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Generator - 1.8L Diesel > < Generator - 2.5L

Mondeo 1997 (08.1996-09.2000)

Generator and Regulator - Generator—1.6L/1.8L/2.0L Mondeo 1997 (08/1996-09/2000)
Removal and Installation

Removal

All vehicles
WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
  1. Disconnect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

  1. Remove the intake air resonator.
    1. Disconnect the mass air flow (MAF) sensor electrical connector.
    1. Disconnect the intake air temperature sensor (IAT) electrical connector (if equipped).
    1. Remove the one bolt and two nuts.
    1. Detach the clamps.
Vehicles built up to 01/1997
  1. Disconnect the generator electrical connectors (shown removed for clarity).
    1. Disconnect the power cable.
    1. Disconnect the electrical connectors.

  1. Disconnect the ground cable from the engine lifting eye.

  1. Detach the wiring harness from the bulkhead.

  1. Detach the power steering pipe.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove the splash shield.

  1. Remove the accessory drive belt.
    • Rotate the accessory drive belt tensioner clockwise and remove the drive belt.

  1. Remove the generator lower bolts.
  1. Lower the vehicle.

  1. Remove the generator upper bolt.

  1. CAUTION:
    CAUTION:There is a very limited amount of space in which to remove the generator. Be very careful not to overstress or damage any pipes or cables.
    Lift the generator clear of the engine.
    • To aid removal, turn the generator so that the pulley is uppermost.

  1. Detach the cable and remove the generator.
Vehicles built 01/1997 onwards
  1. Release the fuel system pressure. For additional information, refer to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  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.
  1. Lower the vehicle.

  1. CAUTION:
    CAUTION:Protect the generator from contamination by fuel drips from the connections.
    Disconnect the fuel lines.

  1. Disconnect the ground cable and detach the power steering pipe bracket from the engine lifting eye.

  1. Disconnect the generator electrical connectors.

  1. Fully loosen the generator left-hand bolt and remove the generator right-hand bolt.

  1. Remove the generator.

Installation

All vehicles
  1. WARNING:
    WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
    NOTE:
    NOTE:To aid installation, push the sliding bushings flush with the generator casing.
    To install, reverse the removal procedure.
Vehicles built 01/1997 onwards

Vehicles built up to 01/1997

Generator - 1.8L Diesel > < Generator - 2.5L