Removal and installation of the generator

Withdrawal

Remove the negative terminal from the battery. Raise the front wheels and secure on stands. Unscrew the bolts and remove the drive belt mudguard (see fig. 5A.1).

V-belt driven alternator with manual adjustment

On models with alternator movement adjustment on the bracket, unscrew the upper alternator mounting bolt.

On models with a rack and pinion type belt tensioner, unscrew and remove the center lock bolt. At the same time, the regulator nut is released.

Loosen but do not remove the lower alternator mounting bolts and rotate the alternator towards the engine. Loosen the drive belt, then remove it from the pulleys (see fig. 5A.2).



Where used, remove the generator heat shield.


While supporting the generator, unscrew its lower mounting bolts. Lower the generator and disconnect the electrical wires from it, then remove it from under the car (see fig. 5A.3).

Flat multi-groove belt driven alternator with automatic belt tension adjustment

Install a ring wrench on the drive belt tensioner and turn it clockwise to loosen the belt tension. Pay attention to the direction of rotation of the drive belt and remove it from the pulleys.

On Zetec engines built prior to 1996, separate the following components to gain access to the alternator:

• disconnect the oxygen sensor wire electrical connector, then unscrew the 2 nuts and separate the exhaust pipe from the exhaust manifold. Support the exhaust pipe by tying it with soft wire.
• remove the mudguard from the base of the radiator.
• Place a jack under the radiator and raise it just enough so that the weight of the radiator is supported by the jack.
• unscrew the radiator support suspension mounting bolts, first on the right side, then on the left.
• unscrew the alternator mounting bolts. Remove it from the installation suspension, disconnect the electrical wires. lower the radiator mount as far as it will go. so that the generator can be removed from the engine compartment.

On other models, unscrew the upper alternator mounting bolt, disconnect the electrical wiring, unscrew the lower bolts and remove the alternator from the engine.

Installation

Installation is made in sequence, return to removal. Install the drive belt and adjust its tension.