Any more detailed steps to replacing alternator?
#1
Any more detailed steps to replacing alternator?
Last night, my 02 Mini Cooper (CVT) died on the way home, it started with the "Battery" light indicating a voltage/charging issue, but within a few miles I'd lost power steering, and had airbags, parking brakes, etc... going crazy.
So, get towed home, and check the voltage, the battery is drained. But, it's a 1 year old Interstate battery, so that shouldn't be the issue. Let's charge it anyway. After a couple hours @ 10Amps the battery has a 12V charge, let it finish off overnight with a 2A trickle charge.
In diagnosing the issue, I start the car, then disconnect the negative battery terminal while car is still running. The car stalls. Hmmm, I then use a voltmeter to measure the battery when car is off (12.5V) and when the car is on (12.4V). So this screams bad alternator to me.
In looking on NAM's boards I see that , chadtoolio in this post said.
But, if I follow the Bentley Mini Cooper Service Manual steps on "Alternator, removing and installing (Cooper)", I don't remove the bumper, but need a "special tool 11 8 390 to release drive belt tension" and a "lock pin (special tool 11 8 280) to lock drive belt tensioner" and have to do the following...
Also, has anyone used an OEM (non-Mini) alternator? The Mini part is $400, then OEM is $160.
Scott
So, get towed home, and check the voltage, the battery is drained. But, it's a 1 year old Interstate battery, so that shouldn't be the issue. Let's charge it anyway. After a couple hours @ 10Amps the battery has a 12V charge, let it finish off overnight with a 2A trickle charge.
In diagnosing the issue, I start the car, then disconnect the negative battery terminal while car is still running. The car stalls. Hmmm, I then use a voltmeter to measure the battery when car is off (12.5V) and when the car is on (12.4V). So this screams bad alternator to me.
In looking on NAM's boards I see that , chadtoolio in this post said.
Remove front bumper cover, bumper reinforcement with crush tubes, pull 4 clips out of RH Rad. core support to fender liner. Disconnect horn wire on RH side, pull Rad. core support out to gain access. Disconnect battery, Remove alt belt, 3 bolts for alternator, one plug in connector at alt. and 10mm nut for B positive wire on Alt.
- Disconnect Battery
- Remove fuel tank vent valve
- Remove Splash Shield
- Remove right front wheel
- Remove right front wheel housing liner
- Release tension using "special tools"
- Remove intake manifold
- Then disconect the alternator and remove
Also, has anyone used an OEM (non-Mini) alternator? The Mini part is $400, then OEM is $160.
Scott
#2
HAhh, theres more than one way to skin a cat....I never even read the repair instructions that were suggested by MINI. I have replaced a few alternators on them over the 6 years of working on them and have always done them my way. However, I just read them and it is exactly how the Bently suggests. I will say that doing it the way that I suggested is very easy and the instructions don't differ in between the "S" and non "S" models. Do which ever way works for you... FYI though, it only takes me about 15 minutes to remove the entire front bumper and every thing needed to get to the Alt.
Chad
Chad
#5
Well, after getting pricing from Brecht Mini for the 2002 R50 alternator ($525 after discount) and online from ToeOut Performance for $353, I called Brecht to get their repair estimate of $1,100 and called another place European Auto Center in Poway (closer to me) for their estimate of $650. I think I'm going to let EAC do it for $650. It would too many days to have ToeOut ship to me and then do it myself, and EAC is only $125 more than the Brecht parts only price. So... I'm solved for now...
Plus, with my CVT I'd need to do a few extra steps...
But since I have built a longer detailed steps for both options in case anyone else needed it, I'll post them here. ENJOY!
Here's the two options spelled out...
5. Disconnect CVT radiator & cap lines
7. Remove bolt mounting each tube to the MFE
8. pull Rad. core support out to gain access.
10. Remove alt belt
1. Replace radiator hose clamp
2. top off CVT fluid
3. top off & bleed cooling system
2. Disconnect battery
3. Remove fuel tank vent valve
5. Remove Right font wheel
6. Remove Right front wheel housing liner
7. Remove alt belt
1. replace intake manifold profile gaskets
2. torque manifold to cylinder head to 26 Nm
3. Coat fuel injector sealing o-rings with anti seize agent
4. torque fuel rail to intake manifold to 25 Nm
5. Replace sealing ring between throttle valve assembly and intake manifold
6. torque throttle valve assembly to intake manifold to 9 Nm
7. torque air filter housing to body 7-10 Nm
8. Replace air duct clamp
Plus, with my CVT I'd need to do a few extra steps...
But since I have built a longer detailed steps for both options in case anyone else needed it, I'll post them here. ENJOY!
Here's the two options spelled out...
Option #1 - Chadtoolio's method.
1. Remove front bumper cover 1. Raise vehicle & support
2. Remove splash shield under engine. 3 bolts, 2 screws
3. Remove screws holding bumper cover to Modular Front End (MFE)
4. Remove plastic rivets securing bumper to lower spoiler
5. Remove bolts securing bumper cover to position adjustment bracket
6. Detach bumper cover clips from bumper carrier
7. Disconnect fog lights, turn signals, & outside temperature sensor
8. Lift off bumper cover
2. Remove Front bumper carrier2. Remove splash shield under engine. 3 bolts, 2 screws
3. Remove screws holding bumper cover to Modular Front End (MFE)
4. Remove plastic rivets securing bumper to lower spoiler
5. Remove bolts securing bumper cover to position adjustment bracket
6. Detach bumper cover clips from bumper carrier
7. Disconnect fog lights, turn signals, & outside temperature sensor
8. Lift off bumper cover
1. Pull out electrical harness for outside temperature sensor
2. Remove fasteners securing front bumper carrier to front frame supports
3. Remove nuts from crush stand tubes
4. Lift out bumper carrier (watch for cables or hoses to be snagged)
3. pull 4 clips out of RH Rad. core support to fender liner.2. Remove fasteners securing front bumper carrier to front frame supports
3. Remove nuts from crush stand tubes
4. Lift out bumper carrier (watch for cables or hoses to be snagged)
1. Detach both front wheel housing liners from MFE
4. Disconnect horn wire on RH side,5. Disconnect CVT radiator & cap lines
1. Remove screw holding CVT radiator to radiator
2. slide left to disengage
3. disconnect & plug CVT radiator lines
6. Remove front crush tubes2. slide left to disengage
3. disconnect & plug CVT radiator lines
7. Remove bolt mounting each tube to the MFE
8. pull Rad. core support out to gain access.
1. Install two 100 mm (4 inch) m8 bolts to support the MFE
2. slide MFE forward
9. Disconnect battery 2. slide MFE forward
10. Remove alt belt
1. ???
11. Remove alternator 1. Remove 3 bolts for alternator, one plug in connector at alt. and 10mm nut for B positive wire on Alt.
When reinstalling, don't forget to do the following...1. Replace radiator hose clamp
2. top off CVT fluid
3. top off & bleed cooling system
Option #2 - Bentley Service Manual method.
1. Raise vehicle & support2. Disconnect battery
3. Remove fuel tank vent valve
1. disconnect vent hoses via quick fit connectors
2. straighten retaining tab
3. slide vent valve off bracket
4. remove electrical harness connector
4. Remove splash shield under engine 3 bolts, 2 screws2. straighten retaining tab
3. slide vent valve off bracket
4. remove electrical harness connector
5. Remove Right font wheel
6. Remove Right front wheel housing liner
7. Remove alt belt
1. Use special tool 11 8 390 to release drive belt tension
2. Use lock pin (special tool 11 8 280) to lock drive belt tensioner
3. lift off drive belt
8. Remove Intake Manifold2. Use lock pin (special tool 11 8 280) to lock drive belt tensioner
3. lift off drive belt
1. Remove air filter housing
6. Detach electrical harness connector from knock sensor
7. Disconnect top fuel vent line and unclip at fuel rail
8. Detach Fuel Rail from top of engine
11. Remove intake manifold mounting bolts in sequence working outside to inside
12. Unclip coolant line below manifold
13. lift manifold
9. Remove alternator 1. Detach air duct from air filter housing
2. detach wire harness
3. Remove air filter housing mounting screws
4. Detach crankcase breather hose
5. Lift air filter housing
2. remove throttle valve assembly2. detach wire harness
3. Remove air filter housing mounting screws
4. Detach crankcase breather hose
5. Lift air filter housing
1. Loosen & remove air duct clamp at throttle assembly
2. detach air duct
3. disconnect electric harness connector
4. detach fuel vent line
5. loosen & remove 4 throttle assembly mounting screws
6. lift off throttle assembly
3. Remove brake booster vacuum line2. detach air duct
3. disconnect electric harness connector
4. detach fuel vent line
5. loosen & remove 4 throttle assembly mounting screws
6. lift off throttle assembly
1. Press brake booster vacuum line locking ring downward to detach from manifold
2. remove hose from PCV valve
4. Remove fuel rail cover2. remove hose from PCV valve
1. Squeeze locking tabs to detach rear of cover
2. tilt and pull cover forward until plastic clips detach from fuel rail (careful, they break easily)
5. Detach electrical harness connector from intake air temp/MAP sensor2. tilt and pull cover forward until plastic clips detach from fuel rail (careful, they break easily)
6. Detach electrical harness connector from knock sensor
7. Disconnect top fuel vent line and unclip at fuel rail
8. Detach Fuel Rail from top of engine
1. disconnect fuel injector electrical harness connector
2. disconnect harness connector
3. remove cover from harness loom and swing harness out of way to left side of engine
4. working at fuel rail, unclip hoses and ducts. Cut wire tires as needed
5. disconnect vacuum line at base of fuel pressure regulator
6. remove 2 fuel rail mounting bolts
9. Remove fuel rail together with fuel injectors from intake manifold2. disconnect harness connector
3. remove cover from harness loom and swing harness out of way to left side of engine
4. working at fuel rail, unclip hoses and ducts. Cut wire tires as needed
5. disconnect vacuum line at base of fuel pressure regulator
6. remove 2 fuel rail mounting bolts
1. unclip fuel line from engine vibrations damper bracket
2. carefully fold hose to right & rear of engine. Protect fuel rail & injectors in a clean plastic bag
10. Remove oil dipstick2. carefully fold hose to right & rear of engine. Protect fuel rail & injectors in a clean plastic bag
11. Remove intake manifold mounting bolts in sequence working outside to inside
12. Unclip coolant line below manifold
13. lift manifold
1. Remove 3 bolts for alternator, one plug in connector at alt. and 10mm nut for B positive wire on Alt.
When reinstalling, don't forget to do the following...1. replace intake manifold profile gaskets
2. torque manifold to cylinder head to 26 Nm
3. Coat fuel injector sealing o-rings with anti seize agent
4. torque fuel rail to intake manifold to 25 Nm
5. Replace sealing ring between throttle valve assembly and intake manifold
6. torque throttle valve assembly to intake manifold to 9 Nm
7. torque air filter housing to body 7-10 Nm
8. Replace air duct clamp
#6
NICE POST, but this would be my complete method...Installation is reverse of removal, and don't forget to bleed the cooling system!
Option #1 - Chadtoolio's method.
1. Remove front bumper cover
1. Raise vehicle & support
2. Remove splash shield under engine. 3 bolts, 2 screws
3. Remove screws holding bumper cover to Modular Front End (MFE)
4. Remove upper bumper cover screws.
5. Remove bolts securing bumper cover to position adjustment bracket
6. Disconnect fog lights, turn signals, & outside temperature sensor
7. Lift off bumper cover
2. Remove Front bumper carrier
1. Pull out electrical harness for outside temperature sensor
2. Remove fasteners securing front bumper carrier to front frame supports
3. Remove 16mm bolts from crush stand tubes to subframe.
4. Remove (2) 10mm bolts from cruch tube to Radiator core support
5. Lift out bumper carrier w/crush tubes (watch for cables or hoses to be snagged)
3. pull 4 clips out of RH Rad. core support to fender liner.
1. Detach both front wheel housing liners from MFE
4. Disconnect horn wire on RH side.5. Detach upper radiator hose from elbow.
6. pull Rad. core support out to gain access.
1. Install two 100 mm (4 inch) m8 bolts to support the Rad Core support
2. slide Radiator core support forward
7. Disconnect battery 8. Remove alt belt, using 3/8ths ratchet in tensioner(you need the special tool if you have an "S"
1. ???
9. Remove alternator1. Remove 3 bolts for alternator, one plug in connector at alt. and 10mm nut for B positive wire on Alt.
Last edited by chadtoolio; 02-08-2008 at 01:35 PM.
#7
I bow before your greatness!
By the way, I just heard from EAC, that Brecht (the place they were getting the alternator from) doesn't have the right one for my car, even though their computer says it's the right part, it doesn't fit. So, they have to get the part from another place, and it'll be in on Tuesday.
C'est la vie, would have happened to me if I did it myself.
Scott
By the way, I just heard from EAC, that Brecht (the place they were getting the alternator from) doesn't have the right one for my car, even though their computer says it's the right part, it doesn't fit. So, they have to get the part from another place, and it'll be in on Tuesday.
C'est la vie, would have happened to me if I did it myself.
Scott
Trending Topics
#8
#11
Hate to drag up a thread that's 5 months old, but I have to say thanks for the write-up!
My girlfriend's '05 had the alternator go bad, and I was wondering how I'd go about doing this. I haven't actually replaced it yet (we're going to pick up the new alternator later today, when the money decides to go home to the bank...), but I've taken the car apart in anticipation. I didn't do everything exactly, but this still helped immensely!
My girlfriend's '05 had the alternator go bad, and I was wondering how I'd go about doing this. I haven't actually replaced it yet (we're going to pick up the new alternator later today, when the money decides to go home to the bank...), but I've taken the car apart in anticipation. I didn't do everything exactly, but this still helped immensely!
#13
#14
I have an 03 MCS that has just succumb to the alternator failure. I have already purchase a reman'd alternator from Alternator Pro for $270 fedex'd & no core charge. I will look into taking photos & using chadtoolio's method and posting up here at a later date.......all going well !!
#15
Yeah, I am a little skeptical, so I will see how it all pans out. I have kept the old one & may just have that rebuilt. Will keep all posted.
#16
Job Done
NICE POST, but this would be my complete method...Installation is reverse of removal, and don't forget to bleed the cooling system!
Option #1 - Chadtoolio's method.
1. Remove front bumper cover
1. Raise vehicle & support
2. Remove splash shield under engine. 3 bolts, 2 screws
3. Remove screws holding bumper cover to Modular Front End (MFE)
4. Remove upper bumper cover screws.
5. Remove bolts securing bumper cover to position adjustment bracket
6. Disconnect fog lights, turn signals, & outside temperature sensor
7. Lift off bumper cover
2. Remove Front bumper carrier
1. Pull out electrical harness for outside temperature sensor
2. Remove fasteners securing front bumper carrier to front frame supports
3. Remove 16mm bolts from crush stand tubes to subframe.
4. Remove (2) 10mm bolts from cruch tube to Radiator core support
5. Lift out bumper carrier w/crush tubes (watch for cables or hoses to be snagged)
3. pull 4 clips out of RH Rad. core support to fender liner.
1. Detach both front wheel housing liners from MFE
4. Disconnect horn wire on RH side.5. Detach upper radiator hose from elbow.
6. pull Rad. core support out to gain access.
1. Install two 100 mm (4 inch) m8 bolts to support the Rad Core support
2. slide Radiator core support forward
7. Disconnect battery 8. Remove alt belt, using 3/8ths ratchet in tensioner(you need the special tool if you have an "S"
1. ???
9. Remove alternator1. Remove 3 bolts for alternator, one plug in connector at alt. and 10mm nut for B positive wire on Alt.
Over all the job took about 2hrs, fairly straight forward. I have some photos along the way, I will edited them & put them in my gallery for anyone interested.
#17
This is a 2004 R50 with CVT Tranny...
I used the below method and it worked great for me. I did not touch the drivers side wheel liner though as others have suggested be removed. I could angle out the radiator enough to get a wrench on the alternator and replace it.
I didn't know what some of it meant but I figured it out. It's not insanely hard, just you gotta remember where all screws and bolts go and get the bumper in place BEFORE you start fully tightening down bolts because if you tighten them too early, other parts won't slide on correctly.
I took just 3 pics during the process of doing it.
Let me know if you have any questions. I'm in Atlanta, so locals could possibly ask me for help.
NICE POST, but this would be my complete method...Installation is reverse of removal, and don't forget to bleed the cooling system!
Option #1 - Chadtoolio's method.
1. Remove front bumper cover
5. Detach upper radiator hose from elbow.
6. pull Rad. core support out to gain access.
8. Remove alt belt, using 3/8ths ratchet in tensioner(you need the special tool if you have an "S"
I used the below method and it worked great for me. I did not touch the drivers side wheel liner though as others have suggested be removed. I could angle out the radiator enough to get a wrench on the alternator and replace it.
I didn't know what some of it meant but I figured it out. It's not insanely hard, just you gotta remember where all screws and bolts go and get the bumper in place BEFORE you start fully tightening down bolts because if you tighten them too early, other parts won't slide on correctly.
I took just 3 pics during the process of doing it.
Let me know if you have any questions. I'm in Atlanta, so locals could possibly ask me for help.
NICE POST, but this would be my complete method...Installation is reverse of removal, and don't forget to bleed the cooling system!
Option #1 - Chadtoolio's method.
1. Remove front bumper cover
1. Raise vehicle & support
2. Remove splash shield under engine. 3 bolts, 2 screws
3. Remove screws holding bumper cover to Modular Front End (MFE)
4. Remove upper bumper cover screws.
5. Remove bolts securing bumper cover to position adjustment bracket
6. Disconnect fog lights, turn signals, & outside temperature sensor
7. Lift off bumper cover
2. Remove Front bumper carrier1. Pull out electrical harness for outside temperature sensor
2. Remove fasteners securing front bumper carrier to front frame supports
3. Remove 16mm bolts from crush stand tubes to subframe.
4. Remove (2) 10mm bolts from cruch tube to Radiator core support
5. Lift out bumper carrier w/crush tubes (watch for cables or hoses to be snagged)
3. pull 4 clips out of RH Rad. core support to fender liner.1. Detach both front wheel housing liners from MFE
4. Disconnect horn wire on RH side.5. Detach upper radiator hose from elbow.
6. pull Rad. core support out to gain access.
1. Install two 100 mm (4 inch) m8 bolts to support the Rad Core support
2. slide Radiator core support forward
7. Disconnect battery 8. Remove alt belt, using 3/8ths ratchet in tensioner(you need the special tool if you have an "S"
1. ???
9. Remove alternator1. Remove 3 bolts for alternator, one plug in connector at alt. and 10mm nut for B positive wire on Alt.
Last edited by DavidBauder; 09-09-2011 at 07:11 AM.
#18
Thanks guys, this was a helpful thread! With a helper, we also used DavidBauder's method. The whole process took about 2 hours. It's actually easier than it looks, which is a testament to the mini MFE being a good design. One of the hardest parts was fishing for a marker light wire after it was all buttoned up ;D
#19
#20
#21
02 alternator out
Hey NAM folks,
My daughter's alternator decided to croak last night. Just beginning my research to add to Daddy's Mini Repair's skill set.....
I found this video on Youtube.
That is more or less what I thought when first looking at it this morning. Now going through this post, I am not super interested in removing the front of the vehicle. I found a reman locally for $204, and there is a shop that will do a rebuild for $95 in half a day.
Any opinions on the removal process outlined by this guy?
Thanks
Mike
Lead Technician - Daddy's Mini Repair Svc
My daughter's alternator decided to croak last night. Just beginning my research to add to Daddy's Mini Repair's skill set.....
I found this video on Youtube.
That is more or less what I thought when first looking at it this morning. Now going through this post, I am not super interested in removing the front of the vehicle. I found a reman locally for $204, and there is a shop that will do a rebuild for $95 in half a day.
Any opinions on the removal process outlined by this guy?
Thanks
Mike
Lead Technician - Daddy's Mini Repair Svc
#22
In response to my own question....
I have no idea how that guy in the youtube video was able to get to the bottom bolt on the alternator. I currently have the front end about 2/3 off. My hands, nor any of my tools were going to pull that off... This is not a simple job in my opinion, and I cannot imagine it being done in two hours unless we were dealing with a relatively new vehicle. As this one has 163k on it, it's going to take a bit.
More later.
I have no idea how that guy in the youtube video was able to get to the bottom bolt on the alternator. I currently have the front end about 2/3 off. My hands, nor any of my tools were going to pull that off... This is not a simple job in my opinion, and I cannot imagine it being done in two hours unless we were dealing with a relatively new vehicle. As this one has 163k on it, it's going to take a bit.
More later.
#23
Hey guys, new member here. I found you by doing a Google search for how to remove and replace my alternator. I came across the instructions below and steps 1+2 went very quickly and easily.
Now I'm stuck on step three (Pull 4 clips out of RH rad support) and I don't know what to do next.
Here is where I am stuck:
-I found (2) of the little plastic star clips attching my passenger side wheel well to the plastic around the radiator. Not 4.
- It says detach both front wheel housing liners from MFE? What is MFE and if I need to remove the liner from both wheel wells, wouldn't I have needed to remove the clips on both sides, not just the RH side?
- 6 says pinstall two 100mm m8 bolts to support rad core support? What bolts? I need to go buy some?? Where do I put them?
So confused.
1. Remove front bumper cover
5. Detach upper radiator hose from elbow.
6. pull Rad. core support out to gain access.
8. Remove alt belt, using 3/8ths ratchet in tensioner(you need the special tool if you have an "S"
9. Remove alternator
1. Remove 3 bolts for alternator, one plug in connector at alt. and 10mm nut for B positive wire on Alt.
Now I'm stuck on step three (Pull 4 clips out of RH rad support) and I don't know what to do next.
Here is where I am stuck:
-I found (2) of the little plastic star clips attching my passenger side wheel well to the plastic around the radiator. Not 4.
- It says detach both front wheel housing liners from MFE? What is MFE and if I need to remove the liner from both wheel wells, wouldn't I have needed to remove the clips on both sides, not just the RH side?
- 6 says pinstall two 100mm m8 bolts to support rad core support? What bolts? I need to go buy some?? Where do I put them?
So confused.
1. Remove front bumper cover
1. Raise vehicle & support
2. Remove splash shield under engine. 3 bolts, 2 screws
3. Remove screws holding bumper cover to Modular Front End (MFE)
4. Remove upper bumper cover screws.
5. Remove bolts securing bumper cover to position adjustment bracket
6. Disconnect fog lights, turn signals, & outside temperature sensor
7. Lift off bumper cover
2. Remove Front bumper carrier1. Pull out electrical harness for outside temperature sensor
2. Remove fasteners securing front bumper carrier to front frame supports
3. Remove 16mm bolts from crush stand tubes to subframe.
4. Remove (2) 10mm bolts from cruch tube to Radiator core support
5. Lift out bumper carrier w/crush tubes (watch for cables or hoses to be snagged)
3. pull 4 clips out of RH Rad. core support to fender liner.1. Detach both front wheel housing liners from MFE
4. Disconnect horn wire on RH side.5. Detach upper radiator hose from elbow.
6. pull Rad. core support out to gain access.
1. Install two 100 mm (4 inch) m8 bolts to support the Rad Core support
2. slide Radiator core support forward
7. Disconnect battery 8. Remove alt belt, using 3/8ths ratchet in tensioner(you need the special tool if you have an "S"
9. Remove alternator
1. Remove 3 bolts for alternator, one plug in connector at alt. and 10mm nut for B positive wire on Alt.
#24
MFE = Modular Front End
You can do some searching on this forum to get a better idea of how the MFE or Modular Front End works, think of it like a barn gate that you can take off the hinges. Your radiator is in the center of the gate. Once it's removed or swung open, the engine and inner chassis is more accessible.
#25
More than 1 way to skin a cat... I seem to recall many folks would jack the car up, remove the tire, wheel well liner, and shields, then disconnect the CV joint....then swap the alternator.
You might want too look at one of the guide to "service mode"...
A girls guide to service mode was the title too one.....was pretty good.
You might want too look at one of the guide to "service mode"...
A girls guide to service mode was the title too one.....was pretty good.