Alternator replacement? - ZR-1 Net Registry Forums

White Bullet · 01-12-2010

Would'nt you know. I am in the process of moving (selling one house and buying another in different states) and working away from my home. Anyway I am living in a hotel and do not have my tools. On the drive here the alternator starts chirping. I first thought that the noise was in the radio until I stopped and checked under the hood. I have ordered a replacement and it should be here in a few days. What I need to confirm is that the alternator can be removed without pulling the plenum. I have seached around the forum and found hints that it is possible but very few details. So is it possible and if so what needs to be done. What tools are needed would be of help as I must borrow them to get the job done. Thanks.

xlr8nflorida · 01-12-2010

You don't remove the plenum.

It's in the front of the engine where it is accessible. The job does take some time though. It's not like slapping an alternator on a LT-1 car.

I would bench test the alternator. We put one in my car a long time back, buttoned everything back up and then heard ding and the alternator was toast. Had to get a replacement under warranty and do the job all over again.

I can't remember how long it took but I would say 1-1.5 hours if you are careful and don't want to scratch up the LT-5. It's a pretty straight forward job. Good luck.

White Bullet · 01-13-2010

Thanks for the reply. Hope it is easy any thought about the tools needed. Again I will need to borrow them and will not have access to a full box.

xlr8nflorida · 01-13-2010

Quote:

Originally Posted by White Bullet

Thanks for the reply. Hope it is easy any thought about the tools needed. Again I will need to borrow them and will not have access to a full box.

You just need basic tools.

When we did mine, we just took the air horn off (in front of throttle body) intake snorkel etc very slowly. You take the bolts out from the 2 brackets and then put in a safe spot. You have to get the oil sensor off with a long 27mm socket. In a pinch you could improvise with some channel locks. Disconnect wiring and you are good to go. Be careful of the horn gasket etc.

Others might be able to give you more concise directions but that is the jist of it. It's pretty straight forward and you can definetly do it in a parking lot.

I would however suggest you "bench test" the alternator as some do come DOA. It would suck if you put it all back together and had to do it again because the alternator was faulty. You say what are the chances of that happening? It happened to me when we changed out mine.

Keep your original alternator because more then likely the AC Delco you buy will be a Reman. You can rebuild your original for about $90.

White Bullet · 01-14-2010

I picked up a NAPA reman. It comes with a three replacement and free towing if it should fail while driving. I will look at the alternator to see if it is a Delco unit and may consider keeping it for repair. The new one was $144.00.

Thanks for the details on the removal it should be pretty easy.

01-14-2010

Yes, you can do an alt replacement with out removing the plenum. But it is extremely tight.

Disconnect the battery first since you will be removing the positive cable on the alt.

1) Pull airhorn off.
2) Remove serp belt.
3) Loosen the 3 13mm bolts holding the alt on. (Only two hold the alt directly, the third will allow you to pivot the brace.)
4) Undo the back 10mm bolt securing the alt on the backside. A 10mm ratcheting box wrench helps a lot here.
5) Loosen the 10mm front bolt on the injector housing.
6) Undo electrical connector.
7) Remove the two 13mm bolts holding it in place.
8) Undo the positive cable.
9) Wiggle it around and get it out.

White Bullet · 01-14-2010

Sweet!! Thanks Jeffvette that is what I needed

. You are the man.

-=Jeff=- · 01-14-2010

Hey White bullet, did the new Alt have a pulley too, could you see if they are both the same size? I got a AC Delco reman and the new pulley is a slight bit smaller

rhipsher · 01-15-2010

Jeffs right pulling the plenum will make the job much easier and you can see everything. On some things its just better to take a little extra time to remove things that are in the way.

jonszr1 · 01-15-2010

Quote:

Originally Posted by -=Jeff=-

Hey White bullet, did the new Alt have a pulley too, could you see if they are both the same size? I got a AC Delco reman and the new pulley is a slight bit smaller

my new alt. had a different size pully so i took it to the parts store and had them put the original on the new alt . i agree about pulling the plenum for this for me it was easier than trying to do it without pulling the plenum .jmho

01-12-2010	#1
White Bullet Join Date: Apr 2008 Location: Gainesville GA Posts: 231	Alternator replacement? Would'nt you know. I am in the process of moving (selling one house and buying another in different states) and working away from my home. Anyway I am living in a hotel and do not have my tools. On the drive here the alternator starts chirping. I first thought that the noise was in the radio until I stopped and checked under the hood. I have ordered a replacement and it should be here in a few days. What I need to confirm is that the alternator can be removed without pulling the plenum. I have seached around the forum and found hints that it is possible but very few details. So is it possible and if so what needs to be done. What tools are needed would be of help as I must borrow them to get the job done. Thanks. __________________ 1991 ZR1, White/Red.

01-12-2010	#2
xlr8nflorida Join Date: May 2008 Location: USA Posts: 1,095	Re: Alternator replacement? You don't remove the plenum. It's in the front of the engine where it is accessible. The job does take some time though. It's not like slapping an alternator on a LT-1 car. I would bench test the alternator. We put one in my car a long time back, buttoned everything back up and then heard ding and the alternator was toast. Had to get a replacement under warranty and do the job all over again. I can't remember how long it took but I would say 1-1.5 hours if you are careful and don't want to scratch up the LT-5. It's a pretty straight forward job. Good luck.

01-13-2010	#3
White Bullet Join Date: Apr 2008 Location: Gainesville GA Posts: 231	Re: Alternator replacement? Thanks for the reply. Hope it is easy any thought about the tools needed. Again I will need to borrow them and will not have access to a full box. __________________ 1991 ZR1, White/Red.

01-14-2010	#5
White Bullet Join Date: Apr 2008 Location: Gainesville GA Posts: 231	Re: Alternator replacement? I picked up a NAPA reman. It comes with a three replacement and free towing if it should fail while driving. I will look at the alternator to see if it is a Delco unit and may consider keeping it for repair. The new one was $144.00. Thanks for the details on the removal it should be pretty easy. __________________ 1991 ZR1, White/Red.

01-14-2010	#6
Jeffvette Guest Posts: n/a	Re: Alternator replacement? Yes, you can do an alt replacement with out removing the plenum. But it is extremely tight. Disconnect the battery first since you will be removing the positive cable on the alt. 1) Pull airhorn off. 2) Remove serp belt. 3) Loosen the 3 13mm bolts holding the alt on. (Only two hold the alt directly, the third will allow you to pivot the brace.) 4) Undo the back 10mm bolt securing the alt on the backside. A 10mm ratcheting box wrench helps a lot here. 5) Loosen the 10mm front bolt on the injector housing. 6) Undo electrical connector. 7) Remove the two 13mm bolts holding it in place. 8) Undo the positive cable. 9) Wiggle it around and get it out.

01-14-2010	#7
White Bullet Join Date: Apr 2008 Location: Gainesville GA Posts: 231	Re: Alternator replacement? Sweet!! Thanks Jeffvette that is what I needed . You are the man. __________________ 1991 ZR1, White/Red.

01-14-2010	#8
-=Jeff=- Join Date: Jul 2007 Location: Bartlett, IL Posts: 7,178	Re: Alternator replacement? Hey White bullet, did the new Alt have a pulley too, could you see if they are both the same size? I got a AC Delco reman and the new pulley is a slight bit smaller __________________ 1990 Corvette ZR-1 #1051 Watson Headers (2" Primary) - Flowmaster Cats - Borla Catback Late Model IH - Plenum Coilovers - 4.10s Shelby Series 1 - Wilwood Brakes Custom Interior NCM Lifetime Member #978

01-15-2010	#9
rhipsher Join Date: Aug 2008 Location: Houston, TX Posts: 2,319	Re: Alternator replacement? Jeffs right pulling the plenum will make the job much easier and you can see everything. On some things its just better to take a little extra time to remove things that are in the way.