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I couldn't find any guides for a 1.6 HDI alternator so I wrote my own. There are plenty of videos on doing the AUX belt but nothing further.
Took me about an hour to complete and can be done on the floor with just a jack.
Tools you need:
- Clip Pry tool
- Large flat screwdriver or ply bar
- 15mm, 16mm spanners
- 3/8 Ratchet
- Short, Mid and long extensions
- 10mm, 16mm sockets
- 7m allen key or allen socket
- Jack and axle stand
- 17mm socket and bar to remove wheel bolts
- Square piece of thick cardboard
1. First step is to park on level hard ground. Hand brake on.
2. Pull the bonnet release and lift bonnet. Under a flap passenger footwell.
3. Disconnect the positive battery terminal and use the cardboard the to put between the terminal and connector.
4. Jack up the drivers front wheel, Under the subframe is a good spot. Place axle stand under the seal.... Safety first!!
5. Remove the front wheel (17mm Bolts) and put aside.
6. Remove the wheel arch lining to expose the engine pullys.
7. Take a photo on your phone of the belt routing. Will be helpful later when putting the belt back on.
8. Laying on your back use the 15mm ring spanner on the belt tensioner. Turn clockwise to loosen the belt and remove the belt.
https://www.youtube.com/watch?v=SfTR_-i3arY - Haynes Guide takes you this far.
9. Undo the 7 Allen key bolt going through the bottom pully/belt guide.
10. Undo the top 16mm bolt on the alternator.
11. Go the under the bonnet. Undo the 2 T30 Torx screws holding the control module and move it aside.
12. Undo the 2 7mm hose clamp on the right turbo expansion hose. Gives you much more room.
13. Unplug the alternator sensor connector and the 13mm nut holding the mains strap.
14. Undo as many 10mm bolts holding the heat shield one as possible. To undo the rest lay on the floor and look up under the car. Also while down there unplug the big yellow connector for AC pump.
15. Once the front of the heat shield is off theres a 10mm bolt behind the back part of the heat shield holding the dip stick on. its not necessary to remove the dipstick but I did for much better access to the right lower alternator bolt.
16. Undo the upper right alternator bolt and loosen the bottom right one. Just a few turns to release the tension collar.
17. Use a pry bar or big flat screwdriver to pull the top of the alternator away from the mount.
18. Slide the alternator to the left (pullyside) and up at an angle to slide the bottom right bolt/tension collar out.
19. Install the bottom right alternator bolt and tensioner collar on the new alternator and reverse the process.
Its pretty straight forward. The stereo clock will need resetting. Let me know if you have any questions.
Jason,
New member
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