Ford Fusion: Generator and Regulator / Generator Pulley. Removal and Installation

Ford Fusion 2013–2020 Service Manual / Electrical / Battery and Charging System / Generator and Regulator / Generator Pulley. Removal and Installation

Removal

Remove the generator.
Refer to: Generator - 1.5L EcoBoost (118kW/160PS) – I4 (414-02 Generator and Regulator, Removal and Installation).
Refer to: Generator - 2.0L EcoBoost (184kW/250PS) – MI4 (414-02 Generator and Regulator, Removal and Installation).
Refer to: Generator - 2.5L Duratec (125kW/170PS) (414-02 Generator and Regulator, Removal and Installation).
Refer to: Generator - 2.7L EcoBoost (238kW/324PS) (414-02 Generator and Regulator, Removal and Installation).

Using a small screwdriver or similar tool, insert the tool through the rubber button on the center of the pulley cap and pry off the cap. Discard the cap. A new cap must be installed if the clutch is ok.

Ford Fusion. Generator Pulley. Removal and Installation

NOTICE: Do not insert anything into the fins of the generator to prevent the rotor inside the generator from turning. Inserting items into the generator could result in damage to the generator.

NOTE: The shaft and rotor will turn during removal.
Using a 17 mm hex tool and an impact gun, remove the clutch pulley. A couple of short bursts with the impact gun will remove the clutch pulley.

Installation

Install the pulley and hand start.

NOTICE: Do not insert anything into the fins of the generator to prevent the rotor inside the generator from turning. Inserting items into the generator could result in damage to the generator.

NOTE: The shaft and rotor will turn during installation.
While holding the outer diameter of the clutch pulley, torque the clutch pulley using a 17 mm hex tool, 75 Nm torque stick and an impact gun for 3-4 seconds. This makes sure the proper torque has been applied.
Torque: 55 lb.ft (75 Nm)

Install a new cap onto the pulley with the rubber button facing inwards.

Install the generator.
Refer to: Generator - 1.5L EcoBoost (118kW/160PS) – I4 (414-02 Generator and Regulator, Removal and Installation).
Refer to: Generator - 2.0L EcoBoost (184kW/250PS) – MI4 (414-02 Generator and Regulator, Removal and Installation).
Refer to: Generator - 2.5L Duratec (125kW/170PS) (414-02 Generator and Regulator, Removal and Installation).
Refer to: Generator - 2.7L EcoBoost (238kW/324PS) (414-02 Generator and Regulator, Removal and Installation).

Generator - 1.5L EcoBoost (118kW/160PS) – I4. Removal and Installation

Removal NOTE: Early build vehicle shown with idler pulley attached to the generator shown. Late build vehicles similar, without idler pulley attached to the generator...

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Ford Fusion 2013–2020 Service Manual: Main Control Cover - 2.0L EcoBoost (184kW/250PS) – MI4. Removal and Installation

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Note: Depending on your vehicle option package, the controls may look different from what you see here.