Alternator Replacement (Mondeo Mk1 TD)

The Ford Mondeo hit our roads in 1993, and has consistently been a sales success. Now on its 4th incarnation, it remains a drivers favourite.
For more information, visit the Ford Mondeo forum on TalkFord.com, the definitive resource site covering all Fords from the present day to the 1970's.

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Overview Guide
Ford Model:	Mondeo Mk1
Petrol/Diesel:	Diesel
Estimated Cost:	£75
Difficulty?	Easy/Medium
How long does this take?	?

Tools Required

• T30 Torx key
• T40 Torx key
• 10mm socket
• 13mm socket
• flat head screwdriver
• 8mm allen key
• rachet
• 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 recommended that you disconnect the battery to avoid any shorting (make sure you have your radio code!).

Next remove the black U-bend pipe between the inter-cooler and the inlet manifold using a flat head screwdriver to undo the jubilee clips, and a T40 Torx 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 necessary fit new ones - a few quid from ford).

Then remove the EGR valve pipe using a T30 Torx key to undo the 3 studs holding it.

The next task is to slacken the alternator belt which is accessed by removing one of the driver's side wheel arch liners (removing the wheel can make this a lot easier). Use a 10mm socket on the 2 bolt heads 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 necessary replace).

Next is the electrical connections which are removed by unplugging the 2 plugs (one is held in with a small U shaped clip; the other is just clipped 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 unplugged 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 don't forget to tension the belt. Start the engine to be sure the light goes out on start up and take for a drive to be sure the belt doesn't squeal (if it does chances are it's either not tight enough or too tight)