Alternator - removal and refitting

Removal
1 Disconnect the battery leads.

2 Disconnect the multi-plug, or disconnect the wires from their terminals on the rear of the alternator, noting their locations (as applicable), then slacken the mounting and adjustment bolts and tilt the alternator towards the engine (see illustrations).

4.2a Disconnecting the multi-plug from a Bosch alternator
4.2a Disconnecting the multi-plug from a Bosch alternator

4.2b Removing the insulating cap from the main wiring terminal on a Lucas
4.2b Removing the insulating cap from the main wiring terminal on a Lucas A127 alternator (CVH model)

3 Remove the drivebelt(s) from the alternator pulley(s).

4 Remove the mounting and adjustment nuts and bolts, and withdraw the alternator from the engine.

Refitting
5 Refitting is a reversal of removal, noting the following points.

6 To avoid breakage of the alternator mounting bracket lugs, it is important that the following procedure is adhered to when refitting the mounting bolts.

7 Always refit the large flat washer (A) (see illustration).

4.7 Alternator mounting bracket arrangement
4.7 Alternator mounting bracket arrangement

A Large flat washer
B Small flat washer (models up to 1985 only) C Mounting bracket (engine) D Mounting lugs (alternator)

8 Earlier models (before 1985) also have a small washer (B) which must be fitted between the sliding bush and the mounting bracket.

9 Ensure that the bushes and bolts are assembled as shown - except on 2.0 litre DOHC models where a through-bolt is used, then tension the drivebelt(s) and tighten the mounting and adjustment bolts as shown in the relevant illustration in Chapter 3.

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