Chapter 1 Routine maintenance and servicing

1595Ford Fiesta Remake5A•4 Starting and charging systems6.3 Removing the drivebelt splash guard(where fitted)6 Alternator -removal and refitting2Removal1 Disconnect the battery negative (earth) lead(refer to Section 1).2 Chock the rear wheels then jack up thefront of the car and support it on axle stands(see “Jacking and vehicle support”).3 Where applicable, undo the retaining boltsand remove the drivebelt splash guard (seeillustration).4 On models with power steering and aseparate drivebelt, remove the auxiliary(power steering pump) drivebelt as describedin Chapter 1.Alternator with manual adjustmentdrivebelt5 On models fitted with a sliding arm typeadjuster strap, unscrew and remove the top(adjuster) bolt from the strap (seeillustration).6 On models fitted with a “rack-and-pinion”type adjuster, unscrew and remove thecentral (locking) bolt whilst, at the same time,loosening the (adjuster) nut (see illustration).7 Loosen off, but do not yet remove,6.5 Alternator sliding arm type adjusterstrapA Adjuster boltB Adjuster bracket to engine boltthe lower mounting bolts, pivot thealternator inwards towards the engine toslacken the tension of the drivebelt, thendisengage the drivebelt from the pulleys andremove it.8 Where applicable, detach and remove thealternator splash cover/heat shield (seeillustration).9 Where applicable, detach and remove thephase terminal and the splash cover.10 Supporting the weight of the alternatorfrom underneath, unscrew and remove themounting bolts. Lower the alternator; notingthe connections, detach the wiring andremove the alternator from the vehicle (seeillustration).Alternator with automatic adjustmentdrivebelt11 Remove the heatshield (if fitted) anddisconnect the alternator wiring.12 Fit a ring spanner onto the drivebelttensioner, and rotate it clockwise to loosen offthe tension from the drivebelt (seeillustration). Note the routing of the drivebelt,then disengage the belt from the pulleys andremove it.13 On pre-1994 model year Zetec engines,disconnect the oxygen sensor wiring multiplug,then undo the two nuts and separate theexhaust downpipe from the manifold. Support6.6 Rack-and-pinion type drivebeltadjusterA Adjuster arm C Central (locking) boltB Pinion (adjuster) nutthe downpipe to avoid straining the exhaustsystem mountings.14 On all models, unscrew the alternatorupper mounting bolts/nuts and disconnect thealternator wiring. Unscrew the lowerbolts/nuts and remove the alternator from theengine. On pre-1994 Zetec engines, it will benecessary to de-tension the drivebelttensioner to provide clearance for removal ofthe upper mounting bolt nut.Refitting15 Refit in the reverse order of removal. Refitthe drivebelt, and ensure that it is correctly reroutedaround the pulleys. Adjust the tensionof the drivebelt (according to type) asdescribed in Chapter 1.7 Alternator brushes andvoltage regulator - renewal31 Disconnect the battery negative (earth) lead(refer to Section 1).2 Remove the alternator from the vehicle asdescribed in the previous Section.Bosch3 Remove the two screws securing thecombined brush box/regulator unit, and6.8 Removing the splash cover from theinner end of the alternator6.10 Wiring loom routing on rear ofalternator (CVH engine)6.12 Automatic drivebelt tensionerTurn tensioner clockwise to release drivebelttension