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
Last edited by methley on 31st Oct 2013 2:49 pm. Edited 2 times in total
17th Aug 2012 9:44 pm
Hairy Dan
Member Since: 19 Jan 2011
Location: Co. Durham
Posts: 12319
Good write upCheers Ian
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17th Aug 2012 10:08 pm
Disco_Mikey
Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 20798
Firstly, before doing anything else, disconnect the battery
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 My D3 Build Thread
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. Mark.
2006, D3 SE Auto - gone but not forgotten.
2014 BMW 530d M Sport Tourer.
1977 Triumph Spitfire 1500
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18th Aug 2012 8:18 am
Disco_Mikey
Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 20798
haroosh wrote:
Hey Mikey, you can have another go replacing mine when it eventually goes
Member Since: 04 Mar 2012
Location: Bankfoot
Posts: 33
Thans very much for this post it made the altenator job a doddle.
1st Sep 2012 2:57 pm
Martin Site Admin and Owner
Member Since: 06 Nov 2004
Location: Hook Norton
Posts: 18531
Excellent guide methley, did this job today in less than an hour 06 D3 SE / 15 LR D90 XS SW / 88 LR 90 Td5 / 68 BMW 2000 ti
Any issues with the site let me know!
11th Dec 2012 3:43 pm
beesle
Member Since: 17 Jun 2008
Location: widnes, cheshire
Posts: 117
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
11th Dec 2012 9:59 pm
Martin Site Admin and Owner
Member Since: 06 Nov 2004
Location: Hook Norton
Posts: 18531
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!
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