REMOVAL & INSTALLATION
| CAUTION | When battery is disconnected, vehicle computer and memory system may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. |
Note. Removal and installation for 2.0L Duratec is not available from manufacturer.
Removal and Installation (2.0L Zetec-E)
- Disconnect negative battery cable. Protect generator with lint-free material to prevent contamination. Remove the fuel pressure sensor. Remove accessory drive belt.
- Remove bolt securing coolant overflow bottle. Remove coolant overflow bottle, and position aside. Remove power steering reservoir, and engine wiring harness bracket, and position aside. Disconnect ground strap near right front shock tower. (Scheme 3)
- Remove evaporative emission canister purge valve, and position aside. (Scheme 4) Disconnect the cylinder head temperature sensor electrical connector. (Scheme 5) Disconnect the ground cable on engine lifting eye and remove the engine lifting eye.
- Remove ground cable on frame rail at right side of engine. (Scheme 6) Mark the position of the engine mounting. Remove front engine mounting retaining bolts. (Scheme 7) Slide engine towards front of vehicle and reinstall one of the retaining bolts into rear bolt hole to prevent engine moving backwards. (Scheme 8)
- Disconnect electrical connectors from generator. Lower retaining bolt must be fully disengaged from the bracket although it is not possible to remove the bolt at this stage. Unscrew 2 generator mounting bolts and remove generator from vehicle.
- To aid in installation, slide back the generator locking sleeves. (Scheme 9) To install, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-139409-S20825101142002043000000).
Scheme 3
Scheme 4
Scheme 5
Scheme 6
Scheme 7
Scheme 8
Scheme 9
Removal & Installation (2.0L SPI)
- Disconnect negative battery cable. Remove cooling fan motor and shroud. Remove accessory drive belt. Remove power steering pipe support brackets from exhaust manifold. (Scheme 10) Remove 3 nuts and exhaust manifold heat shield. (Scheme 11)
- Raise and support vehicle. Disconnect electrical connectors from generator. Remove lower generator mounting bolt. Lower vehicle. Remove wire harness clip from generator mounting bracket, 2 mounting bolts and generator from vehicle. To install, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-139409-S20825101142002043000000).
Scheme 10
Scheme 11
Removal & Installation (2.3L PZEV)
- Disconnect the battery. Remove the generator heat shield top nut. (Scheme 12) Raise and support the vehicle. Remove the screws and the lower splash shield. Release the accessory drive belt tension and remove the belt from the generator pulley. Remove the generator heat shield lower nut and the heat shield. (Scheme 13)
- Release the two air intake tube retainers and remove the air intake tube assembly. (Scheme 14) Remove the generator B+ cable nut and disconnect the B+ cable. Remove the two generator nuts and bolt. Lower the vehicle. Disconnect the generator electrical connector. Remove the upper generator nut.
- Raise and support the vehicle. Remove the engine roll restrictor mount bolt. (Scheme 15) With the help of an assistant, position the engine forward and remove the generator. To install, reverse the removal procedure.
