Thread: Alternator performance

Here's what Rave says

Removing TD5alternator.
Radio code before removing battery terminals do you know the code?
Remove battery cover.
Remove battery negative. 13mm spanner.
Remove fan cowl. 4xCross head screws.
You will be working in area between pulleys and radiator its a good idea to place a sheet cardboard to protect the radiator.
Remove fan (36mm or Ford/GM fan spanner fits perfectly). I usually jam a roll of electrical tape between belt and fan pulley to stop belt slipping.
With jaws of spanner on fan nut a sharp blow with hammer towards the left.

For maximum clearance remove the EGR valve or deEGR trumpet 4x5mm Allen screws and intercooler outlet hose for its clamps a flexy hose clip tool is my favourite.

To remove auxiliary drive belt you'll need a 15mm socket with a long ratchet as the spring tension is significant.
Put the socket on the spring-loaded tensioner nut, in the middle of the pulley.
Using your long ratchet or similar, turn anti-clockwise against the spring tension.
You will find the tensioner lifts away from the belt allowing you to remove the belt pull it forward and up from beneath fan pulley.
Slowly release tension.
Note direction of belt travel so it rotates in the same direction when refitted lay belt on flat surface with the front edge off the ground.
Remove tensioner assembly the bolt is 14mm 12 point a socket is ideal but it needs to be a fairly thin walled to fit as the head of the bolt is recessed and there isn't much clearance.
Disconnect vacuum hose from pump squeeze the legs of clamp together and pull clamp up past the inner pipes flare then pull off pipe from pump.
Pull back rubber boot on top of alternator to expose the 13mm nut if nut feels really tight and corroded soak with WD40 it can be removed later but can be left on the alternator and disconnected at fuse box end no point damaging the terminal.
The multiplug for the excite/indication lead on the back of the alternator is a PITA and its a push to release item we will disconnect it later when alternator is loose.
Remove upper alternator stay two 10mm bolts
Release clip from vacuum pump drain pipe on pump side.
I use a cheap connector crimp tool to squeeze the clip together then push a slim screwdriver blade in from the side to unlatch the clip,then slide it down the pipe past the flare of the inner tube.
Pipe will disconnect when alternator is free.
Remember to refit pipe BEFORE you get all the bolts in on refit.


The clips on the small pipe top of radiator to expansion tank are the same use these to practice your skills.

Remove the oil supply line to pump.
This is done by undoing from the top of the pipe where it screws into the timing chain housing.
It can be a little tricky because of the limited swing you get but its doable with open ended spanner or a pipe spanner 14mm head,
Discard Oring (new needed).
Or it can be disconnected farther down at the banjo bolt on the pipe LH side of pump 12mm spanner needed there should be a copper washer on either side of the banjo be carful not to loose washers.

Remove lower alternator bolt a torx bolt a T50 socket is best.
See below if you have problems with the T50 bolt.
You will need to support the alternator ITS HEAVY before you remove the bolt and release it from mounting bracket the alternator should now be free move it away from engine this will disconnect oil return pipe.
Pull alternator forward and rest it on the mounting disconnect the multiplug from the rear of alternator the plugs push to release is on the middle of plug on the outside push it in and wiggle it off don't force it if its clogged with dirt and oil spray with WD40 and loosen the muck.
Pull alternator and vac pump forward pulley first continue to pull alternator forward and up/out.

T50 Bolt
If its head is chewed up or you haven't got a T50 bit the alternator can be removed complete with its mounting bracket it's held on by three 13mm headed bolts to the engine you will have to remove the earth strap a 10mm head bolt and oil cooler pipe clamp 8mm bolt head.
Access to the mounting is from under the car. Reconnect the top strap to alternator if working below to stop it dropping.

Vacuum pump fitted to TD5 to create vacuum for brake servo.