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Hello everyone. I have used this and other forums to fix and keep running both of my First Gen Zetec Focus. I am now stumped. After searching the forums/ Youtube and google I am at a loss. I need specific help with this.

2001 ZX3 Focus with Zetec engine. Back story as I know it car sat for 2 years needing a battery and Alternator, had the battery light on and would jump start but then kill battery and die. Owner gave up on it. I now own it and have replaced the following. Battery (load tests good), Belt Tensioner, serpentine belt, sparkplugs, oil change, thermostat, radiator fluid., Battery and Alternator (2 times), the pigtail to the alternator, all the fuses/ relays (in engine bay), cleaned all the grounds and cleaned the battery terminals (new harness is on order).

I replaced bad alternator with a used (but tested good) one and the Battery light went away (does light up at start up like it should) but it would not charge. So I took the original Alternator to a local shop I have used many times in the past and had them rebuild it. I installed the 2nd Alternator and the same thing. No codes or warning lights but it still was not charging. Multimeter on battery 12.7V+ fully charged, car running 12.4V and slowly dropping, as I turned items on. So I take the alternator back off and take it to the shop to have them test it. It tests good, charges and handles a load on their machine just fine. Reinstall that alternator, replace the pig tail coming from alternator and still not charging. I have good voltage to the large red wire on back of alternator coming from battery. I even added a ground to the alternators housing to the engine just in case. Also it doesn't charge if I disconnect the pigtail from the alternator.

So anything else I am missing? As far as I can tell from my research if my new battery cables (when they get here) doesn't fix it and I don't think it will. Then my only other item would be the PCM/computer! It doesn't seem to be telling the alternator that it should be charging. I need to get this car drivable since my other focus died recently (Engine issue). Car is a beater but my daily driver to and from work, really want to make sure I covered everything before I break down and replace the PCM, since they are pricey and it still may not be the problem. Any ideas?
 

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There is no way to get a belt on a zetec to where it is tight but will not pull alt right. Every other way results in an unuseable belt with super slack in it.

If original terminals are still on cables and have been cleaned they WILL be loose even with the attaching bolts tight. A problem with that design, twist the terminals by hand and if they move you are there. I NEVER use the OEM Focus terminals, they are scrap. One cleaning and loose enough to not charge right.

The alts crack diode leads that then appear to work fine at testing until they don't. The cracks open up with vibration and close and closed you charge and open you don't. Another bad Ford product, the diode plate on the small 6G alt used there is also garbage. I use a much better plate that cures that fault and you MUST use a heavy duty regulator too as any other will blow out pretty quick. What most over the counter alts use and why they fail so fast.
 

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You are aware of course the new PCM will not work with your ignition key, the two have to be matched to start the car?
 
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