Ford Fiesta (1989-1995). Instruction - part 39

withdraw the assembly from the rear of the
alternator (see illustrations).
4 Check the brush lengths (see illustration).
If either is less than, or close to, the minimum
specified length, renew them by unsoldering
the brush wiring connectors and withdrawing
the brushes and their springs.
5 Clean the slip rings with a solvent-
moistened cloth, then check for signs of
scoring, burning or severe pitting. If evident,
the slip rings should be attended to by an
automobile electrician.
6 Refit in the reverse order of removal.

Magneti-Marelli

7 Remove the three screws securing the
regulator/brush box unit on the rear face of the
alternator, partially withdraw the assembly,
detach the field connector, and remove the
unit from the alternator (see illustrations).
8 If the brushes are worn beyond the
minimum allowable length specified, a new
regulator and brush box unit must be fitted;
the brushes are not available separately.
9 Clean the slip rings with a solvent-moistened
cloth, then check for signs of scoring, burning
or severe pitting. If evident, the slip rings should
be attended to by an automobile electrician.
10 Refit in the reverse order of removal.

Mitsubishi

11 Hold the pulley nut stationary using an 
8 mm Allen key, unscrew the pulley nut and
remove the washer (see illustration).

12 Withdraw the pulley, cooling fan, spacer
and dust shield from the rotor shaft.
13 Mark the relative fitted positions of the front
housing, stator and rear housing (to ensure

correct re-alignment when reassembling).
Unscrew the through-bolts and remove the front
housing from the rotor shaft, followed by the
dust seal and the thin spacer (see illustrations).

Starting and charging systems  5A•5

7.4  Measuring the brush lengths (Bosch

alternator)

7.3b  . . . withdraw the brush box/regulator

unit (Bosch alternator)

7.11  Pulley nut removal on the Mitsubishi

alternator

7.13a  Exploded view of the Mitsubishi A5T alternator

7.7b  Disconnecting the field connector

(Magneti-Marelli alternator)

7.7a  Removing the regulator and brushbox

assembly securing screws (Magneti-

Marelli alternator)

5A

1595Ford Fiesta Remake

7.3a  Undo the retaining screw and . . .

A Pulley
B Fan
C Thick spacer
D Through-bolt
E Dust shield
F Drive end unit
G Bearing
H Bearing retainer
J Dust cap
K Thin spacer
L Rotor
M Seal
N Bearing
O Commutator end
P Diode pack
R Brush box
S Stator

14 Remove the rotor from the rear housing
and the stator. If difficulty is experienced, heat
the rear housing with a 200-watt soldering
iron for three or four minutes.
15 Unbolt the rectifier/brush box and stator
assembly from the rear housing (see
illustration).
16 Unsolder the stator and brush box from
the rectifier, using the very minimum of heat.
Use a pair of pliers as a heat sink to reduce
the heat transference to the diodes
(overheating may cause diode failure).
17 Renew the brushes if they are worn down
to, or beyond, the minimum specified length.
Unsolder the brush wires at the points
indicated (see illustration), then solder the
new brush leads so that the wear limit line
projects 2 to 3 mm from the end of the holder
(see illustration).
18 Clean the slip rings with a solvent-
moistened cloth, then check for signs of
scoring, burning or severe pitting. If evident,
the slip rings should be attended to by an
automobile electrician.

19 Refit in the reverse order of removal.
Insert a piece of wire through the access hole
in the rear housing to hold the brushes in the
retracted position as the rotor is refitted (see
illustration). Do not forget to release the
brushes when assembled.

8

Starting system - testing

1

Note: Refer to the precautions in Section 1
before starting work.
1 If the starter motor fails to operate when the
ignition key is turned to the appropriate
position, the following possible causes may
be to blame.

a) The battery is faulty.
b) The electrical connections between the

switch, solenoid, battery and starter
motor are somewhere failing to pass the
necessary current from the battery
through the starter to earth.

c) The solenoid is faulty.
d) The starter motor is mechanically or

electrically defective.

2 To check the battery, switch on the
headlights. If they dim after a few seconds,
this indicates that the battery is discharged -
recharge (see Section 3) or renew the battery.
If the headlights glow brightly, operate the
ignition switch and observe the lights. If they
dim, then this indicates that current is
reaching the starter motor, therefore the fault
must lie in the starter motor. If the lights
continue to glow brightly (and no clicking
sound can be heard from the starter motor
solenoid), this indicates that there is a fault in
the circuit or solenoid - see following
paragraphs. If the starter motor turns slowly
when operated, but the battery is in good
condition, then this indicates that either the
starter motor is faulty, or there is considerable
resistance somewhere in the circuit.
3 If a fault in the circuit is suspected,
disconnect the battery leads (including the
earth connection to the body), the starter/
solenoid wiring and the engine/transmission
earth strap. Thoroughly clean the
connections, and reconnect the leads and
wiring, then use a voltmeter or test lamp to
check that full battery voltage is available at
the battery positive lead connection to the
solenoid, and that the earth is sound. Smear
petroleum jelly around the battery terminals to
prevent corrosion - corroded connections are
amongst the most frequent causes of
electrical system faults.

5A•6 Starting and charging systems

7.19  Use a length of wire rod to hold

brushes in the retracted position when

reassembling the rotor to the housing on

the Mitsubishi alternator

7.17b  Fitted position of new brush on a

Mitsubishi alternator

7.17a  Unsoldering a brush wire on a

Mitsubishi alternator

7.15  Rectifier/brush box (1) and regulator

unit (3) retaining nuts on the Mitsubishi

alternator. Note that cap (2) covers the

regulator nut

A Pulley nut
B Spring washer
C Pulley
D Through-bolt
E Retainer plate screw
F Drive end housing
G Bearing
H Bearing retaining plate

J Spacer
K Rotor
L Spacer
M Slip ring end bearing
N Plug
P Cap
Q Terminal insulator
R Slip ring end housing

S Rectifier
T Dust cover
V Regulator
W Brush spring
X Brush
Y Regulator screw
Z Stator

1595Ford Fiesta Remake

7.13b  Exploded view of the AOO2T Mitsubishi alternator

4 If the battery and all connections are in
good condition, check the circuit by
disconnecting the wire from the solenoid
blade terminal. Connect a voltmeter or test
lamp between the wire end and a good earth
(such as the battery negative terminal), and
check that the wire is live when the ignition
switch is turned to the “start” position. If it is,
then the circuit is sound - if not the circuit
wiring can be checked as described in
Chapter 12.
5 The solenoid contacts can be checked by
connecting a voltmeter or test lamp between
the battery positive feed connection on the
starter side of the solenoid, and earth. When
the ignition switch is turned to the “start”
position, there should be a reading or lighted
bulb, as applicable. If there is no reading or
lighted bulb, the solenoid is faulty and should
be renewed.
6 If the circuit and solenoid are proved
sound, the fault must lie in the starter motor.
In this event, it may be possible to have the
starter motor overhauled by a specialist, but
check on the cost of spares before

proceeding, as it may prove more economical
to obtain a new or exchange motor.

9

Starter motor -
removal and refitting

1

Removal

1 Disconnect the battery negative (earth) lead
(refer to Section 1).
2 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and vehicle support”). Remove
the front roadwheels.
3 Undo the two retaining nuts, and remove
the starter motor heat shield (where fitted).
4 Prise free the cap, if fitted, then unscrew the
nuts to disconnect the wiring from the
starter/solenoid terminals. Where applicable,
disconnect the oxygen sensor wiring multi-plug
from the locating bracket (see illustration).
5 Unscrew and remove the starter motor
retaining bolts at the transmission/clutch

housing and, where applicable, also unbolt
and detach the support bracket. Withdraw the
starter motor from its mounting, and remove it
from the vehicle (see illustrations).

Refitting

6 Refitting is a reversal of removal. Tighten
the retaining bolts to the specified torque.
Ensure that the wiring is securely reconnected
to the starter motor (and solenoid) and is
routed clear of the exhaust downpipe.

10 Starter motor -

testing and overhaul

4

If the starter motor is thought to be suspect, it
should be removed from the vehicle and taken
to an auto-electrician for testing. Most auto-
electricians will be able to supply and fit
brushes at a reasonable cost. However, check
on the cost of repairs before proceeding as it
may prove more economical to obtain a new
or exchange motor.

Starting and charging systems  5A•7

9.5b  Starter motor rear support bracket

and fasteners (arrowed)

9.5a  Starter motor retaining bolts

9.4  Disconnecting the wires from the

starter motor solenoid

5A

1595Ford Fiesta Remake

5A•8 Starting and charging systems

1595Ford Fiesta Remake

Notes