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

Withdrawal

WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. In such situations, there are always highly flammable mixtures that can ignite. Failure to follow these instructions may result in injury.

WARNING: This procedure is related to fuel handling. Always be aware of the possibility of fuel splashing and observe fuel handling precautions. Failure to follow these instructions may result in injury.

WARNING: The fuel supply system remains under pressure for a long time after the ignition is switched off. Relieve fuel pressure before starting any repair. Failure to follow these instructions may result in injury.

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

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

3. Lower the car.

4. Turn out a bolt of fastening of a broad tank of system of cooling.



5. Release the expansion tank of the cooling system from the clip 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. Disunite the plug connector and disconnect the valve for cleaning the carbon filter of the fuel vapor control system.



10. Disconnect the vacuum lines from the carbon filter cleaning valve of the fuel vapor control system.




11. Disconnect the EVAP carbon filter vacuum line and remove the EVAP carbon filter cleaning valve.



12. Disunite the plug connector of the cylinder head temperature sensor.



13.

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

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

14.

NOTE: The fuel supply connections are painted white or identified by a white rim. Fuel return line connections are colored red or identified by a red rim.

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.

Turn out bolts of fastening of a forward support of the engine.



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




18. Disconnect the electrical connections of the generator.

• Remove protective cap (in the presence of).

19. Turn out a bolt of fastening of the generator.



20.

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

Completely remove the alternator mounting bolt.



21. Remove the generator.

• Turn out a bolt of fastening of the generator.

Installation

WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. In such situations, there are always highly flammable mixtures that can ignite. Failure to follow these instructions may result in injury.

WARNING: This procedure is related to fuel handling. Always be aware of the possibility of fuel splashing and observe fuel handling precautions. Failure to follow these instructions may result in injury.

1.

NOTE: To facilitate installation, slide the alternator interlock bushings back.

Reinstall the elements in reverse order