I read through the Haynes manual and was worried that there was a lot to do to change the alternator, but it can come out the top so is easier than they say.
From on top of the engine, the intercooler black pipe has to come off by loosening the victoria clips first, then remove the four star bolts and remove the intercooler. Be careful with the o rings. Then reach down and remove the three connections to the alternator. One is held in by a wire clip, one has a plastic spring on the connector, and the other is held by a 10mm nut.
Then jack up the front right corner and remove the wheel. Put an axle stand underneath in a safe place. Stick the wheel underneath as well. I am always worried it will collapse! Then remove the cover plate, held by three 10mm bolts. This gives you access to the bottom of the alternator.
Using an allen key, loosen the hex bolt in the middle of the tensioner wheel. Then loosen the belt on the tensioner mechanism with the 10mm bolt. Remove the alternator belt. Remove the lower alternator bolt 13mm.
From on top, remove the 10mm alternator bolt, and then the 13mm alternator bolt. This is last thing holding the alternator on. Then carefully, lift the alternator up through the pipes, not stressing anything too much. You can cause some damage here if you are reckless.
Refitting is the reverse. Specifically:
From on top, Wiggle the alternator back, put in the 13mm and 10mm alternator bolts.
from underneath, put in the 13mm alternator bolt. refit the alternator belt, tension the belt with the tensioner mechanism 10mm bolt, tighten the hex tensioner wheel bolt. needs to be tight!
Put the cover plate back on, with the three 10mm bolts. Refit the wheel, remove the axle stand, drop the car back down and tighten the wheel nuts.
from on top, refit the three connectors to the alternator. There are two ring connectors for the 10mm nut. So really like 4 connectors but only three connections. Drop the intercooler back into place carefully, do up the 4 star bolts. Put the black intercooler tube back on and tighten the victoria clips. and that should be that.
Middlydiddly, April 2007
