Before you begin:
* Safety First: Disconnect the negative battery terminal before starting any work on the electrical system.
* Gather Tools: You'll need a socket set (including metric sizes), wrenches, a ratchet, possibly a breaker bar, pliers, a battery terminal cleaner, and possibly a pulley puller (depending on the alternator's condition). A jack and jack stands are highly recommended for easier access.
* Consult a Repair Manual: A Haynes or Chilton manual specific to your 2003 Ford Focus Ztec is invaluable. It provides detailed diagrams and torque specifications.
Steps:
1. Prepare the Vehicle: Raise the front of the vehicle and securely support it with jack stands. This will give you much better access to the alternator.
2. Locate the Alternator: The alternator is typically located at the front of the engine, towards the passenger side (right side). It's a fairly large component with a pulley and several electrical connectors.
3. Disconnect the Electrical Connections: Carefully disconnect the electrical connectors from the alternator. Take pictures or make notes to ensure you reconnect them correctly later. Usually, there's a main power connector and a smaller wire for the alternator light.
4. Remove the Alternator Belt (Serpentine Belt): This is often the trickiest part. You'll need to loosen the belt tensioner. The location and method of doing this vary depending on the engine. Your repair manual will show you the exact procedure. Using a wrench or socket on the tensioner, carefully release the tension on the belt and slip it off the alternator pulley.
5. Remove the Alternator Mounting Bolts: The alternator is usually held in place by two or three bolts. Locate these bolts and carefully remove them using the appropriate socket and ratchet. You may need a breaker bar if the bolts are particularly tight.
6. Remove the Alternator: Once the bolts are removed, carefully remove the alternator from its mounting position. It might be a bit heavy, so be prepared.
7. Install the New Alternator: Position the new alternator in its mounting location, ensuring it's aligned correctly. Replace the mounting bolts and tighten them to the manufacturer's specified torque (found in your repair manual).
8. Install the Serpentine Belt: Carefully route the serpentine belt around all the pulleys, making sure it sits correctly in all the grooves. Re-tension the belt using the tensioner. The repair manual will show you the correct routing.
9. Reconnect the Electrical Connections: Reconnect the electrical connectors to the new alternator, matching them to the pictures or notes you made earlier.
10. Lower the Vehicle: Carefully lower the vehicle from the jack stands.
11. Reconnect the Battery: Reconnect the negative battery terminal.
12. Test the Alternator: Start the engine and check the alternator's output voltage using a voltmeter. The voltage should be around 13.5-14.5 volts while the engine is running. If the voltage is incorrect, there might be a problem with the new alternator or the installation.
Important Considerations:
* Pulley Removal: In some cases, the pulley might be seized to the alternator shaft. If this happens, you'll likely need a pulley puller tool to remove it. This adds extra complexity to the job.
* Torque Specifications: Always refer to your repair manual for the correct torque specifications for all the bolts. Over-tightening can damage the components.
* Professional Help: If you're uncomfortable performing this repair yourself, it's best to take your vehicle to a qualified mechanic.
This is a general guide, and the specifics may vary slightly depending on your vehicle's exact configuration. Always consult your vehicle's repair manual for the most accurate and detailed instructions. Failing to do so could result in damage to your vehicle or personal injury.
