1999 S80-T6 Removing Alternator

SimLyons · Post by **SimLyons** » 04 Oct 2013, 12:21

I have read a couple write-ups that were fairl good. What I need to know before digging into the replacement is: Is it best to get the car up on ramps/stands and do most of the work from underneath? Will I have to go from above and below? The car is a little high on the ramps and access from above isn't so easy.

Any tips would be greatly appreciated!

Post by **jimmy57** » 04 Oct 2013, 12:32

If you have any notion of doing crankcase vent system service then pull intake and then alternator is about as much trouble as changing the oil.
IT is a top out repair, not from the bottom.

SimLyons · Post by **SimLyons** » 04 Oct 2013, 13:50

Thanks, Jimmy! The car is on a transporter and will be here soon. I just want to be ready. It's running on battery power right now so the first thing must be a new alternator. I plan to drive it a week or so and then do lots of stuff...timing belt, water pump, trans. flush/new filter, cooling system flush, etc. Have almost everything here so I can go at it. I just want to drive it eoungh to be sure there aren't any more issues right now.

SimLyons · Post by **SimLyons** » 05 Oct 2013, 14:55

Stuck. The intake manifold bolt under #4 is a PITA. Have it 'almost" all the way out and the manifold should come out. The dipstick tube is still attached (can't get a wrench on it...anyone know what size the bolt is for the dipstick tube?).

It seems hung on that lower bolt. I noticed a Bosch control unit on the underneath of the manifold. Is that holding me back from lifting? Any ideas?

(I began to pull the PS pump but think that might be a bad way to go....or is it?)

Sim

SimLyons · Post by **SimLyons** » 05 Oct 2013, 16:14

Update: Got the bolt out. Got the dipstick tube off/out. Manifold is somwhat free. Being held underneath by a clamped hose. Just between ports 1 & 2. I think MOST other hindrances are gone but I can't be certain. Feels like a big bungee holding the whole thing on/down. I have about 3" of play. Still can't access alternator.

Will try to loosen the serpantine belt. Maybe go for the PS pump.

Help??!! Sim

SimLyons · Post by **SimLyons** » 05 Oct 2013, 16:49

Update 2: Used my light and mirror. Seems there's a VERY large hose (3" or so?) connected to the bottom of the manifold. I see no way to get access other than from the bottom. Or...pull radiator, etc.

I'll jack it up and get stands under it.

Where is the tensioner? Hard to see. I got a T55 (saw in a forum write up it is needed) and can't see the fem. for it.

SimLyons · Post by **SimLyons** » 05 Oct 2013, 23:11

I guess the few (but proud) S80 T6 members are out for this Saturday night. I'm plain stuck! I have the car up on stands, belly pans off. Can't seem to access any better here. I pulled R-F wheel and small liner to get access to belt but not much help with that, either.

IF, BIF IF!! I can get to the tensioner I can maybe get the PS pump off and then get the alternator off and replaced. I can't seem to find the tensioner...and what I need to release tension. (Done it many times on 850s).I see a likely candidate below ALT. and in towards block with about a 15 mm front to grab on to. Is that it?

THANKS!!!

Post by **jimmy57** » 06 Oct 2013, 07:26

I pulled the manifold on a 99 T6 yesterday to do crankcase vent service.
I removed the plastic turbo inlet and outlet ducts, then the intercooler to ETM hose (be careful with the air temp and boost pressure sensor connectors when un plugging those) after undoing the blow off valve hoses, I remove fuel rail with injectors and uncoupled that fuel hose, I removed or loosened intake bolts, and then unscrewed the hollow bolt for crankcase breather. I was then able to totally remove intake leaving alternator exposed. I use a 14mm or 15mm offset boxed end wrench (whichever size fits the belt roller center bolt on tensioner) and used that to swing the tensioner to release the belt.

SimLyons · Post by **SimLyons** » 06 Oct 2013, 07:32

Hi Jimmy!
How did you disconnect the hoses below (bottom side) of manifold. I can't see the clamps or feel them to get them off.

Post by **jimmy57** » 06 Oct 2013, 08:16

The hose to throttle has a clamp with 7 mm hex.
The crankcase nipple with a vac hose and two smaller hot water hoses is held to manifold with a 17mm head hollow bolt. I don't undo the hoses from the heated nipple fitting.