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Grand Vitara: lower bolt on the alternator assembly.From feeling…

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Hi: We're dealing with a...
Hi: We're dealing with a 2001, Suzuki, Grand Vitara. In attempting to change out the alternator we are running into problems with the lower bolt on the alternator assembly.

From feeling around it feels like a "carriage bolt" with a "female" hex head top.
Question: What size is the hex head? Also. It almost appears frozen ie, when we released the upper assembly bolt, the alternator did NOT move.
Submitted: 8 years ago.Category: Car
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Answered in 2 hours by:
6/24/2010
Auto Mechanic: danny, Mechanic replied 8 years ago
danny
danny, Mechanic
Category: Car
Satisfied Customers: 5,064
Experience: Mechanic at school corp bus garage! Experience in fleet diesel and regular automotive.
Verified

I am wondering if it has been replaced before and someone used a different bolt. get some gum or silly pudding something to make an impression. that way you will have the size. here is the simple replacement procedures and it has a description of bolts and they are not hex. it could be a torque.

 

Generator

REMOVAL

  1. Disconnect negative (-) cable at battery.
  2. Disconnect generator lead ("B" terminal) wire and coupler from generator.
  3. Disconnect canister with canister mounting bracket from body.
  4. Remove generator belt. Refer to "COOLING FAN BELT" or "GENERATOR BELT".
  5. Remove generator drive belt adjusting bolt and generator mounting bolts.
  6. Remove generator.

INSTALLATION

  1. Mount generator on the generator bracket.
  2. Tighten generator bolts to specified torque. Tightening torque Generator mounting bolt and nut (a) : 23 N.m (2.3 kg-m, 16.5 lb-ft)
  3. Install generator (cooling fan) belt. (G16 and H25, H27 engines) or "GENERATOR BELT" (J20 engine).
  4. Install cooling fan belt (J20 engine only). Refer to "COOLING FAN BELT".
  5. Connect "B" terminal (3) wire and coupler to generator. Tightening torque "B" terminal outer nut (b) : 8.0 N.m (0.8 kg-m, 6.0 lb-ft)
  6. Install canister
  7. Connect negative (-) cable at battery.
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Auto Mechanic: danny, Mechanic replied 8 years ago
graphic
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Customer reply replied 8 years ago

Partly answered. Have already done steps 1-3.

The lower bolt, on the alternator is apparently a 50T Torx head. It appears to be paritally stripped and has been overtightened by the previous owner's mechanic, to the point that when the Upper belt tensioner assembly bolt was COMPLETELY removed, the alternator STILL WILL NOT move. I have a feeling that an impact wrench was used to secure it.

 

Is there a method at getting at (removing) the lower bolt from the alternator mounting bracket? Or are we facing using a SawZA to cut the alternator mount bracket?

 

Limited clearance will (I think) limit options to trying to tap bolt head.

Auto Mechanic: danny, Mechanic replied 8 years ago
I think you need to to try a stud puller. that is if you can get the puller on there enough to grab. you use this with a rachet wrench. or channel locks. you may want to heat it up real good with torch before see if you can use the altenator to loosen the bolt by moving it. If all this fails drill middle out use a easy out. and also maybe tap and die it. screw in a bolt with reg head. and tack weld it in there. then use regular socket to get it out.
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