97D90 Alternator installation help - Defender Source
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  #1  
Old August 25th, 2011, 01:17 AM
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kyle scheppler
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Smile 97D90 Alternator installation help

Im going to be installing my new alternator in my 97 D90. Looking for any pointers or important things to remember as I complete the installation. things that may arise and should be aware of during process, or things to remember to check while im doing this.

Mainly,
I was Hoping someone could direct me to a website or tutorial that i could use to reference when Im installing myself. pdf form is fine, a website, or any other source. something with maybe a step by step direction or even something wth things to remember. any help would be much appreciated. maybe its easier than I think, just never attempted myself. thank you again, everyone is usually so helpfull.

Ky
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  #2  
Old August 25th, 2011, 09:31 AM
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Are you going to replace your belt(s) at the same time?

------ Follow up post added August 25th, 2011 09:35 AM ------

If you bought the same Magneti Marelli/factory alternator to replace then it's just slackening the bracket to loosen the belt, check your wires to see which are tach, etc. and remove alternator, replace alternator, tighten bracket and belt tension (NOT TOO TOO TIGHT where you end up f'ing up the bearing), hook up wires, test. Enjoy. My 95 is different, but here was my thread.

http://www.defendersource.com/forum/...t=31806&page=3
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  #3  
Old August 25th, 2011, 10:18 AM
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Just a note, the bushing in the rear hole will slide forward when you tighten up the mounting bolt. If it's already pushed in too far to let you install the alternator, give it a whack rearward so's the alternator will mount.
I also find that it's a good idea to take the adjuster thingy apart and give it a quick wire brush and put some anti-sieze paste on the threads of all the fitting bolts.
The nuts are metric on the Marelli alternator.
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  #4  
Old August 25th, 2011, 11:05 AM
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Hey kids....'97 is a serpentine belt.

- Disconnect negative cable from the battery
- Remove the top of the fan shroud.
- Make sure you know how to re-route the serpentine belt...draw yourself a picture if you need to.
- Get your long breaker bar and a 15mm socket.
- Slacken the belt by moving the belt tensioner.
- Take belt off the alternator pulley.
- Remove the two bolts holding the alternator in place.
- Tip alternator forward so you can see the electrical connections on the back.
- MAKE SURE YOUR NEW ALTERNATOR HAS THE SAME CONNECTIONS.
- Move wires to the new alternator.
- Re-install in reverse order....

Bob....Uncle...TaDaa...


KAA
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  #5  
Old August 26th, 2011, 03:36 PM
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awesome thanks guys...and yes it is the same alternator that your talking about 100 amp magnetti or whatever...
much appreciated everyone
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  #6  
Old August 26th, 2011, 03:56 PM
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BTW - as lore hath foretold (and you may already know), your water pump may bust due to the belt/tension change. Happened in my truck just a couple months ago. I'm not really sure if it was due to age or the belt, but it was pretty much as others had warned..
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Old August 26th, 2011, 04:38 PM
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kyle scheppler
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ok cool im gunna make sure to check all that
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  #8  
Old August 27th, 2011, 12:14 PM
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How's you're h2o pump gonna bust...it's the same tension as before...it's a serpentine set-up!
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  #9  
Old August 30th, 2011, 01:39 PM
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guys i have another question...since this is the first time ive ever done this myself, im having trouble loosening the tensioner to take the belt off the alternator pully...do i need some sort o tool to do this that im not aware of? cause i cant get it to loosen some tension to take the belt off...

the red arrows in the pics are pointing to the tensioner that im trying to turn...i loosened the center bolt but still nothing...what do i need to do that im not think of?
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Old August 30th, 2011, 01:45 PM
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You can't just loosen the bracket that the alternator is attached to, to get enough slack to remove the belt from the alternator pulley??
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  #11  
Old August 30th, 2011, 01:48 PM
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Quote:
Originally Posted by rijosho View Post
You can't just loosen the bracket that the alternator is attached to, to get enough slack to remove the belt from the alternator pulley??

no...im trying as we speak
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Old August 30th, 2011, 01:48 PM
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As per above.....15mm socket and a long breaker bar will do it.

Turn the fan so you can work between the most widely spaced fan blades.

Rotate the bolt in the center of that pulley clockwise....yes, as though you're tightening it...and it will release, okay - maybe "relieve" is a better term, tension on the belt.

Slip the belt off the alternator pulley and THEN slowly release the tension on the idler pulley.
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  #13  
Old August 30th, 2011, 02:02 PM
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kyle scheppler
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oh i need a breaker bar thats what i need...and tightening the bolt is definitely not what I did so thx for that too I loosened it
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  #14  
Old August 30th, 2011, 02:03 PM
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Yup....not particularly intuitive if you've not worked on a serpentine belt system before.

pssttt...it's the same set up as my '94 Disco that's eaten toooo many alternators.


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  #15  
Old August 30th, 2011, 02:19 PM
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kyle scheppler
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ok ok i got it off...is putting it back on going to be tougher>?
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Old August 30th, 2011, 02:34 PM
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Nope. Just push down on the pulley again and slide the belt over the pulley in the alternator.
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  #17  
Old August 30th, 2011, 03:29 PM
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If yo uneed to swap the pulley make damn sure you get it tight enough on the new alternator or it will come loose, speaking from experience. If it does come loose you'll end up with an oversize bore inside the pulley and it will never be good again unless you can get it machined out and an accurately sized bushing inserted to fit over your now undersized alternator rotor shaft. It's got to be a near perfect fit, 0.003" of play is too much.
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  #18  
Old September 10th, 2011, 06:25 PM
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[QUOTE]=rijosho;297044] Are you going to replace your belt(s) at the same time? [QUOTE]

is that the best idea ? because im assuming the belt has only been replaced once and my truk has 86k miiles...

Ky

its only 60$ at store so why not but anything i shoudl also be aware of checking and chaging while im doing this?

Kyle


ps - sorry for beating a dead horse guys
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