Charging System - Generator and Regulator Ford Cutaway E350

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

The charging system consists of the following components

1. battery
2. auxiliary battery (if equipped)
3. primary battery (6.0L)
4. secondary battery (6.0L)
5. generator (single)
6. generator (dual, 6.0L) (if equipped)
7. generator voltage regulator wiring
8. voltage regulator

Refer to CHARGING SYSTEM - GENERAL INFORMATION .

Removal and Installation

Note. This procedure also applies to the primary generator of the dual generator system.

Scheme 75

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Scheme 79

1. Disconnect the dual batteries. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
2. Position the cowl wire harness aside. Remove the bolt and position the manifold absolute pressure (MAP) sensor aside. Remove the bolt and position the ground strap aside. Remove the 2 bracket bolts and position the power steering fluid reservoir aside. Remove the 3 bolts and position the cowl wire harness aside.
3. Remove the intercooler tube bracket. Remove the left stud nut. Remove the 3 bracket screws. Remove the right stud nut.
4. Loosen the 2 clamps and remove the intercooler tube.
5. Rotate the accessory drive belt tensioner clockwise and remove the drive belt from the generator pulley.
6. Remove the transmission dipstick tube bracket nut from the generator stud bolt and position the bracket aside.
7. Remove the generator. Position the rubber cover aside, remove the nut and disconnect the B+ electrical connector. Disconnect the generator electrical connector. Remove the 2 stud bolts and 1 bolt.
8. To install, reverse the removal procedure.

Note. This procedure applies to the secondary generator of the dual generator system.

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1. Disconnect the dual batteries. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
2. Loosen the clamp and remove the intercooler tube from the intercooler and position it aside.
3. Rotate the primary accessory drive belt tensioner clockwise and position the drive belt aside.
4. Rotate the secondary accessory drive belt tensioner clockwise and remove the drive belt from the generator pulley.
5. Disconnect the generator electrical connectors.
6. Remove the bolts and the generator.
7. To install, reverse the removal procedure.

Scheme 83

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Scheme 87

1. Disconnect the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
2. Disconnect the air cleaner assembly. Loosen the worm clamp. Remove the bolts and pull the air cleaner assembly away from its mounted position.
3. Disconnect the mass air flow (MAF) sensor electrical connector.
4. Rotate the accessory drive belt tensioner clockwise (vehicles with A/C) or counterclockwise (vehicles without A/C) and position the accessory drive belt aside.
5. Disconnect the generator electrical connections. Remove the B+ terminal nut and disconnect the terminal. Disconnect the electrical connector. Disconnect the electrical connector.
6. Remove the bolts and the generator bracket.
7. Remove the bolts the generator.
8. To install, reverse the removal procedure.

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Scheme 89

1. Remove the generator. For additional information, refer to «GENERATOR - GASOLINE ENGINES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) .
2. Remove the generator brush and terminal holder and the voltage regulator. Remove the screws. Remove the generator brush and terminal holder and the voltage regulator.
3. Separate the generator brush and terminal holder from the voltage regulator. Remove the screw cap. Remove the screws. Separate the generator brush and terminal holder from the voltage regulator.

Scheme 90

Scheme 91

1. Install the brush and terminal holder on the voltage regulator. Position the brush and terminal holder on the voltage regulator. Install the screws. CAUTION: Make sure the screw cap is installed over test terminal A to prevent accidental shorting of the battery positive (B+) connection. Install the screw cap.
2. Install the generator brush and terminal holder and the voltage regulator. Press the brushes and insert a wire to hold them. Position the generator brush and terminal holder and the voltage regulator. Install the screws. Remove the wire.
3. Install the generator. For additional information, refer to «GENERATOR - GASOLINE ENGINES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) .

See also:
• CHARGING SYSTEM - GENERAL INFORMATION
• BATTERY, MOUNTING AND CABLES
• GENERATOR - GASOLINE ENGINES