Tools You'll Likely Need:
* Socket set: Metric, including various sizes (likely 10mm, 13mm, 15mm, and possibly larger).
* Wrench set: Metric, both open-ended and possibly combination wrenches.
* Ratchet and extensions: To reach difficult bolts.
* Screwdrivers: Both Phillips and flathead, various sizes.
* Pliers: Needle-nose and possibly slip-joint.
* Jack and jack stands: Essential for safety.
* Wheel chocks: To secure the vehicle.
* Battery terminal cleaner: To clean the battery terminals after disconnecting.
* New alternator: Make sure to get the correct replacement for your vehicle.
* Wires and terminals: If you need to replace them.
* Torque wrench: For proper tightening of bolts.
* Gloves and safety glasses: Always recommended.
Procedure (General Steps):
1. Disconnect the Battery: Always disconnect the negative (-) battery terminal first, then the positive (+). This prevents accidental shorts and damage to your vehicle's electrical system.
2. Access the Alternator: The alternator is typically located on the front of the engine, near the passenger side (right side). You may need to remove some components for better access. This might include:
* Removing the serpentine belt: Consult your repair manual for the proper routing and tensioner release method. There are different procedures for releasing tension on the belt.
* Removing air intake components: This might be necessary to get a clear view of the alternator.
* Removing other engine components (potentially): This depends on how much space you have to maneuver. You may need to remove parts like the power steering pump bracket.
3. Disconnect the Alternator:
* Disconnect the wiring harness: There will be several wires connected to the alternator. Carefully unplug them. Take pictures or make notes to ensure correct reconnection.
* Remove the alternator mounting bolts: These bolts will hold the alternator to the engine block.
4. Remove the Alternator: Carefully remove the alternator from its mounting location. It may be heavy.
5. Install the New Alternator:
* Mount the new alternator: Carefully position the new alternator in its mounting location.
* Secure the alternator: Tighten the mounting bolts to the specifications in your repair manual. Avoid over-tightening.
* Reconnect the wiring harness: Reconnect the wiring harness connectors, ensuring they are securely connected.
* Reconnect the serpentine belt: Again, refer to your repair manual for proper belt routing. Ensure it's properly tensioned.
6. Reconnect the Battery: Reconnect the positive (+) battery terminal first, then the negative (-) terminal.
7. Test the Alternator: Start the vehicle and check the charging system using a multimeter to ensure the alternator is charging properly. Verify voltage at the battery terminals with the engine running.
Important Considerations:
* Repair Manual: A repair manual specific to your 2002 Ford Taurus is crucial. It will provide detailed diagrams, torque specifications, and step-by-step instructions.
* Safety: Always work in a well-lit and ventilated area. Use jack stands to support the vehicle properly. Never work under a vehicle supported only by a jack.
* Professional Help: If you're not comfortable performing this repair yourself, it's best to take your vehicle to a qualified mechanic. This is a relatively involved repair and incorrect installation can cause significant damage.
This guide provides a general overview. Always refer to your vehicle's repair manual for specific instructions and safety precautions. Improper installation can lead to serious damage, so proceed with caution.
