Alternator Replacement - with pictures

[Geof180]

Good evening everyone,

I have done a search, and really didn't find a pictorial "how to" showing how to get the alternator out without pulling the plenum. So I figured I'd post up my procedure.

Well, I tackled this job tonight... And naturally with these old cars, nothing is ever as simple as it should be. Forgive me if some of the pictures are rather poor; I was using the trusty iPhone.

I will share my lessons learned. Hey, I have never done this before - and doing it yourself is always an experience. If I can help someone else avoid my own pitfalls, then I have succeeded. ;)

http://sphotos-a.xx.fbcdn.net/hphotos-ash4/486683_10151404963024056_1654957298_n.jpg

1) Disconnect the battery
2) Remove the accordion air duct by loosening the hose clamps and removing the bolts securing the air cleaner assembly

http://sphotos-a.xx.fbcdn.net/hphotos-ash3/550682_10151404963134056_406711047_n.jpg

3) Remove the air cleaner assembly
4) Disconnect the myriad of hoses and connectors running into the air horn

http://sphotos-a.xx.fbcdn.net/hphotos-snc6/198717_10151404963214056_122295909_n.jpg

5) Remove the external and internal Torx bolts holding on the air horn
6) Remove the nuts holding the cover over the throttle body cables

http://sphotos-b.xx.fbcdn.net/hphotos-ash4/393352_10151404963289056_1364744460_n.jpg


The air horn is now free.

http://sphotos-b.xx.fbcdn.net/hphotos-prn1/527427_10151404963364056_1643815789_n.jpg

[Geof180]

Be very careful of the gasket between this and the throttle body. Mine is now in two pieces.

http://sphotos-b.xx.fbcdn.net/hphotos-snc6/253112_10151404963429056_950597711_n.jpg
My new one from Jerry's Gaskets should be here in a few days. It's a 20 dollar part.

7) I started removing the visible bolts holding on the alternator. The first one I did was the one nearest the oil pressure sensor.

http://sphotos-a.xx.fbcdn.net/hphotos-snc6/227833_10151404963504056_1690450575_n.jpg

Be very careful working around this sensor. My new one should be here in a few days. It's a 40 dollar part from CorvetteCentral

http://sphotos-b.xx.fbcdn.net/hphotos-ash4/248478_10151404964094056_1895408169_n.jpg

I needed more room to gain access to the lower bolts securing the alternator, as well as the belt tensioner.

8) I decided to remove the passenger side coolant crossover pipe so I could have more space.

http://sphotos-b.xx.fbcdn.net/hphotos-ash3/541232_10151404963669056_1408118705_n.jpg

There is a gasket here too. Again, Jerry's Gaskets says my new one will be here in a few days. It's like an 8 dollar part.

Oh yeah, despite the high location of the pipe, coolant is in there! It will come draining out! So drain some coolant beforehand if you plan on doing what I did.

9) I used my breaker bar and inserted the tab into the tensioner and pulled towards the passenger side to relieve the belt tension.

http://sphotos-b.xx.fbcdn.net/hphotos-prn1/564230_10151404963829056_107992821_n.jpg

10) Remove the Torx bolts holding on the throttle body.

http://sphotos-b.xx.fbcdn.net/hphotos-snc6/228095_10151404963754056_840724371_n.jpg

[Geof180]

There is a gasket here too! Surprisingly, mine stayed intact! :dancing. Jerry's does carry the part however.

11) There's a lower bracket with three bolts slightly below the alternator. I removed these bolts and thus the bracket.

http://sphotos-a.xx.fbcdn.net/hphotos-ash3/533714_10151404963934056_1637748371_n.jpg

http://sphotos-a.xx.fbcdn.net/hphotos-snc7/598839_10151404964019056_1243428481_n.jpg

12) After disconnecting the plug on theassenger side of the alternator, and the rear red wire, the alternator will simply slide out.

http://sphotos-a.xx.fbcdn.net/hphotos-ash3/546301_10151404963989056_2018132093_n.jpg

http://sphotos-b.xx.fbcdn.net/hphotos-ash4/427803_10151404964049056_1832579150_n.jpg

Now, be careful with the red wire on the back of the alternator. Mine more or less disintegrated when I tried to move it around. I will be splicing in a new wire tomorrow.

I hope this can help someone. After I get my new wire made, I am just gonna reverse the process to button the gal back up again. Oh yeah, replace the coolant which drained out too.

[Pete]

Good job.

I like the powder coating (plenum/IH's) very nice.

Pete

[tomtom72]

Thank you for the write up! Yea, nice work and the powder coat does look really great!


:cheers:
Tom

[scottfab]

Wow would not have thought to do it that way.
Great write-up and pics.
I did the alternator replacement with just a few tools
in a hotel parking lot in 2005. Took 1.5hrs.

http://www.zr1netregistry.com/Old_Proj/old_proj23.htm

[Geof180]

hey scott! i actually saw your procedure.

i thought about following your work, but i have never pulled the plenum.. so to be honest, i was rather nervous about doing so..

this is why i tried to do it without removing the intake..

and to tom and pete, thanks for compliments on the LT5's finish. i certainly cannot take credit for that.. this is all jeff flint's work.

[Mystic ZR-1]

Can ya get the AC compressor out using the same method?

[scottfab]

hey scott! i actually saw your procedure.

i thought about following your work, but i have never pulled the plenum.. so to be honest, i was rather nervous about doing so..

this is why i tried to do it without removing the intake..

and to tom and pete, thanks for compliments on the LT5's finish. i certainly cannot take credit for that.. this is all jeff flint's work.

Well it's good to know the other way works too. The only reason I felt confident about pulling the plenum was that I use a rubber gasket set under the plenum so I knew it would not stick and come apart on me.
That, I did not need being away from home and all.

[scottfab]

Can ya get the AC compressor out using the same method?

Good question. :icon_scra

[jimmy b.]

Great job on the write up! I especially liked the price check on all the parts you bought. Good humor whether you intended it or not made me smile, good job...jimmy

[Corbusa]

Great write up. I appreciate it...

[Geof180]

hey, you're very welcome... i will do the same when i put it all back together again..

*still waiting on my sensor and gaskets to arrive*