2.2dti alternator removal

[tommy k]

How do I remove the alt on a 2.0/2.2 dti. So far airbox off, splash guard off, belt off, top torx bolt out, bottom torx bolt undone but wont go past chassis leg, hence cant lift out alternator!!! Help.

[plasma]

ya aint gonna like this, the vx recommended guide follows...

1. Open bonnet

2. Disconnect battery.
• Detach ground cable


3. Raise vehicle

4. Remove lower engine cover (1)
• Unscrew 10x bolt

5. Detach ribbed V-belt
• Tension ribbed V-belt tensioner at hex lug (1) anti-clockwise (arrow)

• Set ribbed V-belt to one side

6. Remove front exhaust pipe
Important: When removing the centre muffler, a catalytic converter, an exhaust manifold, or an exhaust manifold with catalytic converter, secure that portion of the exhaust system remaining on the vehicle against uncontrolled suspension. The exhaust system piece with the flex pipe inside can be secured for this purpose using suitable means, such as a wire on the vehicle underbody. Bends in the flex pipe with an angle as little as 5 – 10 degrees from the intended installation position may result in damage with subsequent total failure of the flex pipe.

• Unscrew 3x nut (1)

7. Remove exhaust system
Note: 2nd mechanic is required
• Detach 7x rubber


8. Detach starter heat shield
• Unscrew 2x bolt (2)

• Loosen nut (1)



9. Detach oil pressure switch wiring harness plug (1)

10. Detach alternator wiring harness
• Unscrew 2x nut


11. Release alternator wiring trough (2)
• Remove lower bolt

12. Lower vehicle

13. Detach upper engine cover
Important: Carefully pull upwards

• Unscrew 3x bolt


14. Detach alternator wiring trough
• Unscrew 2x upper bolt


15. Remove air intake hose.
• Disconnect wiring harness plug for hot film mass air flow meter (1)

• Release 2x clamp

• Detach engine vent hose
Note: Remove with hot film mass air flow meter (2)



16. Release upper alternator
• Unclip coolant hose (1) out of bracket

• Unscrew bolt, nut (2)

• Remove coolant hose bracket


17. Raise vehicle

18. Remove steering heat shield
• Unscrew 3x bolt


19. Remove alternator
• Unscrew bolt, nut (3)
Note: Carefully press wiring trough upwards. Remove alternator downwards

[Ste]

Christ !

[Gsi3.2]

it's the long winded way of saying it's got to come out of the hole between the engine's sump and the subframe by the steering rack...but the exhaust is in the way......it's quicker in practice than the way it's written.....

[plasma]

from the man thats probaby done 1 or 10 as opposed to the man who just reads about doing it lol

[Gsi3.2]

LOL.....something like that Dad..

[tommy k]

OK Finished, only took 6 hours of head scratching, to remove lower torx bolt, pull till touches chassis leg, grip with molegrips at closest point to alternator, cut bolt with hacksaw and then withdraw the bolt, wayhey. The alternator can then be removed by use of a helping pair of hands working it around the back of the engine and up over at the passenger side. The new alternator can then be dropped in the same way as the other came out, heres the tricky bit, position the alt and fix the top bolt into position, using a long pole or such remove as much of the plastic around the alt leads as the bottom bolt is put in the opposite way around as the original and the plastic bracket surrounding the alt leads gets in the way. It may not be the perfect way to do things but it works.

[Gsi3.2]

it's a bit like mondeo mk1 front NS wishbone bolts.. they put it in so you had to cut the bolt or remove the gearbox to get it out.....

glad you got it sorted matey....