To remove the alternator, start by disconnecting the negative battery cable. For 2.0L Zetec-E engines, remove the coolant expansion tank bolt, drivebelt, and power steering reservoir. Unscrew the wiring loom bracket bolt, move the wiring, disconnect the multi-plug, and remove the power steering reservoir bracket bolt. On 2003 and 2004 Zetec-E and Duratec engines, remove the front engine mount bolts, pry the engine forward, and insert one bolt behind the mount. Remove the canister purge valve bolts, plastic cover, and disconnect the wiring. Unscrew the alternator mounting bolts, lift the alternator, and remove the cooling fan and shroud. For 2.0L SPI engines, remove the power steering pipe bracket bolts, exhaust manifold heat shield, drivebelt, and disconnect the wiring. Unscrew the alternator mounting bolts and lift the alternator. For 2.3L and 2005-2007 2.0L engines, remove the top alternator heat shield nut and the lower one. Remove the lower engine splash shield, drivebelt, and lower alternator mounting nut. Remove the upper alternator mounting nut and the bolt at the roll-restricting engine mount, then remove the alternator. For 2008 and later models, disconnect the small gauge wiring and remove the right driveaxle if needed. Remove the center support bracket, accessory splash shield, drivebelt, lower alternator air duct, and the large wire from the alternator's B terminal. Remove the alternator mounting nuts, unscrew the mounting studs, and remove the alternator. Ensure you have the correct replacement alternator with matching terminals and markings. Installation is the reverse of removal, and tighten all nuts and bolts to specified torque settings. Check if the new alternator comes with a pulley; if not, transfer the pulley or inquire about installation.
Posted by FordPartsGiant Specialist 
