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Old 08-15-2011, 06:47 PM   #1 (permalink)
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HOW-TO: One Hour Alternator Install

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.



Quote: Originally Posted by SRT2MR2 View Post
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

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Last edited by Monster; 06-06-2012 at 01:05 PM.
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Old 08-16-2011, 06:52 AM   #2 (permalink)
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Nice post! I thought I was going to have to wait for a motor swap to put in a higher capacity alternator.
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Old 08-16-2011, 07:07 PM   #3 (permalink)
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Monster thanks so much man, I got your PMs. I will be putting mine in this week thanks to you.
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Old 08-18-2011, 04:20 PM   #4 (permalink)
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Brilliant!! STICKY this. Subscribed for future ref
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Old 08-19-2011, 02:52 PM   #5 (permalink)
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Quote: Originally Posted by tooner View Post
Brilliant!! STICKY this. Subscribed for future ref

Was already stickied.
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Old 08-19-2011, 02:59 PM   #6 (permalink)
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very nice.
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Old 08-19-2011, 03:18 PM   #7 (permalink)
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Nice man!
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Old 08-19-2011, 03:19 PM   #8 (permalink)
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Thanks guys. That last pic is actually a video showing there is room to pull it past the head. Just click it.

I also don't have a water overflow in that location so if you have one its likely that will need to come off as well.
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Old 12-06-2011, 05:08 PM   #9 (permalink)
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Wbt how to replace the band
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Old 12-07-2011, 09:47 AM   #10 (permalink)
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If you don't want to remove the valve cover you can put a jack under the transaxle and remove the bolt that holds it on and lower the engine slightly. You may have to unbolt the exhaust.
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Old 12-24-2011, 01:15 PM   #11 (permalink)
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has anyone done this with a big turbo setup? just wondering if anything gets in the way , like the dumptube or wastegate?
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Old 03-12-2012, 04:04 PM   #12 (permalink)
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Quote: Originally Posted by Monster View Post
Thanks guys. That last pic is actually a video showing there is room to pull it past the head. Just click it.

I also don't have a water overflow in that location so if you have one its likely that will need to come off as well.

yes the overflow gets in the way, i jus used this method to get my old one out as my new one will arrive tomorrow, 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
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Old 11-19-2012, 07:31 PM   #13 (permalink)
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Does anyone know where I can get a replacement locking nut and the bolt thing it spins onto? Mine has snapped off making my alternator useless. Its (2) on the diagram. Thanks.

EDIT

Found a pic of it in a old thread. Do I really have to go to a junk yard?

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Old 05-04-2014, 02:34 PM   #14 (permalink)
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note that if you do jack and remove the passenger tire the bottom bolt is extremely easy to remove.

Thanks for the info OP worked like a charm.
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Old 05-10-2014, 05:20 PM   #15 (permalink)
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wow very handy info ! thanks !
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