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Old 01-12-2008, 07:50 PM
Douglas.Sherida Douglas.Sherida is offline
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Join Date: Nov 2004
Location: CT, USA
Posts: 472
Nice write up.

Here's a similar DIY post I wrote last year (slightly different procedure):

1) Remove the fresh air intake tube to the aircleaner. Remove the aircleaner. Remove the aircleaner to turbo U-tube. Consider removing the tube between the top of the radiator and the coolant expansion tank. Be very carful not to lean on the plastic nipple on top of the radiator while removing installing the alternator, its easy to break off.

2) Remove the battery and put on charger overnight.

3) Unplug the alternator (3-prong plug on the back above the voltage regulator). There may be a spring clip holding it on, just pry the spring with a screwdriver and flip it down (it doesn't come off).

4) There are three bolts that hold the alternator on, all are 17 mm. Loosen all three (toward the rear of the car), then back the 13mm adjusting nut all the way out.

The one on the bottom (goes through a flange on the engine), can be cracked with an open end or box end wrench, and removed with a deep socket.

The inboard one on top is tough to reach. The bolt head is toward the rear of the car and the bolt goes through a flange on the engine block and is threaded into a nut welded to the alternator bracket. Crack the bolt with an open end or box end wrench and then back it out with a short socket, one ratchet click at a time.

The outboard one on the top only needs to be loosened with an open end or box end wrench at the nut towards the back of the car. The head of that bolt should have a long threaded stud coming of the side going to the 13mm adjusting nut.

5) Once you've loosened the two 17mm bolts and one nut, you can back the 13mm adjusting nut all the way out and slip the belts off the pulley.

6) Remove the two 17mm bolts holding the alternator bracket (top) and alternator casing (bottom), and the alternator should drop out the bottom of the engine compartment. Watch your head.

Once its out you can swap the bracket and pulley over. I hold the pulley in a gigantic pair of channel locks wrapped in an old t-shirt to undo/intall the 22mm(?) nut.

Install in reverse order. Put pulley and bracket and adjusting bolt/nut on alternator out of car. Install bottom bolt, install top bolt, snug both up (not tight). Slip on belts, snug up outboard top bolt, tighten belts with adjusting nut. Tighten top outboard bolt, tighten top inboard bolt, tighten bottom bolt. Plug alternator in, flip spring clip back into place (if you have one), install the battery, put all the aircleaner parts back on, reconnect the coolant resevoir, reconnect fully charged battery.

I've done this so many times lately I could do it blindfolded.
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