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I have recently replaced the alternator on my 1986 900 Turbo 16-Valve hatchback and would have liked to have had this advice.
I would like to see this posted in a place where it could easily be found by anyone who could use it.
I was frustrated for almost 3 days. Once you get the alternator out, it is obvious how it is done. While the alternator is in, it is impossible to see what holds it in there. The Bentley manual says to remove the bolts on the bracket but does not say how many (2 or more obviously) or where they are. They show the easy one being removed.
The alternator bracket is a diamond shaped bracket, with the long axis
parallel to the axis of the car. There are 3 bolts holding this bracket, one you can see (towards the front of the car), one is shared with the A/C
compressor bracket and the third is hidden under the alternator. The rear corner of the diamond is the only corner which does not have a bolt.
It wouldn't hurt to go look at an engine which is sitting outside of a car, if one is available, before tackling this job. The way things are packed in there and the way the front of the engine is smack up against the firewall make it impossible to see what you are doing.
Some people suggest removing the A/C compressor, some suggest removing the
master brake cylinder and some suggest disconnecting the front engine mount
but none of these is necessary.
First disconnect battery ground and remove all wires from the alternator
(remember where they go).
Remove the heater hoses from the heater control valve and fold them out of the way. Remove the coolant overflow tank and move that and its hose out of the way. You can drain the cooling system first or just resign yourself to a minor coolant spill.
Loosen the Alternator belt tension and remove the tension adjusting bolt from the alternator. Push the alternator up and towards the A/C compressor and remove the belts. Use a 6 mm allen (hex key) wrench and remove the bolt holding the bracket towards the front of the car. Remove the bolt holding both the A/C compressor and the alternator bracket with a 12 mm box-end wrench (the Queen would call it a ring spanner).
Loosen the bolt hidden underneath the alternator (6 mm allen = hex key). Remove the nut on the back of the bolt holding the alternator to the bracket (17 mm as I remember). Twist the alternator bracket counter clockwise enough so the alternator mounting bolt (that 4"=10cm long bolt) can be removed without hitting the firewall.
Now remove the alternator (not that easy since there's lots of stuff in the
way). Here is where disconnecting the master brake cylinder from the power
brake servo (but leaving brake lines connected) may help.
Installation is the reverse of removal (heh-heh). Be sure you don't cross
the alternator belts and get the belts on right. It's difficult to see in
there. Be sure to backtrack exactly, as not doing so may make it impossible to retrace your steps.
Good luck,
Charles Stoyer
Golden CO USA
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