Fuel filter crash box removal mod - 1.9cdti engine

[alcutler]

Hi, My alternator has packed up again after replacing it 3 months ago, taught me a lesson really bought it of Fleabay been ok since but gone again with no output. The seller has been very good and is sending out a replacement so I have no option but to fit that and see how it goes. Any more problems and I’ll get a genuine Vx one! Still that’s not the reason for this post – I decided to have a leisurely afternoon removing the alternator ready for the arrival of the new one. (getting quite good at it now). I remove the fuel filter and the crash box in order to get the alternator out from behind the engine. However yesterday I could not get the wiper arms off (need to get one of those special pullers for the job) to allow me to remove the trim and gain access to the three nuts that hold the filter crash box in place. Managed to undo them eventually via the pollen filter access hatch but its very tight especially if your like me and have hands like shovels. So having removed the alternator and having a bit of time to spare I thought I would have a look at a better way to remove the crash box. What I did was cut off the three studs on the crash box and then drilled out the remainder of the stud heads. I then put three bolts through the holes in the bulkhead from the inside, and bolted them in place using locking washers which leaves me with three studs to attach the crash box to and therefore easier fitting and removal of the crashbox without having to gain access to the area behind the bulkhead. Obviously you need to be careful with the length of the bolts you use to (a) ensure there is enough thread to take the nuts and (b) that they are not too long that they foul the crashbox itself. I used slightly larger diameter bolts than the original studs together with locking nuts to ensure they cannot work loose. Took about ¾ of an hour to do but will be a big time saver when doing future jobs. Bit of bad design really – why didn’t they fix the studs to the bulkhead in the first place when building the car so that access could be gained from the engine compartment!

[Al 22 dti]

any foto's?

al.

[alcutler]

any foto's?

al.

No not much to see really other than three threaded studs sticking out of the bulkhead. It concerned me a bit that the original arrangement had the back of the crash box in contact with the bulkhead but now there is a small gap caused by the thickness of the three nuts holding the bolts in place. But using slightly bigger toughened bolts, I have tightened it up and it is really solid and not going anywhere.

[lee gsi]

The Astra has studs sticking out.

Much better idea.

Can you get a long bit of metal, mark and drill the mounting holes for the crash box and then use some smaller bolts to bolt the new 'bracket' inplace.

[alcutler]

The Astra has studs sticking out.

Much better idea.

Can you get a long bit of metal, mark and drill the mounting holes for the crash box and then use some smaller bolts to bolt the new 'bracket' inplace.

You mean make a plate the uses the original bulkhaed holes and has tapped holes that you could bolt the crash box onto! Yes I suppose you could but you have to watch that you don't bring the whole fitting to far forward as there isn't a lot of room and the bolts that you need to attach the plate to the bulkhead would be in the same location that you need to bolt the box to - you could make a plate with studs/bolts welded onto it
on both sides but I think my method is a lot simpler.
We ought to design something and sell it I'm sure between us we could come up with something

[the-wizard]

The alternator can be removed without dismantling the fuel filter crash box or any other components.

[alcutler]

The alternator can be removed without dismantling the fuel filter crash box or any other components.

Yea appreciate that - but its a lot easier with it out of the way!