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Hello All,

I wanted to share my experience replacing an alternator on my 2004 Ford Focus Zetec 2.0L DOHC.

It was a pain. So, keep in mind it is not an easy job, but it is doable. I'm not what you call an expert.

Time required: at least two hours.

Here we go:
  1. Remove the battery ground cable.
  2. Raise the front of the car on two jacks.
  3. Remove the splash cover from the under side of the engine exposing the accessory belt.
  4. Remove the accessory belt by pulling on the tensioner pulley clockwise using a 15mm wrench or a breaker bar.
  5. Remove the coolant (antifreeze) reservoir.
  6. Remove the power steering reservoir and push out of the way.
  7. Remove the wire loom bracket and disconnect and push out of the way.
  8. Remove the ground lead and bend the bracket down out of the way.
  9. Unbolt three bolts holding the engine mount to the passenger fender.
  10. With a pry bar or wood 2x4 (I used a pry bar), leverage the engine forward towards the radiator. Be careful not to scratch any paint or to push the engine too far and damage the radiator or fan.
  11. Put a bolt back in an empty engine mount thread so it does not move back in place.
  12. Unbolt the alternator bolt closest to the engine halfway out (Not fully disengaged). Then with a hammer, tap the bolt few times to loosen the alternator from its grip on the bracket..
  13. Do the same with the second alternator bolt near the firewall. Then unbolt until fully disengaged. This bolt will not come all the way out at this point.
  14. Remove the alternator by maneuvering it to get the ears near the firewall clear first, then clear ears near the engine next.
  15. Disconnect alternator wiring.
  16. Now the alternator is free. Move the alternator upwards so the pulley is facing you then remove from car.
  17. Before installing the replacement alternator, screw in one bolt to each thread and tap on it with a hammer few times to make installing to bracket fit easier.
  18. Install the rest in reverse order.
This is my Focus with every thing out of the way.


This is the engine pushed forward. Notice the engine mount.


This is the alternator unbolted but still in place. Notice the second bolt cannot come all the way out.


Have fun.

Acknowledgment: I had a great help from a friend who has more experience than me. So, thank you, Friend.

Disclaimer: Those instructions are provided with no warranty. Do at your own risk. I provided those to share my experience.
 

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i need to replace the alt on my 2001 focus.. i basically follow your way but i use a pile of old rags to cushion the front and use 2 ratchet strap's (around the engine lift point by the alternator) and pull the engine forward anchoring the other end i tried the other way and found one of my arms pinched when while trying to turn the alternator i put a little to much pressure and the block of wood slipped causing the engine to slide back into place.
 

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One little thing that helps is to bend the tab with the screwhole shown in the last pic straight down, it frees up arm room there. Then leave it down, the screw is easy to get to that way as well.
 

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One little thing that helps is to bend the tab with the screwhole shown in the last pic straight down, it frees up arm room there. Then leave it down, the screw is easy to get to that way as well.
mine has Evap junk bolted to that xD.. with the engine tied forward you can get alot more room then using a board but you have to be very careful about the rad [cheers]
 

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I remove evap tubes and purge canister plumbing and tuck them to the center of car and down, sometimes I remove engine mount and sometimes not. Easier of course pulling engine forward like you say. Depends on my mood that day, I have gotten alt out more than once without messing with the mount. If the positive lead to alt locks up to be super tight like they tend to do though that can force a mount removal to have more room to remove it without breakage.
 

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A quickie............what is your favorite way to break the compression blocks loose that hold the alt mounting legs so solidly in place? I've tried several ways but going up under car seems to be the best to get the alt loose to fall out fast.
 

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break bolts loose smack with a big hammer and a flat end prybar.. like a GAF what happens to the old alternator. half the time Canadian alternators are split in half and fall apart anyways due to the hot and cold cycles and the swelling from the corrosion xD

i use a dremil with wire brush end to clean the compression surface then apply a libers splat of antiseize
 

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About the same as me then........I rebuild them so I have to be a bit more dainty about it.
come visit, and bring a pickup you can rifle though the 14 recycling bins of alternators out back that are split, cracked, broken, dead, torched, shorted and seized LOL the one that came off my current wagon i never even loosened the bolts as soon as i released it from the belt the alternator just fell.. xD the brackets were split right off
 

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Aaaiiiii...........caramba
Welcome to Canada xD Aluminum and white metals suck ass in subzero weather i just looked my 2006 alt even has a cracked case but it still works [neener]
 
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