NOTE: This article does not apply if you have a stock alternator with the rear bracket installed.

Alternator Replacement

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.

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






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






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






The air horn is now free. 







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







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

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. 

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.








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

There is a gasket here too! Surprisingly, mine stayed intact! . 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. 



















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

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. 




Source: Geof180
Other Links:
Gerry's Gaskets
Corvette Central
Posted in: Electrical
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