I've noticed the service manual sends people the longest way possible to install an alternator on our beloved turbo charged beasts. Removing motor mounts, axles and requiring lots of tools and time. I searched for a how-to for another member to no avail.
So I figured I'd post up how I do it.
I discovered this method way back in 2005 when I killed my batt then had my alt tested. I've done 5 since. This method only requires a socket set and a couple of screw drivers. No jacks, trans fluid mess or special tools. Until now I hadn't realized everyone else seems to be doing things the hard (service manual) way.
I don't actually need to replace my alternator but since I was replacing my valve cover gasket. I thought I would help another member who inquired about my method of doing it. So bare with me. I decided to take some pics since someone last year called my bluff on an upper removal.
I'm not a mechanic just an auto enthusiast so I will do the best I can to be as clear as possible with my instructions and terminology.
First disconnect the battery
Next disconnect the pcv valve and drivers side breather hose.
Next remove the coilpack and spark plug wires.
Next remove the valve cover.
At this point you should have easy access to the alternator
loosen the heat shield screws (2) on the top of the assembly
There are 3 bolts holding the alternator assembly together.
An adjustment T-Bolt/nut on the back facing the firewall(1) and a locking
mechanism on the left side of the alternator.(2) There is one that the alternator swivels on also underneath the assembly.(3)
loosen the locking nut on the left (2) then loosen the tensioner nut on the back of the assembly (1) all the way till it comes apart.
Here are a pic of the locking nut and tensioner bolts.
Next there is a wire harness toward the bottom of the alternator that needs to be unplugged.
Next Remove the B+ terminal nut and wire
Move the alternator forward a bit so you can wiggle the belt past the pulley.
Remove the lower alternator pivot bolt. (3)
Remove the alternator from the top of the vehicle.
Reverse instructions to install the new one.
I also will suggest you have a 15mm ratchet wrench for #3 bolt, the tension bolt #1 is a 13mm and #2 is also a 15mm