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Old 06-21-2010, 10:24 AM   #1
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Zetec Alternator removal/install

Man, getting that stupid thing out from the back of the engine is a super huge pain in the bottom.

For those who are going to have to do it, here are my observations.
1. Remove the expansion tank, the power steering resevoir, any and all wiring harnesses and plugs,....get everything out of the way. Rotate the tensioner forward and pull the belt off the alternator pulley. I zip tied it to the front of the car to keep it on all the other pulleys so I wouldn't have to mess with rerouting it.

2. Remove the engine hoist bracket...that's key. The top part comes all the way off, the bottom can be spun both ways around to get it out of the way.

3. Be prepared to bend the metal brackets on the strut tower for clearance.

4. Remove the timing belt cover.

5. Put a jack under the oil pan and loosen the motor mounts on the passenger side.

6. Remove the bolts two bolts on the alternator. Get a mallet and big screw driver and knock it loose, then use a small crowbar to continue to rock it out of the bracket.

7. Rotate it and get the plug off then unscrew the other lead on next to plug. It should be free.

8. Now hopefully you've removed enough stuff to sneak it out of the engine. With the motor mounts loose, you can raise and lower the engine to maximize clearance.

9. Once the old one is out, put your new one in in the exact orientation of the one you just pulled. Plug it in and screw on the other wire/plug thing.

10. Rotate it back into place and put everything back on that was removed.

Amazingly, I only had to remove about 10 bolts for all that crap. None were really tough to, but you will need a breaker bar.

Hopefully my little rant will help someone else to there's.

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Old 06-21-2010, 12:40 PM   #2
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Yeah we have a how-to for that here., and yours is about spot on how I do it aS WELL. Its a bear but you did a good job getting that puppy out.
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Old 06-21-2010, 12:59 PM   #3
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Try doing it with a supercharger in the way!
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