Installing the new alternator

Move it forward

The alternator can now be manoeuvred slightly forward to lift the rubber boot off the terminal and then remove the terminal lead securing nut.

Ready to generate

This replacement alternator is a new Denso DAN987. Prices vary widely, so it’s worth shopping around for a good price with quick delivery.

Re-tension

The auxiliary drive-belt tensioner is refitted and the securing bolt tightened to 45Nm. It’s then held using the 3/8-inch square drive while refitting the belt.

Securing lug

The heavy duty cable connection is secured in place on the terminal bolt by a lug (arrowed), this is gently released with a small flat-blade screwdriver.

Fit and connect

The new alternator is held in position while connecting the multiplug, and securing the cable to the upper terminal with the nut before refitting the rubber boot.

Fan unit

The viscous fan is tightened back onto the pulley stub, remembering the left-handed thread, and the electrical multiplug is reconnected.

Final disconnection

The alternator is now free to be pulled forward, allowing the multiplug on the back of the alternator to be disconnected and the unit removed from the vehicle.

Sequence bolting

The alternator is positioned on its mounting and the three bolts refitted (front bolt first) before tightening in sequence (front upper, side front, side rear) to 45Nm.

Final connections

The upper shroud is refitted and the coolant bleed hose reclipped onto it, followed by the intake duct. Finally, the battery negative lead is reconnected to complete.