Need help with 986 Alternator Removal

[TimR]

Can anyone help me with detailed instructions on removeing the alternator in a 986?

I have the rear access panel off, and the two bolts attaching the alternator removed, but I can not remove the alternator. I can barely move the alternator at all. There must be another step I am missing. It looks like I need to rotate the alternator such that the lugs where the bolts attached clear the lugs the bolts go through, but I can not rotate the alternator enough to clear the lugs. I'm about ready to put it back together and pay the price to have the dealer fix it, but I sure would like to get this done myself.

[Tool Pants]

I have never done it. Someone answered your question in the 996 section. Here is some more info but little detail in the 986 section.

http://www.renntech.org/forums/index.php?s...p;hl=alternator

If you figure out the trick then you might want to add your comments in the link.

[Rodger]

Do you have a service manual?

I'm looking at my copy. Did you remove the deflection roller in front of the alternator? It sounds like you need to loosen the roller's center bolt three turns, tap it lightly with a hammer to unseat it, then you should be able to lift the alternator out of its bracket. Once it's lifted up, you should have access to another bolt, then the whole thing comes out with the deflection roller.

"The generator must be turned clockwise so the swivel arm is near the crankcase and the holding arm projects beyond the fastening eye."

Don't forge the connections at the back. Slide the alternator forward a bit and undo them.

Sorry I can't be more helpful......if mine ever craps out I'll be sure to post a DIY!

[TimR]

Can anyone help me with detailed instructions on removeing the alternator in a 986?

I have the rear access panel off, and the two bolts attaching the alternator removed, but I can not remove the alternator. I can barely move the alternator at all. There must be another step I am missing. It looks like I need to rotate the alternator such that the lugs where the bolts attached clear the lugs the bolts go through, but I can not rotate the alternator enough to clear the lugs. I'm about ready to put it back together and pay the price to have the dealer fix it, but I sure would like to get this done myself.

Rodger and Toolspants, thanks for the replies. I successfully removed the alternator with a simple little hint from Butch199. There is a bushing on the rear-right side of the alternator lug that needs to be tapped back a couple mm. I assume when the bolt is tightened, it draws it forward just enough that the alternator will not rotate clockwise which needs to be done to remove.

Now that the alternator is out, I replaced the air cut-off valve (993-113-245-01) which was bad and the electric change-over valve (not sure it was bad, but for $28 I will replace anyway). Should be able to get it back together tonight, and hopefully, the CEL will be cleared for good.

ps. not an easy job. Sounds simple on paper, but I have the torn-up knuckles and fingers to prove otherwise.