How do you get the alternator out of a 1.9TD engine bay???

Xaccers · Post by **Xaccers** » 09 Jan 2008, 20:24

Driving home tonight the battery light came on whenever I did less than 2000rpm.
Belt looks tight, wiggled battery contacts, no difference.
Altenator on it's way out?

deian · Post by **deian** » 09 Jan 2008, 20:30

Sounds like it yes, maybe you can change the bushes in the rear of it?

Post by **CitroJim** » 09 Jan 2008, 21:12

Yes, it does look like the alternator is on the way. As Dei says, it is well worth just changing brushes. An exchange alternator from our local factors is circa £80... Brushes are a fraction of that.

Have a quick look at the charging voltage with a multimeter across the battery. You should see no less than 13.8V when the engine is running on idle and no more than 14.4V when the alternator is really charging hard.

The alternator is actually easier to change than it looks. Belt off, ECU box removed and it is quite get-attable. It may be necessary to slip off the Engine Mount so the engine can be jacked up to give a bit more space. Basically, the alternator slips out into the space normally occupied by the ECU box.

Shout if you want some help with it...

Xaccers · Post by **Xaccers** » 11 Jan 2008, 11:21

Well it finally gave up the ghost this morning just as I parked at work.
Jim, is there somewhere local that sells the brushes so I can get it sorted tonight?

Cpt_Spalding · Post by **Cpt_Spalding** » 11 Jan 2008, 15:22

I tried changing the brushes on the alternator for a Toyota I had once.

Managed to strip it down to the casing then found the casing impossible to get apart, so I dropped it into a specialist shop from there to change the brushes.

When I collected it the chap said "Bloody hell,, what a b!tch of a job getting the casing apart to change the brushes".

"Really? Gosh!" I replied. "I had no idea!"

The reason I tried (other than having the time & facilities) was I had been stung breaking down in Monte Carlo of all places touring with my 1st car (Escort Mk2 1.3). Had to buy a brand new Bosch unit from the local Ford dealer. Even though it was 1988 I still remember the hurt of paying £130 when a refurb Lucas in UK would have been a mere £28.

Xaccers · Post by **Xaccers** » 12 Jan 2008, 22:35

Managed to remove the two retaining bolts and now the alternator is free.
Slight problem, all the gaps around the alternator are too small for it to pass through.
I've tried with the engine high, and with it low.

What magic do you need to remove the alternator from a 1.9TD?

Post by **CitroJim** » 12 Jan 2008, 23:53

Andy,

Have a look at this post.

http://www.frenchcarforum.co.uk/forum/v ... alternator

It was how I swapped my Activa Alternator.

I'd forgotten just how tricky the job was

The TD should be similar.

See you tomorrow morning...

Xaccers · Post by **Xaccers** » 13 Jan 2008, 00:21

Oh joy that looks like a fun job!
So much for the BoL "manouver the alternator out of the engine" making it sound so simple!

Xaccers · Post by **Xaccers** » 13 Jan 2008, 22:03

Well, Jim and I managed it, and it was suprisingly easy.

Remove the intercooler pipe, the oval one, and you may want to remove the intake manifold pipe connected to it as well.
Then remove the oil filter.
With someone holding the radiator pipe out the way, there's enough room to remove the alternator.

Course it wasn't really that simple, Motorserv had given Jim the wrong alternator so we had to dash back and get it changed, but it wouldn't be as much fun if it was easy right?