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Thread: Alternator.

  1. #1
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    Alternator.

    I have purchased a new alternator and hoping to fit it before too long. I have bought a Hella and I see it does not have a heat shield on the back as the original alternator has. It's not too far away from the hot exhaust.
    It looks like there are sufficient differences on the Hella to make it not possible to simply fit the original heat shield to the new alternator.
    So I was wondering how others may have solved this? Or if anyone has fitted an alternator without a heat shield and how that went?
    Many thanks.
    Cliff.
    1995 Tdi.

  2. #2
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    Quote Originally Posted by Cliff View Post
    .....
    So I was wondering how others may have solved this? Or if anyone has fitted an alternator without a heat shield and how that went?
    Many thanks.
    Cliff.
    1995 Tdi.
    Q: 300 Tdi?

    Did your original have a heat shield?

    My original(Denso/Marelli) didn't.

    Original died, couldn't get one small 5mm nut off the reg, so just got another alternator from a local parts store. OEX(Ashdown), fit perfectly.
    First one lost it's pulley tho, but I discounted that one as one bad egg in a batch plus the fact that I buggered up installing the harmonic balancer when I did my timing belt, so I'm not blaming the OEX for this fault.
    Replaced under warranty, 2 years later now, still working fine .. hence the above blame(once the harmonic balancer was fitted proper!)

    I too thought that its rear is a bit too close to the exhaust, so went looking for a heatshield too.

    I got one off ebay thinking it needed it. Won't fit either alternator(neither the Marelli, nor the OEX now) .. without slight modding anyhow. I think it just needed some new holes drilled.
    Couldn't be bothered, so the idea was abandoned.
    Shield is hiding somewhere in the shed, need to fish it out .. may try again one day soon.
    But in saying that, 2+ years now without hasn't caused any issues either.

    Probably does need it for longer long term longevity .. but short term longevity should be fine without .. at least until you figure out a way to make the shield fit too.
    Arthur.

    '99 D1 300Tdi Auto
    '03 D2 Td5 Auto

  3. #3
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    [QUOTE=AK83;2931342]Q: 300 Tdi?

    Did your original have a heat shield?

    My original(Denso/Marelli) didn't.

    Yes 300Tdi. And yes my original has a heat shield.
    Thanks for your advice. I'll try and figure some way to maybe adapt the old heat shield - or make a new one.
    If all else fails I'll go without. Need to do the job in the next 3 weeks.

  4. #4
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    Just in case anyone looks at this thread in the future. I saw on another forum someone had fixed the original heat shield to a new alternator using cable ties - a couple of holes drilled in the heat shield and the cable ties around the alternator cables. Not sure how much difference it will make but that is what I have done. I'll try and attach a photo.
    Attached Images Attached Images

  5. #5
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    Y'know, it's been about a week since my reply, and I went scrounging in the little shed to try to find the spanking new one I got some years back.
    Always had it in mind to fit one day, but out of sight ... out of mind, and this thread reminded me about it.

    Fished out the old alt, still can't get that little 5mm nut off to get it apart and look into rebuilding it ... but I've scrounged just about every nook I reckon it could have fallen into and can't find this damned heatshield!

    Did check the rear of the alternator during the past week, and looks absolutely fine, no heat fatiguing, or any other dubious looking issues back there .. so for now still doesn't look like it's a priority to worry about.
    Arthur.

    '99 D1 300Tdi Auto
    '03 D2 Td5 Auto

  6. #6
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    I have just run into another difficulty with this. I have fitted the new Hella alternator and now discovered that the pulley size is smaller than the original alternator - hence the original belt (1595) is too long. I guess I can pull it out and try and swap over the pulleys but maybe best to just go with a shorter belt?
    Wondering if anyone else has encountered this and what size (length) belt I would need?
    Many thanks.

  7. #7
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    Smaller pulley size will also affect the tacho and display more than reality.
    Probably better to swap it.

    On the topic of fan belt length, I'm sure the standard belt is supposed to be 1580.
    technically 7PK1580. 7 ribs 1580 length.
    I recently had issues with this too.
    Changed belt, and did some other works in that area, and soon after fitting I started getting an engine knock.
    Sounded like tappets. adjust them, still knocking.
    Thought it was a dud tensioner, so got it replaced, same deal.
    Belt was from a landy spares shop, Dayco . 7PK1580.
    Searched for ages what this occasional knock was couldn't find nothing, until one day I noted that the tensioner was getting very close to it's full travel.
    Turned out that the belt wasn't exactly 1580 .. so got another new belt Dayco 7PK1580 .. same thing.
    Got another Gates this time .. same thing. Drove me mad!
    Then ordered a "Continental" branded one off ebay, but when it came it wasn't "Continental" it was Gates(again) ... but different design to those I'd been getting here(both from landy shop and my local R&E).
    Even tho this one also says 7PK1580 it was a slightly tighter fit(hard to get it over the last pulley, it was shorter by enough to stop the tensioner bottoming out on itself.
    The top face of the belt has a crosshatch pattern instead of being smooth.

    There's a thread about squealing belts I answered too HERE.
    Arthur.

    '99 D1 300Tdi Auto
    '03 D2 Td5 Auto

  8. #8
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    Cliff

    Only just saw this. The heat shield rattled off my D1 and I never did anything for about 150,000km. When I bought the 95 130 defender, I swapped across the disco alternator as it was higher output than a standard defender unit. Ran that old girl for 250,000km

    Did change the bearing once in that 400,000km but I’m guessing the heat shield is Not that important?

    Re: pulley size there is definitely different sized pulleys (belts) across the 300tdi years.
    As mentioned above your tacho will be different if you run a different pulley - depending on diameter difference - if not too different I’d just run a longer belt?

    S

  9. #9
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    Thanks for all the help.
    Yes the belt size did change over the years. This is from the Dayco Application Guide:

    Jan 1994 - Dec 1995
    2.5L 4 cyl OHV 8V DTi Turbo Diesel 300Tdi
    Eng code: 21L
    Belt Alt, Air P & P/S................................................. ...........7PK1595
    Belt A/C (Factory Air).............................................. ...........4PK1320
    Belt A/C (Aust Air).............................................. ...............4PK1360
    Automatic belt tensioner......................................... ..........APV1004

    Jan 1996 - Mar 1999

    2.5L 4 cyl OHV 8V DTi Turbo Diesel 300Tdi
    Eng code: 21L
    Belt Alt, Air P & P/S .................................................. .........7PK1580
    Belt A/C (Factory Air).............................................. ...........4PK1320
    Belt A/C (Aust Air).............................................. ...............4PK1360
    Automatic belt tensioner......................................... ..........APV1004

    My Disco, being 1995 model, originally had the 1595 (mm) belt. With the new alternator (smaller pulley) I have now used a 1580 belt. It seems to be OK - I now get 10mm between the cast lines on the tensioner.
    And yes - the tachometer does now read a little higher. I was going to change the pulleys but that was proving to be a bit difficult and I ran out of time. Maybe a job for the future.

    Thanks again for all the help with this.

    Cliff.

  10. #10
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    Wanted to update this. Just completed return trip from Cairns to Flinders Ranges and all went well with the new alternator.
    But I did find it annoying to have the tacho reading high with the smaller pulley on the new alternator.
    So now I want to put the pulley off the old alternator on to the new one.
    I would appreciate any advice as to how to remove the alternator pulley.
    Thanks.
    Cliff.

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