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Alternator Replacement Guide
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methley
a.k.a. Big Hairy Ski Monster 


Member Since: 07 Oct 2008
Location: Marshfield, South Glos
Posts: 2433

England 2006 Discovery 3 TDV6 SE Manual Java BlackDiscovery 3
Alternator Replacement Guide

For those who need a guide to replace their alternator, see below. It's actually quite an easy job.

{EDIT} It should be obvious but please disconnect the battery before starting this procedure!

First remove the air pipe which sits across the top of the radiator. It's held on by the two screws you can see and a jubilee clip at the air box end. Once the screws and clip are out, simply pull the pipe out and plug the resulting hole with a rag to stop anything falling in.



Once the pipe is removed you need to detach the fan cowling. No need to remove the coolant pipe, it can be moved to one side. The cowling simply pulls out.



Disconnect the electrical plug on the fan.

Click image to enlarge


This is how I removed the fan, using standard tools. Large adjustable wrench on the 36mm hex fan spindle. 10mm spanner on a retaining nut on the pulley braced against the fan spindle. Remember left hand thread, so unscrews clockwise looking from the front of the vehicle.





This is what now greets you.

Click image to enlarge


Disconnect the alternator battery cable (seen under the red boot). It's a 13mm nut. A ratchet spanner is a great help here.

Click image to enlarge


Use a large screwdriver to lever the tensioner and slipt off the belt. Note As Disco_Mikey has said below there is also a 3/8' square hole in the tensioner arm to release the tension on the belt

Click image to enlarge


Unbolt the alternator. There's this bolt and two underneath. For the two underneath, again a ratchet spanner (13mm) is ideal and will help a lot.

Click image to enlarge




Once it's out, remove the multiplug from the back.

Click image to enlarge


Job done.

Installation is the reversal of the removal as they say in other places....
 Andy

Fridge Slide for sale https://www.disco3.co.uk/forum/post2064622.html#2064622 


Last edited by methley on 31st Oct 2013 1:49 pm. Edited 2 times in total 
Post #96692517th Aug 2012 8:44 pm
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Hairy Dan
 


Member Since: 19 Jan 2011
Location: Co. Durham
Posts: 12319

United Kingdom 2016 Discovery 4 3.0 TDV6 Landmark LE Auto Santorini BlackDiscovery 4

Thumbs Up Good write up
 Cheers Ian
--------------------
Club N.E.R.D.S
Kielder 4x4 Safari
Discoless 
 
Post #96693517th Aug 2012 9:08 pm
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Disco_Mikey
 


Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 19086

Scotland 2005 Discovery 3 TDV6 HSE Auto Cairns BlueDiscovery 3

Firstly, before doing anything else, disconnect the battery Shocked

Also, there is a 3/8's square hole in the tensioner arm to release the tension on the belt. You could potentially damage it or the pulley if you lever with a screwdriver

I see you have done it, but not mentioned it. After removing the big air pipe on top of the fan cowling, stuff the air intake with rags or a towel to prevent anything falling in there while you are working. It's not easy fishing bolts and spanners out of these EDIT: yes you did Embarassed
 My D3 Build Thread

TDV8 Retrofit Build Thread 
 
Post #96696718th Aug 2012 5:03 am
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haroosh
 


Member Since: 16 Nov 2010
Location: Perth & Kinross
Posts: 624

Scotland 2005 Discovery 3 TDV6 S Manual Rimini RedDiscovery 3

Hey Mikey, you can have another go replacing mine when it eventually goes Laughing
  
Post #96696818th Aug 2012 6:04 am
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anglefire
 


Member Since: 09 Mar 2010
Location: In the Club House
Posts: 4180

England 

One thing I would add - when you pull the top cowl off, don't do what I did the once and catch your finger on the jubilee clip on the pipe from the air filter box to the top of the engine - I ended up in A&E as it tore part of the skin off my finger and had a couple of stitches. Big Cry
 Mark.
2006, D3 SE Auto - gone but not forgotten.
2014 BMW 530d M Sport Tourer.
1977 Triumph Spitfire 1500

_________________________________________________
Disco Picture Website Here 
 
Post #96697318th Aug 2012 7:18 am
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Disco_Mikey
 


Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 19086

Scotland 2005 Discovery 3 TDV6 HSE Auto Cairns BlueDiscovery 3

haroosh wrote:
Hey Mikey, you can have another go replacing mine when it eventually goes Laughing


Have faith! Laughing
 My D3 Build Thread

TDV8 Retrofit Build Thread 
 
Post #96707318th Aug 2012 6:52 pm
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KOOS BEST
 


Member Since: 14 Feb 2010
Location: Mtunzini
Posts: 122

South Africa 2006 Discovery 3 TDV6 S Auto Alaska WhiteDiscovery 3

Hi , what's the make of that alternator.
  
Post #96760220th Aug 2012 1:49 pm
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methley
a.k.a. Big Hairy Ski Monster 


Member Since: 07 Oct 2008
Location: Marshfield, South Glos
Posts: 2433

England 2006 Discovery 3 TDV6 SE Manual Java BlackDiscovery 3

 Andy

Fridge Slide for sale https://www.disco3.co.uk/forum/post2064622.html#2064622 
 
Post #96762920th Aug 2012 2:58 pm
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Cliff2ord
 


Member Since: 04 Mar 2012
Location: Bankfoot
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Scotland 2006 Discovery 3 TDV6 S Manual Bonatti GreyDiscovery 3

Thans very much for this post it made the altenator job a doddle. Very Happy
  
Post #9720731st Sep 2012 1:57 pm
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Martin
Site Admin and Owner 


Member Since: 06 Nov 2004
Location: Hook Norton
Posts: 17915

Wales 2006 Discovery 3 TDV6 SE Manual Buckingham BlueDiscovery 3

Excellent guide methley, did this job today in less than an hour Bow down
 06 D3 SE / 15 LR D90 XS SW / 88 LR 90 Td5 / 68 BMW 2000 ti
Any issues with the site let me know! 
 
Post #101732711th Dec 2012 2:43 pm
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beesle
 


Member Since: 17 Jun 2008
Location: widnes, cheshire
Posts: 112

2005 Discovery 3 TDV6 Base 7 Seat Manual Zermatt SilverDiscovery 3

jist tried to do this but failed

i cant get the fan off.

the tut says the main 36mm nut is removed by turning it clockwise. The pulley is held fast by a 10mm sapnner on the 10mm nuts.

i did this but all that happened was the 10mm nuts cam loose instead on the main nut i wanted to remove

am i doing something wrong? i cant see how holding the 10mm nuts will stop the pulley from turning without them undoing
  
Post #101759211th Dec 2012 8:59 pm
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Martin
Site Admin and Owner 


Member Since: 06 Nov 2004
Location: Hook Norton
Posts: 17915

Wales 2006 Discovery 3 TDV6 SE Manual Buckingham BlueDiscovery 3

I had a screwdriver wedged in between the bolt heads and the boss and that was enough.
 06 D3 SE / 15 LR D90 XS SW / 88 LR 90 Td5 / 68 BMW 2000 ti
Any issues with the site let me know! 
 
Post #101759511th Dec 2012 9:01 pm
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bp
 


Member Since: 06 Jan 2010
Location: Stuck On The High Road
Posts: 1325

United Kingdom 

beesle wrote:
jist tried to do this but failed

i cant get the fan off.

the tut says the main 36mm nut is removed by turning it clockwise. The pulley is held fast by a 10mm sapnner on the 10mm nuts.

i did this but all that happened was the 10mm nuts cam loose instead on the main nut i wanted to remove

am i doing something wrong? i cant see how holding the 10mm nuts will stop the pulley from turning without them undoing



..... hit the spanner with a hammer to shock it loose
 Don’t worry it is supposed to sound like that...honest  
Post #101761211th Dec 2012 9:22 pm
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methley
a.k.a. Big Hairy Ski Monster 


Member Since: 07 Oct 2008
Location: Marshfield, South Glos
Posts: 2433

England 2006 Discovery 3 TDV6 SE Manual Java BlackDiscovery 3

Brace the 10mm spanner against an adjacent nut or fan spindle then give the big spanner a whack! Thumbs Up
 Andy

Fridge Slide for sale https://www.disco3.co.uk/forum/post2064622.html#2064622 
 
Post #101762011th Dec 2012 9:28 pm
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beesle
 


Member Since: 17 Jun 2008
Location: widnes, cheshire
Posts: 112

2005 Discovery 3 TDV6 Base 7 Seat Manual Zermatt SilverDiscovery 3

all done, finally

hardest bit was removing the fan. it just didnt want to budge

nothing a little heat from my blow torch wouldnt fix

it came straight off then
  
Post #101948215th Dec 2012 3:53 pm
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