I replaced both auxiliary belt tensioners today and the result was diddly squat so it can only be the alternator now (3rd time lucky I guess
). I was going to leave it to another day but then changed my mind and decided to just dive in and have a crack at it while I still had some time and daylight left.
Even though everyone seems to talk about doing the job from underneath, with all the grief I've heard people have had trying to do it that way (one guy took 11 hours just to get the old one out
), I didn't really fancy that one little bit. I had a nosey around underneath the back of the engine and that was enough to put me off completely so I instead decided to take a gamble and try to tackle it from above. After unclipping and unbolting the inlet, it was a bit of a bugger to get out of the gap between the inlet manifold alloy pipes and the bulkhead but after unclipping all the cables from the bottom of it (that wasn't awkward enough!) and with some brute force I eventually managed to force the plastic inlet assembly through the gap without doing any damage. I couldn't find any other way of getting it through the gap except by force, and there wasn't enough room to remove the alloy inlet pipes from the head what with them being on studs. Anyway, once the plastic inlet has been removed, it's then just a case of removing the manifold T-bar support bracket, unbolting the electrical connections on the back of the alternator, unbolting the alternator from it's 2 mounting points and then simply lifting it out through the hole which you could get a bus through
It was pretty straight forward and very easy once the inlet was off. Why people bother trying to tackle it from underneath with all that limited space and having to scrabble around on your back I have no idea
Anyway, start to finish it took me 2.5 hours to get the old alternator out through the top. I now just need to find somewhere to either get a new alternator or somewhere that will recondition of part-exchange mine. Any recommendations?