Step 1: Using the 10mm socket/ratchet, disconnect the vehicle's negative battery cable.
Step 2: Loosen and remove the 10mm bolt (1) that secures the coolant overflow reservoir to the PASSENGER'S side of the vehicle. Disengage the clip on the BACK of the reservoir. You can now lift it and slide it out of the way.
DO NOT disconnect the hoses"¦we are only interested in sliding it out of the way!
Step 3: Lift and slide the power steering fluid reservoir out of the way.
Step 4: Jack up the vehicle and support it with stands.
Step 5: Loosen and remove the 10mm bolts (2) that secure the belt cover to the UNDERSIDE of the vehicle. Remove this cover.
Step 6: Turn the 15mm tensioner bolt (1) CLOCKWISE to release the tension on the belt. You can now remove the belt from the vehicle. SLOWLY release the tensioner bolt back to its resting position.
NOTE: If the serpentine belt looks worn or frayed, we recommend replacing it, as it'll never be easier than it is right now!
Step 7: Loosen and remove the 7mm bolts (2) that hold the component to the FIREWALL just behind the alternator.
This creates room.
Step 8: Loosen and remove the 10mm bolt (1) that secures the wiring harness to the vehicle (near where the coolant reservoir mounted). Move this harness aside.
Step 9: Loosen and remove the 10mm mounting bolts (2) that secure the alternator to the vehicle.
NOTE: The REAR 10mm bolt will likely need a flexible joint or handle with the socket.
Step 10: Lift the alternator from its position. Disconnect the alternator's wiring harness (1).
Step 11: Loosen and remove the 10mm bolt (1) that secures the electrical connection to the alternator. You can now remove this connection.
Step 12: Lift and remove the alternator from the vehicle.
You may need to disconnect some wiring harnesses to move them out of the way. There are several wiring connections that span the TOP of the area. Just be sure you notate which connections attach to which!
Step 13: Move the new alternator into position. Tighten the 10mm bolt (1) that secures the electrical connection to the assembly. Connect the alternator's wiring harness.
Step 14: Reconnect any wiring harnesses, hoses, or cables that you disconnected in Step 12.
Step 15: Tighten the 10mm mounting bolts (2) to secure the alternator.
Step 16: Tighten the 7mm bolts (2) to secure the component to the REAR firewall.
Step 17: Tighten the 10mm bolt (1) to secure the wiring harness to the vehicle (near the reservoir's mounting area).
Step 18: Using the belt routing diagram posted near the radiator, on the UNDERSIDE of the hood, or in the owner's manual, route the belt around the proper pulleys.
Step 19: With the belt in position, turn the 15mm tensioner bolt (1) COUNTER CLOCKWISE to increase the tension on the belt.
NOTE: The belt should be taut, but not stretched or overly tight!
Step 20: Tighten the 10mm bolts (2) to secure the belt cover to the UNDERSIDE of the vehicle.
Step 21: Reattach the power steering fluid reservoir.
Step 22: Reattach the coolant overflow reservoir.
Step 23: Reconnect the battery cable.
These Part Change / Installation Instructions Apply to
04 2004, 03 2003, 02 2002, 01 2001, 00 2000 Ford Focus Alternator Replacement Instructions