DIY generator repair ford focus 2

In detail: do-it-yourself generator repair Ford Focus 2 from a real master for the site my.housecope.com.

b. Remove the three bolts securing the alternator.

8. Install the generator in the reverse order of removal, while the accessory drive belt must be replaced with a new one (see "Replacing the accessory drive belt on engines 1.4 l R4 Duratec-HE 16V and 1.6 l R4 Duratec-HE 16V" , p. 83); "Replacing the accessory drive belt on the 1.6 l R4 16V Duratec Ti-VCT engine", p. 83; "Replacing the accessory drive belt on engines 1.8 l R4 Duratec-HE 16V and 2.0 l R4 Duratec-HE 16V", p. 84).

You will need: a high socket head "24", a hex key "8", welding pliers.

1. Remove the generator from the car (see "Removing and installing the generator", page 226).

2. Hold the generator shaft with the key.

3.. unscrew the pulley retaining nut ..

5. Make marks on the generator body.

6. Remove the bolts and, gently prying with a screwdriver, remove the cover of the diode bridge of the generator.

8. Remove the mounting bolts.

9. . and remove the brush holder assembly with brushes.

eleven. . bend the contact and remove the voltage regulator.

12. Remove the mounting bolts.

thirteen. . and, using a screwdriver, remove the cover from the drive side of the generator.

We disassemble the Ford Focus 2 generator to check and replace the voltage regulator with a brush holder and a rectifier unit.

Image - DIY generator repair ford focus 2

Using the "7" head, unscrew the four nuts securing the generator casing.

Image - DIY generator repair ford focus 2

With a knife we ​​clean the sealant from the inside of the casing ...

Image - DIY generator repair ford focus 2

… And remove the generator casing.

Image - DIY generator repair ford focus 2

We clean the nut that secures the generator output from the sealant.

Image - DIY generator repair ford focus 2

Turn off the nut with the "10" head ...

Image - DIY generator repair ford focus 2

... and remove the generator output.

Video (click to play).

Image - DIY generator repair ford focus 2

Using the "8" head, unscrew the nut for fastening the brush holder with a voltage regulator.

Remove the washer under the nut.

Image - DIY generator repair ford focus 2

Using a Phillips screwdriver, unscrew the two screws securing the brush holder with a voltage regulator.

Image - DIY generator repair ford focus 2

Remove the brush holder with voltage regulator assembly.

Image - DIY generator repair ford focus 2

Remove the protective film from the brush holder.

Image - DIY generator repair ford focus 2

Image - DIY generator repair ford focus 2

Use a screwdriver to unclench the three outputs of the rectifier unit.

Image - DIY generator repair ford focus 2

Using the "8" head, unscrew the two nuts securing the rectifier unit.

Image - DIY generator repair ford focus 2

We remove the rectifier unit.

To check the rotor winding short circuit to ground ...

Image - DIY generator repair ford focus 2

… We connect the tester probes (in ohmmeter mode) to the slip ring and the rotor shaft.

The tester should show infinity, otherwise the winding is shorted to ground and you need to replace the rotor or generator.
To check if the rotor winding is broken ...

Image - DIY generator repair ford focus 2

… We connect the tester probes (in ohmmeter mode) to the slip rings.

If the tester shows infinity, then there is an open circuit in the winding and you need to replace the rotor or generator.
We inspect the stator windings.
There should be no traces of overheating on the insulation of the windings, which is the result of a short circuit in the valves of the rectifier unit. If the windings show signs of overheating, the stator or generator must be replaced.
To check for a break in the stator windings ...

Image - DIY generator repair ford focus 2

… We connect the tester probes (in ohmmeter mode) to the winding terminals.

If the tester shows infinity, then there is an open circuit in the winding and you need to replace the stator or generator.
Similarly, we check the rest of the stator windings.
To check the short circuit of the stator winding to ground ...

Image - DIY generator repair ford focus 2

… We connect the tester probes (in ohmmeter mode) to the winding terminal and the generator case.

The tester should show infinity, otherwise the winding is shorted to ground and the stator or generator must be replaced.
Similarly, we check the rest of the windings.
To check the short circuit in the positive diodes of the rectifier unit ...

Image - DIY generator repair ford focus 2

... the "plus" of the tester (in ohmmeter mode) is connected to the output of the generator, and the "minus" - to one of the outputs of the rectifier unit.

The tester should show infinity. If the tester indicates a circuit is present, one or more positive diodes are punctured.
To check the short circuit in the negative diodes, we connect the "plus" of the tester to one of the terminals of the rectifier unit, and the “minus” - to the bottom plate of the rectifier unit. The tester should show infinity. If the tester indicates a circuit is present, one or more negative diodes are punctured. In both cases, the rectifier unit must be replaced.
To test the voltage regulator ...

Image - DIY generator repair ford focus 2

... we connect a lamp (1-3 W, 12 V) to the brushes, and a DC power supply to the brush holder terminals, first with a voltage of 12 V, and then 15-16 V.

In the first case, the lamp should be on, in the second - not. If the lamp is on in both cases - there is a breakdown in the regulator, if it is not lit - there is an open or broken contact between the brushes and the terminals of the voltage regulator. In both cases, the regulator must be replaced.
We assemble the generator in the reverse order. At the same time, crimping the terminals of the rectifier unit at the terminals of the stator winding ...

Image - DIY generator repair ford focus 2

... we solder the places of their connection.

Before installing the brush holder, put the protective film of the brushes on the back cover of the generator. Having sunk the brushes, we install the brush holder in place ...

Image - DIY generator repair ford focus 2

The original source of content - WiKi of the site of the magazine "Za Rulem"

REMOVING THE GENERATOR

We remove the generator for repair or replacement if it fails.
Disconnect the terminal of the wire from the negative terminal of the battery.
Remove the accessory drive belt (see "1.3.6. Ford Focus II. Checking the condition and replacing the accessory and air conditioning drive belts. Replacing the spark plugs").
Remove the power steering reservoir without disconnecting the hoses from it and move the reservoir to the side (see "8.6. Ford Focus II. Removing the reservoir and removing air from the power steering hydraulic drive").

Read also:  Saeco xsmall coffee machine does not work DIY repair

Pressing the latch, disconnect the wiring block from the generator connector.

Remove the protective cap.

Using the "10" head, unscrew the nut that secures the wire tip to the generator output.

We remove the tip of the wire from the output of the generator.

Using the "15" head, unscrew the bolt of the lower mounting of the generator.

With the same tool, unscrew the bolt and nut of the upper mounting of the generator.

We take out the bolt ...

… And remove the power steering reservoir bracket.

We move the generator off the stud ...

… And take the generator out of the engine compartment.

Generator marking
Install the generator in reverse order.

DISASSEMBLY OF THE GENERATOR

We disassemble the generator to check and replace the voltage regulator with a brush holder and a rectifier unit.

Using the "7" head, unscrew the four nuts securing the generator casing.

With a knife we ​​clean the sealant from the inside of the casing ...

… And remove the generator casing.

We clean the nut that secures the generator output from the sealant.

Turn off the nut with the "10" head ...

... and remove the generator output.

Using the "8" head, unscrew the nut for fastening the brush holder with a voltage regulator.
Remove the washer under the nut.

Using a Phillips screwdriver, unscrew the two screws securing the brush holder with a voltage regulator.

Remove the brush holder with voltage regulator assembly.

Remove the protective film from the brush holder.

Remove the cover of the brushes.

Use a screwdriver to unclench the three outputs of the rectifier unit.

Using the "8" head, unscrew the two nuts securing the rectifier unit.

We remove the rectifier unit.
To check the rotor winding short circuit to ground ...

… We connect the tester probes (in ohmmeter mode) to the slip ring and the rotor shaft.
The tester should show infinity, otherwise the winding is shorted to ground and you need to replace the rotor or generator.
To check if the rotor winding is broken ...

… We connect the tester probes (in ohmmeter mode) to the slip rings.
If the tester shows infinity, then there is an open circuit in the winding and you need to replace the rotor or generator.
We inspect the stator windings.
There should be no traces of overheating on the insulation of the windings, which is the result of a short circuit in the valves of the rectifier unit. If the windings show signs of overheating, the stator or generator must be replaced.
To check for a break in the stator windings ...

… We connect the tester probes (in ohmmeter mode) to the winding terminals.
If the tester shows infinity, then there is an open circuit in the winding and you need to replace the stator or generator.
Similarly, we check the rest of the stator windings.
To check the short circuit of the stator winding to ground ...

… We connect the tester probes (in ohmmeter mode) to the winding terminal and the generator case.
The tester should show infinity, otherwise the winding is shorted to ground and the stator or generator must be replaced.
Similarly, we check the rest of the windings.
To check the short circuit in the positive diodes of the rectifier unit ...

... the "plus" of the tester (in ohmmeter mode) is connected to the output of the generator, and the "minus" - to one of the outputs of the rectifier unit.
The tester should show infinity. If the tester indicates a circuit is present, one or more positive diodes are punctured.
To check the short circuit in the negative diodes, we connect the "plus" of the tester to one of the terminals of the rectifier unit, and the “minus” - to the bottom plate of the rectifier unit. The tester should show infinity. If the tester indicates a circuit is present, one or more negative diodes are punctured. In both cases, the rectifier unit must be replaced.
To test the voltage regulator ...

... we connect a lamp (1-3 W, 12 V) to the brushes, and a DC power supply to the brush holder terminals, first with a voltage of 12 V, and then 15-16 V.
In the first case, the lamp should be on, in the second - not. If the lamp is on in both cases - there is a breakdown in the regulator, if it is not lit - there is an open or broken contact between the brushes and the terminals of the voltage regulator. In both cases, the regulator must be replaced.
We assemble the generator in the reverse order. At the same time, crimping the terminals of the rectifier unit at the terminals of the stator winding ...

... we solder the places of their connection.
Before installing the brush holder, put the protective film of the brushes on the back cover of the generator. Having sunk the brushes, we install the brush holder in place ...

... and install the brush cover.

The article will focus on replacing a generator on a Ford Focus 2 car with engines of 1.6, 1.8, 2.0 liters, signs of a device malfunction, checking its performance and replacing the brush assembly.

On Ford Focus 2 cars, the on-board network is powered with the engine running and the battery is recharged from a three-phase alternator, which is installed on all modifications of this car.

The conversion of alternating current into direct current is carried out by a rectifier unit, which is part of the generator's design, and the voltage stabilization and maintenance at the required level is performed by an electronic voltage stabilizer.

In addition, the ECU of the power plant affects the operation of the unit. This allows the generator to function properly under different conditions.

It is driven by the crankshaft of the power plant through a belt drive, which is also used to drive other attachments (air conditioning). The unit is cooled by an impeller mounted on the rotor.

Read also:  How to make repairs in the house with your own hands

The generator on Ford Focus 2 is considered maintenance-free due to the use of closed-type bearings on the rotor, the resource of which is designed for the entire period of operation of the car.

In reality, the device is not very reliable and breaks down quite often.

Symptoms of a malfunction are:

  • Increased noise from under the hood (squeal, squeak);
  • Lack of battery recharge;
  • Lack of electricity when using electrical equipment in a car (the headlights shine weakly, and when they are turned on, the warning lamps on the dashboard dim).

At the same time, despite the fact that the generator is connected to a self-diagnosis system, a malfunction signal is not always displayed on the on-board computer. In this case, the breakdown can be detected empirically.

Before removing the generator from the Ford Focus 2 for replacement or repair, you should first make sure it is faulty. The verification technology is very simple and fast.

Before diagnosing the functionality, it is necessary to loosen the positive terminal on the battery.

  • we start the engine;
  • wait until the turnover stabilizes;
  • turn on the headlights;
  • on the running engine, remove the positive terminal from the battery.

If the generator is in good working order, the power plant should not stop, on the contrary, its speed should increase slightly, since the ECU will correct the operation of the motor in order to provide the on-board network with energy.

Stopping the unit after removing the terminal will indicate a malfunction of the generator and the need to repair or replace it. And for this, the unit must be removed from the car, which turns out to be not so easy.

You can use the official instructions, which are presented below, but it does not reflect all the subtleties and nuances of the work, and therefore it is more suitable for acquaintance than as a detailed guide that is understandable to everyone.

The Ford Focus 2 uses several modifications of power plants with different design features that affect the algorithm of work during removal.

On engines with a volume of 1.4 and 1.6 liters, the generator is located in the upper part, which somewhat simplifies dismantling.

As an example, consider the technology for removing a node from a Ford Focus 2 equipped with a 1.6-liter unit.

To complete the work you will need:

  • Keys for 8, 10, 12 and 13 (better - heads of the indicated sizes with extensions and a wrench equipped with a ratchet mechanism);
  • Flat screwdriver;
  • Bit Torx E10.

These tools will be enough to get the job done. Dismantling is carried out on a cold engine.

Inspect the device for external damage. Smell, if it smells burnt, then most likely the wiring is burnt out.

Installation of a repaired or new unit is performed in the following sequence:

  1. First, the stud and nut are screwed in (Torx head 10, head 15);
  2. We put on the plastic bracket that holds the power steering reservoir; Image - DIY generator repair ford focus 2
  3. Insert and tighten the lower bolt under the pulley; Image - DIY generator repair ford focus 2
  4. We bait and tighten the upper bolt (to the left of the hairpin);
  5. Install the belt;
  6. We connect the connector and the generator wire. In the latter case, we use a nut for 10; Image - DIY generator repair ford focus 2
  7. We put the coolant reservoir in its regular place;
  8. We put a pipe clamp;
  9. We install the power steering barrels; Image - DIY generator repair ford focus 2
  10. We connect the power wire;
  11. Do not forget to install all the hoses in their places;
  12. We start the car and check the generator.

You need to choose a new generator by the VIN code of the car. The original products are manufactured by the Italian company DENSO.

The sticker must indicate that this is FORD, the amperage and original engineering code - 115 IM.

Difficulty installing the generator can cause the drive belt to land in place, since there is no tension roller on the 1.6-liter Ford Focus engine. Therefore, the installation of the drive is carried out using special tools that come with the original belt.

On Ford Focus 2 1.8 and 2.0 liter engines, the location of the generator differs from the 1.6-liter engine, and when dismantling, you cannot do without a viewing hole or overpass.

To carry out work from the tools, you will need all the same keys and heads for 8, 10, 12 and 13, as well as a screwdriver and an open-end wrench for 19.

Let us consider the algorithm of work on removal using the example of a 1.8-liter unit. Some of the work is done on top of the engine, and some on the bottom.

  • We install the car on the pit;
  • Remove the plastic protection from the engine;
  • Remove the terminal from the battery;
  • With a key 17 (19), we shift the tension roller towards the cab and remove the drive belt; Image - DIY generator repair ford focus 2
  • Using a 10 key, unscrew 3 roller fasteners, 1 - at the top (short, so mark it) and 1 - at the bottom under the engine, remove them. Pay attention, there are 2 bolts at the bottom, but so far only one is unscrewed; Image - DIY generator repair ford focus 2Image - DIY generator repair ford focus 2
  • We unscrew the bracket fastening bolt, which is used to attach the air conditioning pipe to the body, which goes to the air conditioner radiator. This is necessary so that you can then bend the tube and get the generator; Image - DIY generator repair ford focus 2
  • Turn off the chip using a flat screwdriver; Image - DIY generator repair ford focus 2
  • Unscrew the second lower mounting bolt;
  • After the knot drops down a little, we turn it, which will allow us to get to the wiring block and the nut for fixing the power cable. We disconnect the block and the power wire with a 13 head; Image - DIY generator repair ford focus 2
  • Taking the air conditioner branch pipe to the side, we take out the generator.
Read also:  DIY inverter generator repair

Installation of the assembly is carried out in the reverse order. Do not mix up the bolts.

Similarly, assembly and disassembly is carried out on a 2.0-liter unit.

On engines with a volume of 1.8 and 2.0 liters, the operation is convenient in that special equipment is not required to land the drive belt due to the presence of a tension roller.