bulbs <strong>and</strong> fuses . . . . . . . . . . . . . . . . . . .See “Weekly Checks”Degrees of difficultyEasy, suitable fornovice with littleexperience1SpecificationsFairly easy, suitablefor beginner withsome experienceGeneralSystem type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BatteryRating - Cold cranking/Reserve capacity . . . . . . . . . . . . . . . . . . . . . . . .12 volt, negative earth270 A/50 RC, 360 A/60 RC, 500 A/70 RC, 590 A/90 RC or650 A/130 RCCharge condition:Poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5 voltsNormal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.6 voltsGood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.7 voltsAlternatorMake/type:Bosch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K1-55A, K1-70A, KC-70A or KC-90AMagneti-Marelli . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A127/55 or 127/70Mitsubishi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5T or A002TOutput (nominal at 13.5 volts with engine speed of 6000 rpm) . . . . . . . 55, 70 or 90 ampsRegulating voltage at 4000 rpm engine speed <strong>and</strong> 3 to 7 amp load . . . 14.0 to 14.6 voltsMinimum brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 mmStarter motorMake/type:Bosch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Magneti-Marelli . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Nippondenso . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Minimum brush length:Bosch <strong>and</strong> Magneti-Marelli . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Nippondenso . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2Fairly difficult,suitable for competentDIY mechanicCharging system - testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Electrical fault finding - general information . . . . . . . . . . . . . . . . . . . 2General information, precautions <strong>and</strong> battery disconnection . . . . . . 1Starter motor - removal <strong>and</strong> refitting . . . . . . . . . . . . . . . . . . . . . . . . . 9Starter motor - testing <strong>and</strong> overhaul . . . . . . . . . . . . . . . . . . . . . . . . . 10Starting system - testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DM, DW or EVM79 or M80RNo type numbers given8.0 mm9.0 mm3Difficult, suitable forexperienced DIYmechanic4Very difficult,suitable for expert DIYor professional55ATorque wrench settings Nm lbf ftAlternator mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18Alternator adjustment bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 9Alternator adjustment centre lockbolt . . . . . . . . . . . . . . . . . . . . . . . . . . 22 16Adjuster link-to-mounting bracket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . 12 9Alternator pulley nut:With key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 37Without key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 44Starter motor mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 26Starter motor support bracket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 181595Ford Fiesta Remake
Change language