I've seen guides (incl. this forum) how to replace alternator for D3, which seems fairly simple. But same procedure doesn't seem to be applicable for SDV6. On the top of the engine there are much more pipes on the way and also the fan cowling seems to be fixed, with only narrow rim being removable and it doesn't seem give enough clearance to do the job.
How should it be done for the SDV6? From the bottom? Any guides available? I don't have a lift, is it doable without?
28th Mar 2019 3:40 pm
Member Since: 11 May 2008
look for workshop manual on here
if you wont find it ping me your email i will share my drive with you to get it
28th Mar 2019 3:43 pm
Member Since: 26 Mar 2013
Found the D4 workshop manual, thanks for the tip. Manual was for TDV6 but steps seemed to apply also to SDV6.
Overall it seems much more involved than on D3. Coolant needs to be drained, number of pipes, hoses and boxes removed (fan included ofc), working from both below and above. Has anyone done this yet?
I read somewhere that the wiring has more slack if it is disconnected from starter first. Any other tips?
28th Mar 2019 6:34 pm
Member Since: 11 May 2008
I'm doing this now on my D4 and it's quite tedious task. There is so little space and lousy access. Anyhow I've now progressed up to the point where I'm trying to disconnect the last electrical connector from the back of the alternator. The problem is that despite all my efforts the connector won't come off.
I assume there is a clip I'm supposed to press and then pull it off? I've tried till my fingers are numb and bloody but it just stays stuck. Access is so limited and there is hardly no slack on the wire, so you cannot see what you are doing and you can just barely squeeze your hands in there and try to work with your fingertips. Any hints how to get it off?
Checked some images and this connector seems to have just one wire in D4 instead of three as in D3 images. I assume that is expected?
I finally got it! Holy s*** what kind of task this is for D4 compared to D3. My arms have bruises up to shoulders after doing this. Hint for someone who wants to do this: reserve a lots of time and patience.
And btw. the single wire setup seems to be the case with D4.
30th Apr 2019 1:39 pm
Member Since: 22 Feb 2014
Top tips from me for this job is.....
1, remove the small plastic panel from the front of the wheel arch and work mostly from there, you will still have to remove the fan etc to get the belt off from the top and to remove the alternator but I find it much easier.
2, remove the power cable from the starter and then small bracket from the power cable, with that out the way removed the bolts and move the alternator forward from the wheel arch, then working from the top take the power cable and the control wire off.
3, have tiny but very strong fingers that mover in any direction
Pete.IID, webasto software and workshop facility's available.
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