Thread: Replacing Alternator D2a Td5

Originally Posted by wardy1

Well my alternator didn't enjoy the Wombat mud it seems. Picked up a 2nd hand one and have spent the day so far trying to change them over.

What a BITCH of a job! You have to virtually dismantle the front right side of the engine bay just to get at it

Now I have everything disconnected and the top bolt out...... How in the hell do you undo the bottom bolt? It has a T45 Torx head and it's bloody tight and you can't get any leverage on the bloody thing.

Why they went for a Torx head instead of a hex bolt (as it is shown in RAVE) I have no idea.

Any ideas? This is currently my daily drive so I really need this fixed by yesterday.

Torx socket - Torx head bolts are far better fastener than any hex head bolt - beats welding nuts on to try to get bolts off any day.

And to make you feel better, besides the Torx you can get the unit out only removing the EGR piece

Good to see you back around Tombie!
Fortunately all the EGR stuff is gone from mine anyway, all removed while the engine rebuild was happening.
I have the Torx socket. I guess my point with the Torx is that you just can't get any leverage on it, it's in a bitch of a spot and there is bugger all room between the fan and the bolt. If it were a hex bolt at east you'd be able to get a socket on it with a ratchet driver (which there would be just enough room for).

Wardy, are you using a torx socket drive?

Remove the fan shroud and put some cardboard in there to protect radiator.

Now get your extension bar, and undo it

If I was in a position to come assist I would...

Thanks to all for their suggestions and offers of help.
Finally got her back on the road on Wednesday and all good......
Up until yesteday when I got home and noticed lots of oil dripping! Oh NO I thought, do I have to take it all apart again
Got underneath with the engine running this morning and could see where it was coming from... the junction/nut on the bottom of the vac pump on the oil inlet With every extension I had plus a uni I could get a 12mm socket on to it and turn it about 1/10th of a turn..... that's all and it stopped. Went for a 100kmh run on the freeway etc and not a drop now..... thank christ.