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Unread 01-20-2011, 11:28 PM   #1
Drewd
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CRD Alternator; cheap rebuild units and instructions

Phew, local stealership wanted $800 dollars to replace my failed alternator on my 07 CRD. I suspect it was from oil leaking (no splash guard in TSB).

I replaced it myself with an alternator from http://www.maniacelectricmotors.com/alfor20jegrc.html

It was about $200 bucks with a core charge.

I was VERY pleased with their service and am 100% happy with the new alternator.

If anyone needs help or tips on replacing the alterntor, just holler. It was a PITA but well worth saving almost $600.00. I also replaced the alternator belt with a nice USA made Gates belt and did a resononator internal baffle delete when I was under the car.

The alternator splash guard was only 8 bucks from the dealership and hopefully will prevent any future issues.

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Unread 02-12-2011, 10:41 AM   #2
crd_rubicon
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Thanks so much, Drewd, for the link. My alternator is giving up the ghost as we speak. Dealership wanted $400 here + about $100 labor. I'll be hittin ya up for details on the install when the new alternator arrives. Thanks again.
Jeff
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Unread 02-12-2011, 11:25 AM   #3
SmallsWk
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How many miles do you guys have before your Alternator Issues?
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Unread 02-12-2011, 04:23 PM   #4
crd_rubicon
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I'm close to 50,000 now.
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Unread 03-17-2011, 09:23 AM   #5
crd_rubicon
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Hey Drewd, I'm finally getting around to changing out my alternator. I'm hoping you can give me some tips/advice on removal of the old one. I do appreciate any help you can give.
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3.0 CRD, 2" OME HD, 265/70 17" Destination A/T, Black Rock wheels, Elephant Hose Mod, Gutted turbo resonator
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Unread 03-19-2011, 07:22 AM   #6
Drewd
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I probably removed more stuff than necessary but i wanted as much free room to work in to get the alternator out. sorry,but may be in correct order

disonnected battery

removed entire airfitler assembly

removed and moved the entire coolant overflow reservoir assembly

removed a coolant line to the radiator

removed egr throttle valve and brought it up to the front of the engine, involved also removing intake air 'hose' to the egr throttle valve

removed connectors and electrical to alternator

removed alternator bolts

i had trouble with clearance getting alternator out. i ended up bending the airconditioning lines out of the way to get the necessary clearance. if you don't want to do this you can remove an engine mount and jack engine up to get clearance between engine and body frame to pull alternator out.

if replacing serpentine belt
remove turbo muffler and all assocated lines
i think i removed another coolant line

its not a hard job, just a little time consuming. i wasted too much time figuring out how to get clearance for the alternator. once i bent/moved the a/c lines, i was able to pull the alternator out without any problems.

good luck
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Unread 03-19-2011, 07:33 AM   #7
Drewd
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  1. Disconnect negative battery cable at battery.
  2. Remove plastic dress-up cover at top of engine.
  3. Remove coolant reservoir tank mounting bolt and position tank toward rear of engine compartment.
  4. Remove air filter cover and air filter element.
  5. Remove air filter housing (one bolt).
  6. Remove generator drive belt. Refer to Cooling System for procedure.
  7. Remove two generator upper mounting bolts (1).
  8. Raise vehicle.
  9. If equipped, remove skid plate below generator
  10. Disconnect field wire connector (5) at rear of generator (4) by pushing on connector tab
  11. Remove two generator lower mounting bolts (2).Lower vehicle.
  12. Remove throttle body-to-cylinder head support bracket (four bolts).
  13. Remove throttle body (four bolts). Refer to Throttle Body Removal in Fuel System.
  14. Unsnap plastic insulator cap from B+ output terminal.
  15. Remove B+ terminal mounting nut (2) at top/rear of generator and remove cable eye (1) from mounting stud (3).
  16. Remove generator from vehicle.
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Unread 03-19-2011, 07:50 AM   #8
Drewd
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here are some pics
gc-crd-alternator-1.jpg   gc-crd-alternator-2.jpg   gc-crd-alternator-3.jpg   gc-crd-alternator-4.jpg  
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Unread 03-19-2011, 07:53 AM   #9
Drewd
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don't forget to order the splash guard.
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Unread 03-19-2011, 08:46 AM   #10
sal-XK
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Nice wright up bro that will help a lot of dudes out.
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Unread 03-19-2011, 06:04 PM   #11
crd_rubicon
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Great info, Drewd. Helped me out alot. It was, as you said, a pain in the arse, but worth the $$ saved. Once the airbox was out of the way, the escape route for the alternator was pretty obvious. it was just a matter of getting enough of the other stuff out of the way. Thanks again.
Oh, and I did get the splash guard, but as my buddy was tryin to snap it on the tab broke off - doh!! Off to the dealership to order another. At least it's only $5.
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Unread 03-19-2011, 07:13 PM   #12
Drewd
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crd rubicon,
i drilled a couple of holes and zip tied the splash guard on one side to oen of the a/c coolant lines so it would not go anyway. i didn't like how it snapped on and easily popped off.

drewd

sorry, but keyboard is broke no caps and no question marks either.


also, did you have to bend or move any a/c lines to get the alternator out/
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Unread 03-19-2011, 08:42 PM   #13
crd_rubicon
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Thanks for the advice on the splash guard. I'll give that a try. I thought it fit kinda loose too. I think that's why it broke. We were tryin to get it to fit tighter. To get the alternator out, we unclipped the a/c line that ran to the firewall and took the bracket off the canister up front. That gave the line just enough wiggle to let the alternator slip by. It was tight though.
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Unread 03-20-2011, 09:28 AM   #14
Drewd
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you were smarter than me. i just bent the lines and made permament space. did you buy your alternator from maniac too? i was very impressed by their customer service. they misjudged their ship times and my shipment was one day late which caused me a lot of grief becuase i only had one day off that week and was working the weekend. they wanted to know what they could do to make me happy and i just asked them to double their warranty which they gladly did for the inconvenience.
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Unread 03-20-2011, 11:51 AM   #15
scootr29
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So what kind of things pointed toward the alternator going bad...no charge. I am going on 3 years and everything is going ok for me.
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