FTO Drivers Club, Western Australia

[wilmik]

Any one know how to get an alternator back in on a GR. Got it out by undoing balljoint and pulling drive shaft out but cant seem to get new one back in! Any ideas

[RichardH]

That's a tight spot in there!! Not done it myself.

Your best bet is to download the FTO workshop manuals, availabled here:

http://www.fto-ireland.com/downloads.html

That should tell you all you need to know!

- Rich

[Buzz from UK]

Tools you will need.
y pulley brace
ratchet
1/2" 2' breaker bar
22mm socket
14mm socket
12mm socket
14mm deep ring spanner (or 3/8" breaker bar and shallow 14mm socket)
various extension bars (I use 2 12" ones and a 6" one)
(possible you may need a bearing puller)
Axle stand
Long nose pliers
cross head screwdriver

1. remove the front drivers side wheel and then the wheel arch liner.
2. remove both auxiliary belts, the deep ring spanner or 38" breaker and shallow socket are used to get at the center bolt on the alternator tensioner pulley.
3. with both belts off brace the cranky pulley with the y pulley brace and use the 24mm socket enough extension bars to get out of the wheel arch and the 1/2" breaker bar to crack off the crank pulley bolt, you will find this is very tight but once cracked will be only hand tight.
4. remove the crank pulley this should waggle off but you may find you need a bearing puller to start it off, make sure the puller pulls from the back of the pulley other wise it will break the edges of the pulley.
5 remove the alternator tensionor pulley completely.
6 remove the tension er pulley mount 4 x 12mm bolts which also mounts a pipe running to the bulk head on the bulk head side of the mount and the dip stick on the forward side of the mount
7 remove the dip stick by pulling it upwards its just held in the sump by a rubber o ring.
8 undo the lower alternator mounting bolt 14mm this may require the ring spanner as the room to maneuver a ratchet between the drive shaft and the steering arm isn't great.
9 disconnect the battery either earth or positive doesn't matter which.
10 disconnect the 2 cables from the alternator large red on is bolted to and the other is a multiclip.
11 slacken off the upper alternator mount 12mm and swing the bottom of the alternator away from the lower mount
12 remove the lower alternator mount 3 14mm bolts once this is removed the cam belt tensioner underneath it is exposed (do not disturb this)
13 undo the upper bolt of the alternator whilst supporting it and once its loose you will find it will now slide out easily between the drive shaft and where the lower alternator mount was previously.

Refitting is reverse or removal
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"Gort...Klaatu Barada Nikto"