General How to replace 2005 Panda alternator?

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General How to replace 2005 Panda alternator?

Timpanda7

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After 5 weeks of thinking I had an earth or starter motor problem it turned out to be a stuck alternator.


It was a good journey as I learnt things about my car I did not know.


Can someone explain how a diy guy can remove a 2005 Panda alternator as access to the top bolt under the air-conditioner unit and other access makes it look like an auto shop issue to remove...


Thank you in advance for this knowledge.


Timpanda
 
I have done this job. Access to the alternator mounts really is horrendous. I suspect Fiat would say that you'll need to remove the air conditioning pump.

Jack up the car and remover driver's side front wheel support on stands. Later, you will need to get underneath but don't lift the car just yet. You need to reach behind the engine.

Use a pair of ring/open spanners to lift the belt tensioner. This gives enough leverage. Remove the flat drive belt. Access is from under wheel arch. Wheel arch liner and inner wing access cover have to come off. I find a Pozi screwdriver works best on the screws. But use what fits snugly as the self tapper screws are often rusty. Clean the slots with a small scraper otherwise the screw top gets chewed.

The alternator has three bolts. Two at front one at back. The front two bolts have ok access, but the threads are open at the back end so expect them to be hard to loosen. A soak of penetrating oil at the open end might help. On mine, it made no difference but try anyway. The bolt at the back is beneath the aircon pump. You cannot see it directly so will be working with mirror and torch.

You need a mirror on a stick, small torch, 1/4" or 3/8" ratchet, 13mm socket and extension bars. The 3/8 will loosen the bolt, but the 1/4 is needed to wind it out. I had to use a lever against the 3/8 handle to move it. This was not using excessive force just the only safe way with such poor access.

When you have the alternator loose, it cannot be taken up an out. The only way is down.

Now, jack the car up enough to get underneath support on axle stands.

The alternator is heavy so be careful not to trap a finger if it drops unexpectedly. I also had to disconnect the exhaust from the catalyst outlet but you might get lucky.

Replacement alternator goes in the same way. Mine was used, so came with a drive pulley. If you get a new alternator, you might need to ask a tyre fitter or mechanic with power hammer wrench to loosen the centre nut so you can remove the drive pulley..

Run the bolts into the holes with a good quality anti seize paste. You might be the poor sap doing the job next time.

Get the new alternator in from under the car. Fit the easy access bolts first but do not do up tight. They will hold it while you fit the horrible top bolt.

Put everything back and it's job done. It's not fun but needs (almost) no fancy tools.
 
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