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<TITLE>altbushregreplace</TITLE><BODY TEXT=White BGCOLOR=Blue LINK= ALINK= VLINK=Yellow><P><FONT SIZE="+2" FACE=Charcoal COLOR=><B><I>ALTERNATOR,
VOLTAGE REGULATOR, ALT BUSHING REPLACEMENT 81-93 900, 94
Convertible</I></B></FONT><FONT SIZE="+3" FACE=Charcoal COLOR=Red><B>
<HR>
</B></FONT><FONT FACE=Charcoal>You can get the alternator off with
the following 'tricks'</FONT><P><FONT FACE=Charcoal>Disconnect the battery negative cable and
the wiring to the alternator. Remove the alt. belts(you don't have to
take all the belts off, just remove the alt adjusting bolt and pull
the alternator closer to the engine and slip the belts off it, leave
the belts on the car). Now let the alternator fall back away from the
engine as far as it will. Removing the a/c belt and loosening the two
6 mm Allen's holding the top of the a/c compressor bracket to the
head now will ease later stages.</FONT><P><FONT FACE=Charcoal>Remove the nut from the bottom bolt holding
the alternator to its lower bracket. Do this by getting a wrench on
the nut to hold it and turn the 17 mm bolt from the front. The bolt
is too long to come out of the bracket as it will hit the firewall,
but pull it out until it just misses the firewall, you use it for a
lever in a sec. Now remove the 6 mm Allen at the rear of the alt
lower bracket, holding it to the block, a long extension, a swivel
and a 6 mm Allen socket make this easy, but you can do it with a
regular Allen wrench. This bolt would have been blocked by the oil
filter. Now remove the 12 mm bolt holding the bottom of the a/c
compressor bracket. It is long and you can just get it past the
alternator with the long 17 mm (lever) bolt pulled back. A long
extension and a swivel 12 mm socket make this easy, but you can do it
with a wrench. </FONT><P><FONT FACE=Charcoal>Now use the long 17 mm bolt in the bottom of
the alt to turn the bracket up, swiveling it on the remaining
'hidden' 6 mm Allen in its lower point, until the bracket turns
enough to allow you to remove the 17 mm bolt past the firewall and
out of the alt and bracket. The alternator will now come out, though
you will have to maneuver it past the heater hoses and wiring and
brake master cylinder.</FONT><P><FONT SIZE="+1" FACE=Charcoal COLOR=><B>ALTERNATOR
BUSHINGS</B></FONT><P><FONT FACE=Charcoal>Once it is out, now is the time to change
the rubber bushings in the bracket for the alternator as well as the
bushings in the upper adjusting arm for the alt where it meets the
block/timing cover. These wear and get hard and allow excessive
vibration and cocking of the alternator, increasing wear on the belts
and water pump. They push in and out. A little shot of WD-40 will aid
in the installation of the new bushings. If you have access to a
bench grinder, removing the inner metal part of the new bushings
until they are flush with the rubber or a little below will tighten
up the mount.</FONT><P><FONT SIZE="+1" FACE=Charcoal COLOR=><B>VOLTAGE
REGULATOR/BRUSHES</B></FONT><P><FONT FACE=Charcoal>Before you go through this though, check the
brushes on the voltage regulator. You can remove them from the
alternator with it still on the car by the means of two screws
holding the regulator to the alt. If they are less than 8-10 mm long,
they are probably the reason the alternator quit working. You can
also buy just the voltage regulator that comes with new brushes
already installed.</FONT><P> </P>
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