Alternator Replacement (Mondeo Mk1 TD)

Tools Required 30 star key, 40 star key, 10mm socket, 13mm socket, flat head screwdriver, 8mm allen key, rachet and possibly extension bars.

Prices£75 for an exchange alternator from halfords (take the old one in and give them that with £75 for the new one)

How To First things first, it is recomended that you disconect the battery to avoid any shorting (make sure you have your radio code!) next remove the black U-bend pipe between the intercooler and the inlet manifold using a flat head screwdriver to undo the jubilie clips, and a 40 star key to undo the studs which secure the intercooler to the engine, and remove (check the "O" rings where it slots into the turbo and if nessaccery fit new ones-a few quid from ford)) then the EGR valve pipe using a 30 star key to undo the 3 studs holding it. the next task is to slacken the alternator belt which is accesed by removing one of the drivers side arch liners using a 10mm socket on the 2 screws (removing the wheel can make this a lot easier) to slacken the tensioner you need an 8mm allen key to undo the centre bolt on the tensioner and then a 10mm socket on the stud on the side of the tensioner to wind it in so that you can remove the belt (check the condition of this belt and if nessacerry replace) Next is the electrical connections which are removed by unpluging the 2 plugs (one is held in with a small U shaped clip the other is just cliped in) and the main terminal which is a 10mm socket and lift the whole loom out of the way. The alternator itself is removed by undoing a 10mm stud at the back of the alternator (looking from the front of the car this is on the right) and 2 13mm studs from the side of the alternator-one at the top (also holding the clip for the unpluged loom) and one at the bottom, to the left of the oil filter (looking from the front of the car this is at the back near the bulkhead), once these have been removed it is just a case of lifting the alternator out through the top of the engine bay. replacement is simply a reverse of this procedure with a replacement belt if required and dont forget to tension the belt, then start the engine to be sure the light goes out on start up and take for a drive to be sure the belt dosent squeal (if it does chances are its not tight enough or too tight)

John