FYI - Notes on replacing 9-5 alternator - Saab 9-5 Bulletin Board - Saabnet.com


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FYI - Notes on replacing 9-5 alternator
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Posted by Mark in Marine [Email] (#1837) [Profile/Gallery] (more from Mark in Marine) on Sun, 5 Jan 2020 12:45:44 Share Post by Email
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I just replaced the alternator on a 2006 9-5 SC - a job I have done on 9-5's three times before. BUT, two things caught me out that others might like to know:

1) When I did this job on the same car 4.5 years ago, I was doing other things too, and the rigid PCV hoses from PCV box to the valve cover and the cobra pipe were off at the time - this time I had to specifically remove them from the PCV trap to give room to pull the alternator out the top past the intake. This is for the final version of the PCV system, 2005 and up.

2) I had an unexpected problem fitting the new alternator into the LOWER bracket. Yes, I pressed the LOWER alternator bolt sleeve back into the bracket as far as it would go with a Channel Lock.
Here's the thing: The designers made the sleeve LONGER than the thickness of bracket into which the sleeve is inserted. So the outside (open) end of the sleeve was flush with the ear of the bracket, but the inside stuck out too much to fit the new alternator. It took me a while to understand the issue. Some new alternators will fit anyway, while others may not.

The solution was a 19mm 12-point socket on the outside with an M8 bolt through it and nut on the the inside (closed end) of the bolt sleeve. The 19mm 12-point socket is just barely large enough to fit the open end of the sleeve inside of it and to allow you to draw the sleeve flush on the inside of the bracket. A nickle's worth worth of aluminum for a thicker ear on the bracket or a shorter sleeve would have made this an error that could never happen. The upper bracket/bolt sleeves sit in a deeper hole, and this is not an issue.

The alternator I replaced was a Bosch AL0857X reman unit that went about 47K miles. It was still charging the battery, but the rear bearing (brush end) was making a scraping noise - I suspect this "premium" reman was mostly new brush/regulator and paint . . . .

Hope this information helps someone in the future.

Mark in Marine

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