Just finished getting the alternator out of my Super Exceed and thought I would post what I learned...
1. Small hands and thin arms really help; this baby is really tucked away and accessing the bolts are a pain.
2. Rather than disconnect all the hoses going to the oil pump; I opted to remove it from the back of the alternator. There are three bolts that hold it on (and two shorter bolts that hold the pump together; leave those two alone!). You will need to remove the big hose that returns to the oil pan as later it will get in the way when removing the alternator. Also, when trying to move the pump out of the way so that I could get the alternator out, I was thinking it may have been easier if I had also removed the braided hose that goes up to the oil filter.
3. Nut and bolt holding the alternator in are 12mm.
4. Really hard to get at the top bolt that holds the belt tension arm to the block.
5. Adjusting the belt tension is going to be a real pain; I have a 1/4 drive ratchet and a shallow 12mm socket that barely fit up there.
6. The nut holding the output wire is 10mm. Unfortunately mine was seized on and when I would turn it the mounting bolt would turn with it. Tried anti-seize oil but it did not help. I was able to rig up a strong wire to hold the wire lug from rotating which kept the bolt from rotating enough to brake the nut free. This saved the day!!
Removal steps (wish I would have had this list to start):
1a. Disconnect negative terminal on battery.
1b. Remove skid pan.
2. Clean up grim.
3. Disconnect wires.
4. Remove big hose going to oil pan (a small amount of oil while drip out of the pump).
5. Remove braided hose going to oil filter from pump (I did not do this and oil from the filter may drain out this hose).
6. Remove three bolts (8mm) holding pump to alternator (leave pump in place for now).
7. Remove upper bolt (12mm) that attaches tension adjustment arm to frame (Good Luck!). I used a ratchet and a 2 inch extension which allowed the ratchet to clear the pulleys and I was able to move the ratchet up in the area where the fan is. There is a radiator hose that really is in the way for getting the socket on the bolt.
8. Remove the nut (12mm) on the lower pivot bolt; push bolt out.
9. Slide oil pump of the back of the alternator and tuck it up out of the way (easier said than done).
10. Wiggle alternator off the pivot and position it so that you access the tension adjustment bolt.
11. Remove the tension adjustment bolt that holds on the arm so that it is easier to get the alternator out.
12. Move alternator into various positions until you figure out how to get it out.
Hope this helps. Can't wait to put the rebuilt alternator in
(NOT!).
Alternate Removal steps (from my Third R & R
6/9/2012)
1. Disconnect negative terminal on battery.
2. Remove fan shroud.
3. Remove fan (4x 10mm bolts)
4. Remove upper bolt (12mm) that attaches tension adjustment arm to engine. (I used a ratchet and a 2 inch extension which allowed the ratchet to clear the pulleys and I was able to move the ratchet up in the area where the fan is.)
5. Remove the bolt (12mm) that attaches the tension adjustment to the alternator. The tension adjustment arm will now be free. (Note: remove this bolt is a bit of a pain as there is a radiator hose that really is in the way for getting the socket on the bolt.)
6. Remove skid pan.
7. Disconnect wires from alternator.
8. Remove big hose going to oil pan (a small amount of oil while drip out of the pump).
9. Remove braided hose going to oil filter from pump (a fair amount of oil will drip from the hose but it will eventually stop).
10. Remove three bolts (8mm) holding oil pump to alternator; slide oil pump of the back of the alternator and tuck it up out of the way (oil will come from between the pump and alternator).
11. Remove the nut (12mm) on the lower pivot bolt; push bolt out.
12. Wiggle alternator off the pivot and you should be able to guide it out quite easily.