Charging System - Generator & Regulator: Removal & Installation Ford Econoline E250

Removal and Installation

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

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1. Disconnect the dual batteries. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
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 bolts and position the power steering fluid reservoir aside. Remove the 3 bolts and position the cowl wire harness aside.
3. Remove the 3 bolts, 2 nuts and the intercooler tube bracket.
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.

Generator - 6.0L Diesel, Dual Generator

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»(ref-210181) .
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 bolts and position the power steering fluid reservoir aside. Remove the 3 bolts and position the cowl wire harness aside.
3. Remove the 3 bolts, 2 nuts and the intercooler tube bracket.
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. Disconnect the generator electrical connectors.
7. Remove the bolts and the generator.
8. To install, reverse the removal procedure.

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1. Disconnect the battery. For additional information, «BATTERY, MOUNTING AND CABLES»(ref-210181) .
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. Remove the drive belt from the generator. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-165012) .
5. Disconnect the generator rear connections. Remove the B+ terminal nut and disconnect the terminal. Disconnect the S electrical connector. Disconnect the ASI electrical connector.
6. Remove the bolts retaining the upper intake plenum to the generator bracket.
7. Remove the bolts and lift out the generator.

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1. To install, reverse the removal procedure.

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1. Remove the generator. For additional information, refer to «GENERATOR - 4.6L»(ref-213723-S16480821872005123000000) , «GENERATOR - 5.4L»(ref-213723-S29048575292005123000000) , «GENERATOR - 6.0L DIESEL, SINGLE GENERATOR»(ref-213723-S14200521602005123000000) , «GENERATOR - 6.0L DIESEL, DUAL GENERATOR»(ref-213723-S40770004772005123000000) or «GENERATOR - 6.8L»(ref-213723-S23482496242005123000000) .
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.

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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 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. Depress 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.