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Alternator Removal & Serpentine Tensioner
Posted by Brett R. Hall (more from Brett R. Hall) on Mon, 22 Nov 1999 13:36:21
In Reply to: , Kok Chen, Sat, 17 Dec 1988 12:00:00 

I've got the Alternator replaced on my '94 9000 Aero.  After you know the
basic steps it's no problem at all.  Here are the steps I took if anyone is
interested.  I also have a question that is at the end of the message about
the Serpentine Tensioner.

An air ratchet is extremely nice to have for this job.  You will also need
a 13mm socket for the PS pump bracket bolts, a 16mm socket for the strut
assembly bolts, a 19mm socket for the tensioner pulley bolt, and an 8mm
allen wrench for the alternator bolts.

This applied to at least the '93+ 9000 owners.

1) Jack up car
2) Remove pass. front wheel
3) Remove fender guard (on edge of fender)
4) Remove plastic inner wheel well towards rear of car
5) Remove plastic inner wheel well towards front of car
6) Compress tensioner and hold compressed with homemade contraption (read
the posts about tensioners)
7) Remove tensioner pulley (reverse thread)
8) Remove serpentine belt (didn't write down belt configuration....don't
worry, it's in the owner's manual)
9) Disconnect both wires going to alternator
10) Disconnect both bolts holding alternator (the top bolt cannot be
removed from the holes, only completely unscrewed)
11) Remove the four bolts holding the PS pump bracket on (the top pass side
bolt is a pain)
12) Remove the three bolts holding top of the strut assembly
13) Drop the strut assembly down and back
14) Drop the ps pump down as much as possible
15) The alternator will now fit out the wheel well.
16) Reverse order.

My question is how do I compress the tensioner?  I screwed up #6 and my
tensioner is now fully uncompressed and cannot get it compressed enough to
get everything back together.  It went so uncompressed that the rubber boot
came off the shaft section, but that's now back on.  Should I remove it and
compress it on a vise or should it not be that difficult to re-compress?

Anyway, thanks to everyone who replied and I hope someone puts this in an
FAQ somewhere for all those '93+ 9000 owners.

Brett
'94 9000 Aero (87k)
'82 900 RIP
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