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Thread: Alternator fan cutting into top radiator hose

  1. #1
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    Alternator fan cutting into top radiator hose

    The existing alternator on my 91 Range Rover has the sharp tipped cooling fans typically used on Defenders, Diesels and Series 3 vehicles. The top hose is so close it eventually gets cut by the fan. I have tried a longer belt to move the alternator further away but that is not a successful fix.

    I may make up a steel guard and that will be cheaper than changing the alternator to the type that does not have the sharp fans.See pictures

    Has anyone else had this problem and found a simple fix?
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  2. #2
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    Are you sure you have the correct hose for a 1991 ?

    Mine has no issues. Perhaps you have the serpentine belt version hoses or an incorrect hose of some other kind
    Roads?.. Where we're going, we don't need roads...

  3. #3
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    Quote Originally Posted by Mercguy View Post
    Are you sure you have the correct hose for a 1991 ?

    Mine has no issues. Perhaps you have the serpentine belt version hoses or an incorrect hose of some other kind
    You could well be right. Here is the bush it is not easy to resolve issues like this. The answer is of course to have the two hoses side by side to compare them. It is quite likely that the pre-serp version rises away from the spigot, whereas the serp version does not and hence sits too close to the alternator.

    I got a new hose from Repco yesterday - listed for Holden since they had no listing for Land Rover and it is identical to the one I currently have that was was supplied by Coopers who usually do not make that kind of mistake but they may have supplied the Serp version instead of pre-serp.

    Bloody phone is out of service - again - Thanks Telstra! ASAP I'll get Ciaig to put the two hoses alongside each other to compare. In the short term, I'll fabricate a plate to lift the hose clear of the alternator fan.

  4. #4
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    Fixed

    The "officia;" hose turned out to be identical to the Holden one I purchased from Repco so a fabricated shield was the only viable solution other than changing the alternator

    Took less than half a hour to find some suitable bits of steel in the shed and cut them to shape. (never throw any bits away - you will need them one day). Initially, I added only the flat plate, but the hose kept pushing it down so I added a short length of steel angle bolted to the alternator bracket

    No more contact between the hose and the fan!
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  5. #5
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    OK, there just has to be something else going on there, it shouldn't touch at all...

    I've listed some possible areas for further investigation:

    1. check the alternator is correct original unit and not longer legs (offset from body), which would raise it closer to the hose
    2. alternator belt too long or too short (I think from memory it's ridiculously short, something like 675 or roundabout) - as you know, the alternator pivots in an arc, and if the belt is 'just the right amount' of length, it will mean the alternator is at the highest point in the arc.
    3. engine mounts too high (unlikely.... but)
    4. radiator mounts sagged / rotten / bent / etc (possible, wouldn't need much to drop the radiator by enough to cause the problem)
    5. bent front end (previous accident repair?) a possibility
    6. radiator outlet possibly not correct, or radiator is from another model? (seems unlikely, but again.... possible)

    I have well over an inch of clearance between the hose and alternator on my 91 (its v-belt), so I am wondering exactly how you ended up like this...

    Also, my top alternator belt-tensioning bracket doesn't look as though it sits as high as yours, I do not know what would be the cause of that, other than the leg offset / alternator bolt mounting PCD is greater, or perhaps the v-belt is a different length.

    Is your alternator the original marelli unit or is it a Lucas reman? or Denso / Bosch / etc. perhaps this is contributing to the problem?

    Whatever it is, obviously the hose should not be resting on the alternator and LR engineering wouldn't be "that stupid" to create a problem for no reason ( or would they haha). I know it can get close if the tensioner adjustment is not at the desired length (i.e. the belt is too short or too long) but regardless, it makes it an annoying 'something else to keep an eye on', because issues like this have a tendency to not go away.

    It seems strange and I can understand your frustration.
    Roads?.. Where we're going, we don't need roads...

  6. #6
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    With very hot air coming straight off the Rad. would that fan even have a cooling effect?

    Is that a 3.9 donk? My old Discovery hose had a definite upward kink at the bend but she has gone so I cannot compare.


    Just sayin'

  7. #7
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    Thanks Guys

    I certainly do not remember having this problem before. during the 7 or so years I have owned this vehicle.

    Yes 4Bee, It previously must have had the Disco version there with its upward kink to clear the alternator fan. because I distinctly remember the 1" clearance mentioned by Mercguy. That was the hose used by Coopers when they installed this engine so maybe they had a problem with the correct RR 3.9 version that did not provide enough clearance.

    Mercguy - several of your suggestions are valid, especially about the length of the alternator belt. After the problem occurred, I changed it to a slightly longer one I had in the shed. It is a bit better but it still did not allow sufficient movement for clearance. I have not changed anything else, so the Disco hose is probably the answer to a permanent fix.

    Meanwhile, the new guard works - no problems during a 160 Km trip this week, so I'll live with it for the time being, but I will try a longer belt

    Thanks again

  8. #8
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    Well on the way then, so long as the fan doesn't wreck itself on your guard.

    Not really clear from the image but is your Rad missing the top plastic clipon Cowl which could assist in protecting the hose?

  9. #9
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    Quote Originally Posted by 4bee View Post
    Well on the way then, so long as the fan doesn't wreck itself on your guard.

    Not really clear from the image but is your Rad missing the top plastic clipon Cowl which could assist in protecting the hose?
    No, the guard is not touching the alternator fan - it is resting on the angle piece bolted to the bracket. but thanks for warning me. As stated earlier, the real solution will be a different hose configuration and/or lengthening the alternator belt

  10. #10
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    Quote Originally Posted by aussiebushman View Post
    No, the guard is not touching the alternator fan - it is resting on the angle piece bolted to the bracket. but thanks for warning me. ....
    Kind'a doesn't make sense!

    If the alt fan is now not touching the new guard fitted, then in addition to Mercguy's reasons, there's a chance that the bonnet is pushing the hose downwards for some reason.
    Bonnet alignment, maybe some under bonnet insulation has come loose, possibly doubled up under itself, making a thicker section right on the wrong spot! ..

    .. or something else to that effect.

    Look for obvious rubbing marks on the bonnet insulation, and hose, where they could possibly interfere with each other.
    Try some marking stuff, like paint, liquid paper, or texta or whatever! .. thick oil or a dab of grease maybe .. just something on the top of the hose where it's likely to be forced on by the bonnet. Close bonnet, open again and look for obvious smearing.

    Alternative could be to set up a smart phone, or action camera under bonnet with video running. Set the device up so that it's facing right onto the hose. Close bonnet. Most cameras now are auto exposure, so as it gets dark .. hopefully it'll still expose right to allow you to see if there is interference.
    Is the under bonnet insulation still intact?, can you see the bonnets frame?
    I'm pretty sure that the bonnet cover itself is aluminium, but the frame that supports the clamshell is steel. Maybe if it's rusted, it may have distorted just enough to push on the hose?
    Arthur.

    '99 D1 300Tdi Auto
    '03 D2 Td5 Auto

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