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[ali]

After a VERY long day and thanks to The Boy & Darth Loo-knee  I now have an alternator that will hopefully get Syd running again. I have looked everwhere on here and can not find any guide/steps on what is the best order of removal and refitting. I had hoped to be back by lunchtime, have the car in bits and all done by now. But due to a sight seeing trip around London , or ok I got a bit lost Im only just back. So I now have 3 hours in the morning to get old one off, new one on and then must head off to Great Yarmouth to collect my daughter :-/ So any tips for the morning will be gratefully received

[Turk]

Can't remember everything involved, but I do recall bending the battery tray upwards at the corner nearest the alternator with a large angled pliers. It'll bend easily enough, and bend back just as easily. This will give you a little more room to rotate the alternator and slide it out towards the rear. I didn't remove the power steering pipes when I did mine. It's a case of wiggle, rotate and tilt, but it will come out.
I know it sounds a bit dim, but I can't remember whether I took the inlet manifold off. I've just been out to look and I suspect I did remove it as doing so would allow a lot more room to access and manouver.

If Syd is your only means of getting to Great Yarmouth then I would be a little concerned of running out of time. Ok, I'm not the fastest spanner in the west and it was very much a learning curve when I did mine, but 3 hours won't give you much time if things don't go to plan.

I don't know what the problem is with your current alternator, but if it's not charging I'd stick the battery on charge tonight and drive it with minimum use of blowers, rear demister etc. for tomorrow. Once it's started, the battery isn't needed to keep the 2.5td running. You could actually take it off and it'll still run.
 
If overcharging is the issue, as it was with mine, I'd keep the revs below 1500rpm and drive with the lights, blowers etc on. I drove mine for over a week like this.

[Omegatoy]

hmm think i would be checking to ee if the brush pack and diode can be replaced by just undoing the 2 screws and replacing im prety sure it can!!! ten min job then!!!!

[ali]

Ok thanks for that, Im glad you said that about driving with no battery as AA man told me last week that at any point the car could stop and I loose power as car runs on battery I didnt think was correct :-/
I have 3 hours in the morning and then can carry on late afternoon until its done. I have no time limit as to when I get to Yarmouth but can not leave until at least 6pm so will need lights
As for taking out screws and checking diode, I guess this can be done with out taking it off :-? sorry if thats obvious, Im tired

[Turk]

If it's just the brush pack and diode then OT is correct (yet again ).
Remove the battery completely tho. It'll give you a lot more room. Also, I'd remove the bonnet alarm switch from it's holder. It may get damaged whilst your leaning over.
I always knocking it. I can be doing something in the boot and I'd still manage to catch it.   

[semisheen]

In the past i allways took the inlet manifold off to remove the alternator wich is a pain in the ass to do in itself ....ive now put the batery in the boot and removed the batery tray alltogether

[Turk]

In the past i allways took the inlet manifold off to remove the alternator wich is a pain in the ass to do in itself ....ive now put the batery in the boot and removed the batery tray alltogether

There ya go, I thought I had. How could I not remember whether I did that ?!? 

[semisheen]

its a piece of Cake with the inlet manifold off ...its nigh impossible with it on ..been there got the T shirt 

[ali]

if I take the manifold off will the gaskets be ok :-?

[Turk]

I've had a manifold on and off many times and only the last time did I need (decide to) get new gaskets. I smear a little oil on the manifold face and that stops them sticking the next time it's removed.
If they do tear or crack, they should be ok to match up and re-use. I'm reasonably confident they'll be ok.
Re-fitting is a case of easy does it wiggling. Don't use excessive force and re-tighten evenly. Don't overtighten or you may crack the inlets. 
Using a dab of grease in the socket will stop the nuts falling out on removal and re-fitting, and the last 3 nuts are best accessed by reaching under the manifold with a spanner. 
Having said that, I think you've done this before, so you probably know the score with removal etc

[ali]

I've had a manifold on and off many times and only the last time did I need (decide to) get new gaskets. I smear a little oil on the manifold face and that stops them sticking the next time it's removed.
If they do tear or crack, they should be ok to match up and re-use. I'm reasonably confident they'll be ok.
Re-fitting is a case of easy does it wiggling. Don't use excessive force and re-tighten evenly. Don't overtighten or you may crack the inlets. 
Using a dab of grease in the socket will stop the nuts falling out on removal and re-fitting, and the last 3 nuts are best accessed by reaching under the manifold with a spanner. 
Having said that, I think you've done this before, so you probably know the score with removal etc

Yes I have had it off lots of times I havent found it a problem with my little hands no chance of over tightening

[TheBoy]

Manifold off, and from memory its just 2 long bolts (after removing aux belt, obviously. 2 wires on back of alternatoer as well.

Hard part is the fiddly bit of getting alternator out - the battery tray is in the way to lift it up.

[ali]

Manifold off, and from memory its just 2 long bolts (after removing aux belt, obviously. 2 wires on back of alternatoer as well.

Hard part is the fiddly bit of getting alternator out - the battery tray is in the way to lift it up.

Have got manifold off, bolts all out, wires off. Not sure how to get belt off :-? I will search again but any help would be

[ali]

I've had a manifold on and off many times and only the last time did I need (decide to) get new gaskets. I smear a little oil on the manifold face and that stops them sticking the next time it's removed.
If they do tear or crack, they should be ok to match up and re-use. I'm reasonably confident they'll be ok.
Re-fitting is a case of easy does it wiggling. Don't use excessive force and re-tighten evenly. Don't overtighten or you may crack the inlets. 
Using a dab of grease in the socket will stop the nuts falling out on removal and re-fitting, and the last 3 nuts are best accessed by reaching under the manifold with a spanner. 
Having said that, I think you've done this before, so you probably know the score with removal etc

Is that the manifold or me
All 6 gaskets did tear but think they will be ok. I had to work this afternoon so I have left Syd in bits and will borrow friends x trail again to drive to Yarmouth. Not as comfy as Syd but will get me there and back
So belt is still on if any one can shine some light on how I get it off tomorrow

[TheBoy]

Aux Belt  (if you could take pics, or even video, that would make ideal Maintenence Guide )
=======

Remove viscous. Left hand thread!

Remove all 'Turbo Diesel' plastics (assume already have if manifold off)

See the tensioner, that looks like a mini damper? And the (normally black) plate its top edge mounts to?  Loosen the 2 bolts holding black plate to engine. Put a pair of molegrips on black plate on right side (looking from front), then remove the bolt that goes through tensioner. When bolt removed, gently angle the black plate upwards, pivotting on remaining bolt. This will loosen bolt.

To retension afterwards, pivot the black plate downwards with molegrips and reinsert removed bolt.



As said, piccy worth a thousand words if you can take a couple to make a guide