97 Volvo 960 Alternator replacement

steelerfanatic · Post by **steelerfanatic** » 22 Jan 2013, 14:29

Hi guys,
I am having a bit of trouble with my mother in laws 97 960. I am trying to remove the alternator so I can replace it but I am not having any luck. I removed the three bolts that hold it on as well as the electrical connections and it wont even budge. What makes it worse is that I have called everywhere and no one sells a haynes or chilton manuel for the 960.

Any help would be greatly appreciated.

Thanks,
Jason

Post by **precopster** » 22 Jan 2013, 14:39

It's a lot more than 3 bolts. Keep taking bolts off until you feel it loosen. Photos of the process will help re-assembly. It's essentially the same setup as an 850.

steelerfanatic · Post by **steelerfanatic** » 22 Jan 2013, 14:47

Thanks for the help. I don't see any more bolts? Hopefully someone will have a mounting diagram or something since there doesn't seem to be a manual for this thing.

steelerfanatic · Post by **steelerfanatic** » 22 Jan 2013, 14:55

Found this so I am going to get back at it shortly.

http://volvospeed.com/vs_forum/index.ph ... placement/

Post by **precopster** » 22 Jan 2013, 19:59

Read the whole thread and you'll see that he went about it the long way. I'll have a look at Vadis and see if I can pull the procedure off it.

Post by **precopster** » 23 Jan 2013, 14:10

The procedure doesn"t seem to be there on Vadis or Vida. ( engine pulls are)

I took one off an 850 (same setup) and I recall that the rear trangular bracket is just the beginning.....

Bagger · Post by **Bagger** » 27 Jan 2013, 07:46

Did you get the alternator out and in? If not, I just went through the process with two 98 S90's and I can help you.

lindy8_man · Post by **lindy8_man** » 27 Jan 2013, 21:05

The chilton manual is for all 1990 - 98 coupes/sedans/wagons it's number is 72302. Generally a good resource. However, the isntructions for pulling the altenator are very terse. It says "keep track of their location, and their lengths since they are different lengths. .. Remove the mounting bolts from the bracket... After bolts are removed, lift the bracket and place the alternator on top of the engine... proceed as one would expect... Except the last step is to unfasten the alternator mounting bolts...

So it sounds like you pull the alternator with the bracket, then take the alternator off the bracket...

lindy8_man · Post by **lindy8_man** » 27 Jan 2013, 21:19

OK, so I studied the pic for removal for a little while. Now I think I understand. The backet is one big piece that has the tensioner, the idler, and powersteering pump. The alternator may or may not be attached to the "bracket". That information seems unclear. because it says "place the alternator on the engine". Yet the pics show the alternator still in it's place...

jaxomlong · Post by **jaxomlong** » 04 Aug 2013, 12:44

I did this a couple of weeks ago. (160,000 miles and pulled original alternator. Volvo just may not plan on pulling short of overhaul.) All of the preceding posts have bits of it, so read them.

The power steering pump, alternator, serpentine belt tensioner and idler pulley are all mounted to the two brackets. Once you have disconnected the hoses from the pump and the electrical the assembly is held on by two bolts, and friction.

The upper bolt head is accessible right under the tensioner mount. I think you can see it with the serpentine belt out of the way. It goes through the lower, back lugs on the power steering pump.

The other is the lowest, farthest back mount bolt for the alternator. It goes into a square nut welded to the big, front bracket. That nut is kinda under the idler pulley, if you want to feel it. You might want to pull the idler pulley, but you don't need to. I got at it with a 1/4" 10mm deep socket and a breaker bar. I have big arms, but it is doable with the power steering pump hoses out of the way.

After that the only thing holding it is friction. I had the brackets off (which included the pump, tensioner and idler) and I had to use a three foot pry bar on the alternator to get it off it's lug on the block. You probably want to loosen stuff up. Putting the puzzle back together did take a while. It would have been easier to . . . ?

Also have a Ford Excursion.