1989-1994 Ford Capri 1.6L EFI Service & Repair Manual

31-01-1 GROUP 31 CHARGING SYSTEM (10000) SECTION TITLE PAGE SECTION TITLE PAGE ALTERNATOR-INTEGRAL REGULATOR-EXTERNAL FAN CHARGING SYSTEM-SERVICE ................................ 31-o1·1 TyPE ......................................................................... 31·17·1 IGNITION SWITCH .....................................................31-20-1 BATTERIES ...............................................................31-02·1 SECTION 31-01 Charging System-Service SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION ................................ 31·01·1 SPECIFICATIONS ......................................................31-01·9 DIAGNOSIS ............................................................... 31·01·1 TESTING ................................................................... 31 ·01·4 SPECIAL SERVICE TOOLS ......................................... 31·01·9 VEHICLE APPLICATION .............................................31·01·1 VEHICLE APPLICATION Capri. DESCRIPTION AND OPERATION The alternator charging system is a negative ground system consisting of an alternator with an integral regulator, a charge indicator lamp, a storage battery, and associated wiring. The integral regulator is solid·state.lt is mounted onto the rear of the alternator and contains the alternator brushes. DIAGNOSIS Battery and charging system trouble is frequently due to physical rather than electrical factors including loose or corroded wiring connections, damaged wiring, slipping drive belts, dirty battery surfaces and terminals, or poor maintenance. Thoroughly inspect the system. 1. Make sure battery terminals and cable connections are clean and tight. Refer to Section 31-02. 2. Inspect battery cable connections to starter and engine ground for surface dirt or foreign matter. 3. Check alternator drive belt for glazing or cracking which may have been caused by belt slippage. If sides of belt are shiny or feel slick, replace them. Check belt tension. Refer to Section 27 -02 for belt replacement or tension adjustment. 4. Make sure that top surface of battery is clean and free of moisture or foreign matter. Charging system troubles such as low alternator output, no alternator output (indicated by the indicator lamp being on while the engine is running), or alternator output voltage too high, require testing of both the alternator and the voltage regulator. Copyright © 1990, Ford Motor Co. www.techcapri.com

31-01-2 Charging System-Service 31-01-2 DIAGNOSIS (Continued) Voltage regulator failures are usually not recognized except by the direct affect on the alternator output. and eventual battery discharge. The regulator is the control valve for the alternator. It protects the battery by preventing excessive voltage output. Discharge of the battery to ground through the alternator is prevented by the diodes of the alternator which permit current flow in one direction (to the battery) only. A discharged battery is not always due to a problem in the charging system. Excessive use of lamps and accessories while the engine is either off or running at low idle. corroded battery cables and connectors. low acid level in the battery. or prolonged disuse of the battery. which would permit self-discharge are all possible reasons which should be considered when a battery is run down or low in charge. NOTE: Always determine the cause of failure as well as making the repair. 1. Polarity and Connections. The alternator is for use on negative ground electrical systems only. Polarity cannot be reversed and any attempt to do so will damage the alternator. 2. Installing Vehicle Battery. Reversed battery connections will damage the alternator rectifiers. When installing. first connect the positive connector to the battery positive terminal and then connect the negative connector to the negative battery terminal. 3. Battery Charging. Disconnect the battery negative cable to isolate the alternator from the battery and external charging equipment. 4. Battery Connections. Never disconnect the battery while the engine is running. Damage to the rectifier and lor other electrical components may occur. Using a slave battery to start the engine and then reconnectil1g the original battery while the engine is running must not be attempted. Do not break or make any other connections in the alternator circuit while the engine is running. 5. Alternator Main Output Cable. • The cable connecting the alternator and the battery has constant battery voltage even when the engine is not running. Care must be taken not to ground this cable if it should ever be removed, or damage to the cable will occur. • Never run the alternator with the main output cable disconnected either at the alternator or battery end while the field remains energized or the rectifiers may be damaged. 6. Arc Welding. Isolate the control box and alternator by disconnecting their wiring connectors prior to performing any arc welding on the vehicle. 7. lamps and Fuses Fall Prematurely, Short Battery life. Other systems covered under this heading are: battery uses excessive amount of water; high battery charging rate. Check all charging system wiring connections including the regulator ground and battery sensing wire. lighten or service as required. Check the alternator voltage limiter setting. Replace if not to specification. 8. Alternator Noisy. When diagnosing the complaint of alternator noise. isolate the noise area and make sure that the alternator is at fault rather than the alternator belt. water pump. or another part of the vehicle. Start the engine and use a stethoscope or similar tool to isolate the noise. An alternator bearing, water pump bearing or belt noise is usually evidenced by a squealing sound. An alternator with a shorted diode will normally whine (magnetic noise) and will be most noticeable at idle speeds. Perform the alternator output tests. If the output is approximately 10 amperes less than that specified. a shorted diode is usually indicated. To eliminate the belt(s} as the cause of noise, check the belt(s} for bumps, apply a light spray of water to the belt(s}. If the alternator belt is at fault. adjust the belt to specification. or replace the belt if necessary. If the belt(s) is satisfactory and the noise is believed to be in the alternator or water pump, remove the alternator belt. Start the engine and listen for the noise to be sure that the noise Is not caused by another component. Use this test and the sound detector test to isolate the noisy component. If the noise Is traced to the alternator, remove it and check bearings for play or roughness. 9. Charge Indicator /Warning lamp Flickers. This condition may be caused by loose or damaged connections in the charging system wiring harness, worn brushes. or improper brush tension. Copyright © 1990, Ford Motor Co. www.techcapri.com

31-01-3 Charging System-Service 31-01-3 DIAGNOSIS (Continued) CHARGING SYSTEM DIAGNOSIS CONDITION POSSIBLE SOURCE ACTION • Battery Does Not Stay Charged - • Battery. • Test battery, replace if necessary <2J. Engine Starts OK • Loose or worn alternator belt. • Wiring or cables. • Alternator. • Regulator. • Other vehicle electrical systems. • Adjust or replace belt (j). • Service as required (j). • Test and/or replace components as required @. • Test, replace if necessary @. • Check other systems for current draw. Service as required @. • Alternator Noisy • Loose or worn alternator belt. • Bent pulley flanges. • Alternator. • Adjust tension or replace belt (j). • Replace pulley @. • Service or replace alternator@. • Lamps and/or Fuses Burn Out Frequently • Wiring. • Alternator/Regulator. • Battery. • Service as required. • Test, service, replace if necessary @ • Test, replace if necessary <2J. • Charge Indicator Lamp Flickers • Loose or worn alternator belt. • Adjust tension or replace (j). After Engine Starts or Comes On While Vehicle is Being Driven • Alternator. • Field circuit ground. • Regulator. • Lamp circuit wiring and connector. • Operation at low engine speed (idle) with heavy electrical load - IAR alternator onl)( • Service or replace @. • Service or replace worn or damaged wiring. • Test, replace if necessary @. • Service as required. • Test, replace if necessar)( • Charge Indicator Lamp Flickers • Loose or worn alternator belt. • Adjust tension or replace belt (j). While Vehicle is Being Driven • Loose or improper wiring connections. • Alternator. • Regulator. • Service as required. • Service or replace @. • Test, replace if necessary @. • Voltmeter Pointer Reads in the Red • Loose or worn alternator belt. • Adjust tension or replace (j). Area (High or Low) • Damaged or worn wiring (battery to alternator for ground or open). • Field circuit ground. • Alternator. • Regulator. • Voltmeter indicator gauge wiring and connections. • Damaged or worn gauge. • Other vehicle electrical system malfunction. • Service or replace wiring. • Service or replace wiring. • Service or replace @. • Test, replace if necessary @. • Service as required. • Replace gauge. • Service as required. (j) Refer to Section 27"()2. @ Refer to Section 31·17. (ID Refer to Section 31-02. @ Refer to procedure in this Section. CJ3484·A Copyright © 1990, Ford Motor Co. www.techcapri.com

Charging System-Service TESTING The following system test charts have been arranged in a series to isolate the component or cause of a charging system complaint. Start at the beginning and continue through the test steps even after the cause of the complaint is found. This will rule out the possibility that the original condition was not caused by more than one charging system problem. Copyright © 1990, Ford Motor Co. www.techcapri.com

31-01-5 Charging System-Service 31-01-5 TESTING (Continued) CHARGING SYSTEM TEST TEST STEP RESULT ACTION TO TAKE A1 CHARGE LAMP FUNCTION CHECK • Without starting engine, turn ignition switch to RUN position. Charge lamp should come on. • Disconnect voltage regulator at alternator. Charge lamp should go off. • Ground L terminal of voltage regulator connector to engine. Charge lamp should come on. VOLTAGE REGULATOR S TERMINAL NOTE: Alternator shown removed for clarity only. Testing to be performed on wiring harness side. Lamp functions properly Lamp does not come on Lamp does not go off Lamp comes on only with L terminal grounded .. .. .. .. GO to A2. REPLACE lamp fuse or lamp bulb or SERVICE open in lamp feed circuit. SERVICE short to ground in lamp feed circuit. SERVICE open circuit. CHECK rotor, brushes, or regulator. REFER to Section 31-17. A2 BATTERY CONDITION • Perform sealed battery voltagelload test. Refer to Section 31-02. Battery passes load test Battery fails load test .. .. GO to A3. REPLACE battery. A3 B + WIRING CHECK • With ignition switch in OFF position, use a voltmeter, such as Rotunda 014-00407 or equivalent to test for battery voltage at alternator B + terminal. • Voltage should be within 0.2 volts of battery voltage. Within 0.2 volts Greater than 0.2 volts .. .. Go to A4. SERVICE loose, corroded or damaged B + wire. NOTE: Test step must be performed with alternator installed and all wiring connected. Alternator shown removed for clarity only. CJ3377-A Copyright © 1990, Ford Motor Co. www.techcapri.com

31-01-6 Charging System-Service 31-01-6 TESTING (Continued) CHARGING SYSTEM TEST - Continued TEST STEP RESULT ." ACTION TO TAKE A4 I BATTERY GROUND Within 0.2 volts ." GO to AS. negative post to ground. • Use a voltmeter to check voltage drop from battery Greater than 0.2 volts ." SERVICE loose or corroded connections or damaged ground cable. • Voltage drop should be less than 0.2 volts. AS JALTERNATOR GROUND Within 0.2 volts ." Go to AS. alternator frame to engine ground • Use a voltmeter to check voltage drop from Greater than 0.2 volts ." SERVICE excessive resistance in alternator mounting. • Voltage drop should not exceed 0.2 volts. AS I BATTERY DRAIN TEST - KEY OFF Test lamp does not ." Go to A7. illuminate • Turn ignition to OFF position. • Disconnect battery positive cable. Test lamp illuminates ." CHECK vehicle positive termina! and positive cable. • Connect an ammeter or test lamp between battery circuits for drain by pulling fuses from fuse panel one at a (clock draw). Test lamp should not light. • Current draw should be no more than .05 amps time until affected circuit is found. SERVICE as necessary. CJ3378-A Copyright © 1990, Ford Motor Co. www.techcapri.com

31-01-7 31-01-7 Charging System-Service TESTING (Continued) CHARGING SYSTEM TEST - Continued TEST STEP RESULT ACTION TO TAKE A7 REGULATOR BYPASS 16 volts Less than 16 volts REPLACE regulator. Go to AS. • Connect voltmeter across B + terminal and ground. • Start engine and run at an idle. • Use a screwdriver or other similar tool to ground connecting strip between brush assembly and regulator to alternator frame. • Increase engine speed slowly while monitoring voltage at B + terminal. • Alternator should be capable of producing 16 volts. CAUTION: Do not increase engine speed any more than necessary to produce a 16 volt output. An unregulated alternator can produce excessively high voltage at high speed. BRIDGING BRUSH ASSYI REGULATOR CONNECTING STRIP TO ALTERNATOR FRAME (GROUND) BRUSH ASSYI REGULATOR CONNECTING STRIP VIEW A NOTE: Alternator shown removed for clarity only. AS BASE VOLTAGE AND NO·LOAD TEST Voltage increase but less than 2.5 volts No voltage increase or increase greater than 2.5 volts. GO to A9. SERVICE or REPLACE alternator or regulator. REFER to Section 31·15. • Connect voltmeter across battery terminals. Read and record voltage (this is base reading). • Start engine, run at 1500 rpm with no electrical load. Voltage should increase from base reading, but not more than 2.5 volts. NOTE: Test step must be performed with alternator installed. Engine should be running at approximately 1500 rpm. Alternator shown removed for clarity only. CJ3379·A Copyright © 1990, Ford Motor Co. www.techcapri.com

31-01-8 Charging System-Service 31-01-8 TESTING (Continued) CHARGING SYSTEM TEST - Continued TEST STEP RESULT ACTION TO TAKE A9 LOAD TEST Within limits Out of limits Problem is not in charging system. CHECK other vehicle systems for a constant or intermittent current overdraw by repeating battery drain test with various auxiliary circuits tuned on. REPLACE or SERVICE alternator for shorted or open stator and field windings or diodes breaking down under load. • Disconnect battery ground cable and alternator B + lead. • Connect a 100-amp ammeter between the alternator B + terminal and the B + lead. • Connect a carbon pile load rheostat across the battery terminals. Turn carbon pile to OFF or NO· LOAD before connecting. • Connect a voltmeter from B + terminal to ground. • Start engine and run at an idle. Adjust carbon pile until the voltmeter reads 13.5 volts. Record ammeter reading. Repeat test step at 1000 and 2000 rpm. • Compare results with the following: ENGINE SPEED OUTPUT CURRENT IDLE ....... . 1000 ....... . 2000 ...... . AT 13.5 VOLTS 30·40 AMPS 55·65 AMPS 80-90 AMPS AMMETER ALTERNATOR GROUND-=- ALTERNATOR B+ WIRE VOLTMETER CARBON PILE RHEOSTAT BATTERY CONNECT NEGATIVE LEAD OF TACHOMETER TO GROUND REMOVE BATTERY NEGATIVE CABLE BEFORE 0 ........ ---- HOOKING UP METERS. CONNECT CABLE TO PERFORM TEST TACHOMETER CONNECT POSITIVE LEAD OF TACHOMETER TO NEGATIVE SIDE OF COIL CJ3380·A Copyright © 1990, Ford Motor Co. www.techcapri.com

31-01-9 Charging System-Service 31-01·9 SPECIFICATIONS SPECIAL SERVICE TOOLS ROTUNDA EQUIPMENT Model Description 014-00407 Digital Volt-Ohmmeter Deec:r!ptIon Specification Ground Polarity Negative Nominal '«Iltage 14 \tits Nominal DC Output 85 amps Stator Phases 3 Stator Winding Connection Star Number 01 Poles 12 Resistance 01 Rotor Windings 2,6 ± ,13 ohms Resistance 01 Stator Windings ,037 + 10% ohms Brush Length (Prolrusion) New 9,8mm (0,39 Inch) Minimum 3,Smm (0,15 Inch) Minimum Diameter 01 Slip Rings 26.7mm (1.05 Inch) CJ3485-A Copyright © 1990, Ford Motor Co. www.techcapri.com

31-02-1 Batteries SECTION 31-02 Batteries SUBJECT PAGE MAINTENANCE Battery Cleaning ..••••••••.••••••••••.••..•.•.•.•.••.•••••••••••.... 31·02·6 Jump Starting ........................................................31·02·6 REMOVAL AND INSTALLATION Battery ..................................................................31·02·4 SERVICE Battery Cable Clamp Spreader ............................... 31·02-5 Battery Cable Puller ...............................................31-02-4 Battery Carrier ....................................................... 31·02-5 Battery Pliers ......................................................... 31·02·4 SUBJECT PAGE SERVICE (Cont'd.) Terminal Cleaning Brush ........................................ 31-02-5 Tools ..................................................................... 31-02-4 SPECIAL SERVICE TOOLS ......................................... 31-02-6 TESTING Battery Capacity Test ............................................31-02-3 Battery Charging ................................................... 31-02-3 Battery Voltage Check ...........................................31-02-1 VEHICLE APPLICATION .............................................31-02-1 VEHICLE APPLICATION Capri. TESTING Tests are made on a battery to determine the state of charge and also its capacity or ability to crank an engine. The ultimate result of these tests is to show that the battery is good, needs recharging, or must be replaced. Before attempting to test a battery, it is important to give it a thorough examination to determine if it has been damaged. WARNING: ALWAYS DISCONNECT THE BATTERY CABLE WHEN CHARGING THE BATrERY OR ARC WELDING ON THE VEHICLE. KEEP ALL FIRE AWAY FROM 'rHE TOP OF THE BATTERY WHEN CHARGING "rHE BATTERY. AVOID CONTACT OF SULFURIC ACID WITH SKIN, EYES, CLOTHING AND VEHICLE. WARNING: BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES WHICH CAN CAUSE PERSONAL INJURY. THEREFORE, DO NOT ALLOW FLAMES, SPARKS OR I.lGHTED TOBACCO TO COME NEAR THE BATTERY. WHEN CHARGING OR WORKING NEAR A BATTERY, ALWAYS SHIELD YOUR FACE AND PROTECT YOUR EYES. ALWAYS PROVIDE VENTILATION. Battery Voltage Check 1. With the ignition OFF and no electrical loads on, connect the negative (-) lead of Rotunda Voltmeter 059-000 1 a or equivalent to the negative battery cable clamp. NOTE: The range setting on the voltmeter should be at least a to 15. WHEN LIFTING A PLASTIC-CASED BATTERY, EXCESSIVE PRESSURE ON THE END WALLS COULD CAUSE ACID TO SPEW THROUGH THE VENT CAPS, RESULTING IN PERSONAL INJURY. LIFT WITH A BATTERY CARRIER OR WITH YOUR HANDS ON OPPOSITE CORNERS. WARNING: KEEP OUT OF REACH OF CHILDREN. BATTERIES CONTAIN SULFURIC ACID. AVOID CONTACT WITH SKIN, EYES, OR CLOTHING. ALSO, SHIELD YOUR EYES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION. IN CASE OF ACID CONTACT WITH SKIN OR EYES, FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF 15 MINUTES AND GET PROMPT MEDICAL ATTENTION. IF ACID IS SWALLOWED, CALL A PHYSICIAN IMMEDIATELY. 2. Connect the positive (+) lead of the voltmeter to the positive battery cable clamp. 3. Ifthe voltmeter reading is over 12.4 volts at 21°C (70°F) the battery voltage is acceptable. If the reading is 12.4 volts or less, the battery needs charging. Copyright © 1990, Ford Motor Co. www.techcapri.com

1989-1994 Ford Capri 1.6L EFI Service & Repair Manual

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