Removing and installing the generator (Escort 5)

Removal

Remove the negative terminal from the battery. Raise the front wheels and secure them on stands. Unscrew the bolts and remove the drive belt splash guard (see Fig. 5A.1).

Generator with V-belt drive and manual adjustment

On models with adjustable generator movement along the bracket, unscrew the upper generator mounting bolt.

On models with a rack and pinion type belt tensioner, unscrew and remove the center locking bolt. At the same time, the adjuster nut is released.

Loosen, but do not remove, the lower alternator mounting bolts and rotate the alternator toward the engine. Loosen the drive belt tension, then remove it from the pulleys (see Fig. 5A.2).



Where used, remove the generator heat shield.



Supporting the generator, unscrew its lower mounting bolts. Lower the generator and disconnect the electrical wires from it, then remove it from under the car (see Fig. 5A.3).

Generator with flat multi-groove belt drive and automatic belt tension adjustment

Place a spanner on the drive belt tensioner and turn it clockwise to release the belt tension. Note the direction of rotation of the drive belt and remove it from the pulleys.

On Zetec engines manufactured before 1996, remove the following components to access the alternator:

• disconnect the electrical connector of the oxygen sensor wire, then unscrew the 2 nuts and separate the exhaust pipe from the exhaust manifold. Support the exhaust pipe by tying it with soft wire.
• remove the splash guard from the base of the radiator.
• place a jack under the radiator and raise it so that the weight of the radiator is supported by the jack.
• unscrew the radiator support suspension mounting bolts first on the right side, then on the left.
• unscrew the generator mounting bolts. Remove it from the installation hanger, disconnect the electrical wires. Lower the radiator hanger so that you can remove the generator from the engine compartment.

On other models, remove the top alternator mounting bolt, disconnect the wiring, remove the bottom bolts and remove the alternator from the engine.

Installation

Installation is performed in the reverse order of removal. Install the drive belt and adjust its tension.