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Brian
Brian, Service Engineer
Category: Car
Satisfied Customers: 1227
Experience:  Master Tech, Bachelor's of Science in Automotive Technology, Ford Factory Trained
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how do you change the alternator on a 2002 ford focus se

Customer Question

i have the bttery disconnected and the wire leading to the alt. disconnected. i know about the 3 bolts to loosen as well. its just when i put a socket on the main pulley the belt slides around either way. do i have to let tension off at all.

Optional Information:
2002 Ford focus se 2.0






Submitted: 8 years ago.
Category: Car
Expert:  Fordanswerman replied 8 years ago.
Thanks for your question. Are you talking whether to take the tension off of the alt to remove the belt? You do need to remove the belt off of the alt.
Expert:  Brian replied 8 years ago.
First you need to remove the belt. In order to do that, you must
relieve the tension on the belt by using a socket wrench on the bolt
head in the center of the tensioner pulley to rotate the tensioner so
the belt loosens. The tensioner is at the bottom of the engine, just
below the alternator, and must be accessed from underneath or possibly
through the wheelwell with the wheel removed.



Here is a picture of the tensioner:







Here are the instructions for removing the belt, from the Factory Shop
Manual (the instructions say to remove certain components like the fuel
pressure sensor to provide easier access to the alternator, but it may
not be absolutely necessary as long as you can remove the alternator
without damaging anything:

Accessory Drive Belt — 2.0L Zetec-E (Zetec)

Removal

All vehicles

  1. Disconnect the battery ground cable. For additional information, refer to
    Section 414-01 .

  1. Raise and support the vehicle. For additional information, refer to Section
    100-02 .

  1. Remove the splash shield.




  1. Remove the accessory drive belt.
    1. Rotate the accessory drive belt tensioner clockwise.

    1. Remove the accessory drive belt.




Installation




  1. To install, reverse the removal procedure




Here is the Alternator Removal and Installation Instructions:



Removal





  1. CAUTION: The generator must be protected from contamination. Failure
    to follow this instruction may cause premature failure of the generator.

    Protect the generator with lint-free material to prevent contamination.




  1. Remove the fuel pressure sensor. For additional information, refer to
    Section 303-14 attached below





  1. Remove the accessory drive belt. For additional information, refer to
    Section 303-05 .




  1. Lower the vehicle.




  1. Remove the coolant expansion tank retaining bolt.





  1. Detach the coolant expansion tank from the retaining clip and secure it to
    one side.





  1. Detach the power steering reservoir and secure it to one side.





  1. Disconnect and detach the engine wiring harness and secure it to one side.





  1. Disconnect the ground cable.





  1. Disconnect the electrical connector and detach the evaporative emission
    canister purge valve.





  1. Disconnect the vacuum lines from the evaporative emission canister purge
    valve.





  1. Disconnect the evaporative emission canister vacuum line and remove the
    evaporative emission canister purge valve.





  1. Disconnect the cylinder head temperature (CHT) sensor electrical connector.





  1. Disconnect the ground cable and remove the engine lifting eye.





  1. Disconnect the ground cable.






  1. NOTE: Mark the position of the engine mounting.

    Remove the front
    engine mounting retaining bolts.











  1. Slide the engine towards the front of the vehicle and reinstall one of the
    retaining bolts into the rear bolt hole to prevent the engine moving backwards.





  1. Disconnect the generator electrical connectors.
    • Remove the protective cap (if equipped).





  1. Remove the generator retaining bolt.






  1. NOTE: The retaining bolt must be fully disengaged from the bracket
    although it is not possible to remove the bolt at this stage.

    Unscrew the
    generator retaining bolt fully.





  1. Remove the generator.
    • Remove the retaining bolt from the generator.




Installation





  1. NOTE: To aid installation, slide back the generator locking sleeves.

    To install, reverse the removal procedure.









Fuel Rail Pressure (FRP) Sensor — 2.0L Zetec-E (Zetec)


Removal


WARNING: Do not smoke or carry lighted tobacco or open flame of any
type when working on or near any fuel related components. Highly flammable
vapors are always present and may ignite. Failure to follow these instructions
may result in personal injury.


WARNING: This procedure involves fuel handling. Be prepared for fuel
spillage at all times and always observe fuel handling procedures. Failure to
follow these instructions may result in personal injury.


WARNING: The fuel system remains pressurized for a long time after the
ignition is switched off. The fuel pressure must be released before attempting
any repairs. Failure to follow these instructions may result in personal injury.


  1. Release the fuel pressure. For additional information, refer to Section 310-00 .

  1. Disconnect the battery ground cable.

  1. Disconnect the fuel pressure sensor electrical connector.


  1. Disconnect the fuel and vacuum lines.


  1. Remove the fuel pressure sensor.


  1. Remove and discard the O-ring seal.


Installation



  1. WARNING: Do not smoke or carry lighted tobacco or open flame of any
    type when working on or near any fuel related components. Highly flammable
    vapors are always present and may ignite. Failure to follow these instructions
    may result in personal injury.


    WARNING: This procedure involves fuel handling. Be prepared for fuel
    spillage at all times and always observe fuel handling procedures. Failure to
    follow these instructions may result in personal injury.


    WARNING: The fuel system remains pressurized for a long time after the
    ignition is switched off. The fuel pressure must be released before attempting
    any repairs. Failure to follow these instructions may result in personal injury.


    NOTE: Install a new fuel pressure sensor O-ring seal.

    To install,
    reverse the removal procedure.
    • Lubricate the fuel pressure sensor O-ring seal with clean engine oil to aid
      installation.















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