Generator (1.8L/2.0L/2.0L Duratec RS/1.6L Zetec-E) — removal and installation (Focus 1)

Removal

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

WARNING: This procedure involves handling fuel. Always be prepared for possible fuel splashing and follow proper fuel handling precautions. Failure to follow these instructions may result in injury.

WARNING: The fuel system remains under pressure for an extended period of time after the ignition is turned off. Relieve the fuel pressure before attempting any repairs. Failure to follow these instructions may result in personal injury.

1. Relieve fuel system pressure. Refer to Section 310-00A for additional information.

2. Remove the accessory drive belt. Refer to Section 303-05 for additional information.

3. Lower the vehicle.

4. Unscrew the bolt securing the expansion tank of the cooling system.

4. Unscrew the bolt securing the expansion tank of the cooling system.

5. Release the coolant expansion tank from the clamp and secure it to the side.

6. Disconnect the power steering fluid reservoir and secure it to the side.

7. Disconnect and disconnect the engine wiring harness and secure it to the side.

8. Disconnect the ground wire.

9. Disconnect the plug connector and disconnect the fuel vapor control system charcoal canister cleaning valve.

10. Disconnect the vacuum lines from the fuel vapor control system charcoal canister purge valve.

11. Disconnect the vacuum line of the carbon filter of the fuel vapor control system and remove the carbon filter cleaning valve of the fuel vapor control system.

12. Disconnect the cylinder head temperature sensor connector.

13.

CAUTION: Protect the generator from contamination. Failure to follow this instruction may result in premature failure of the generator.

Cover the generator with a lint-free material to prevent contamination.

14.

NOTE: Fuel supply line connections are colored white or identified by a white border. Fuel return line connections are colored red or identified by a red border.

Disconnect the fuel supply and return lines from the fuel pressure regulator.

15. Disconnect the ground wire.

16.

NOTE: Mark the position of the engine mount.

Remove the front engine mount mounting bolts.

17. Slide the engine towards the front of the vehicle and install one of the engine mounting bolts into place in the rear bolt hole to prevent the engine from moving rearward.

18. Disconnect the electrical connections of the generator.

Remove the protective cap (if present).

19. Remove the generator mounting bolt.

20.

NOTE: The mounting bolt must be completely released from the bracket, although the bolt cannot be removed at this stage.

Completely unscrew the generator mounting bolt.

21. Remove the generator.

Remove the generator mounting bolt.

Installation

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

WARNING: This procedure involves handling fuel. Always be prepared for possible fuel splashing and follow proper fuel handling precautions. Failure to follow these instructions may result in injury.