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Discussion Starter #1
I'm about 95% sure that its an alternator issue b/c I put my A/C on, rear defroster on, wipers front & back on, Mach HIDs on, fans on 4 and NO radio at all.

and voltage dropped below 12.

soon as I turn off one piece, the voltage goes up 1v or so.

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I'm going to be getting a replacement, but I don't have a haynes manual handy.

Has anyone done an alt. removal on a zetec DOHC?

Any special tools needed?
Any special instructions?

Do I need to remove the intake manifold? (removing it gives me an opportunity to port the opening for the TB to match my 65mm FC piece. lol, but i'd rather not have too)

Do I need to remove the belt completely?

is it as easy as this pix walkthrough on FH.com

if so, I can do that easily.
 

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taking off the intake manifold is not necesary but would make the job easier. yes the belt needs to come off.
 

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have fun, Its a bitch.
 

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It fits very tightly in the bracket and the intake manifold gets in the way. On my crate motor, I started putting the alternator on and couldnt do it with the intake mani on. I took the manifold off and got the alternator on but then the intake mani wouldnt fit.
I checked all my part numbers for the bracket, alternator, and intake manifold and its all legit.
I havent tried it again in about 4 months. I think you have to light a circle of black candles and recite incantations from the necronomicon to make it fit.
 
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