My Alternator DIY thread - 2003 - LONG

I just finished a DIY on my alternator for my 2003, 76K miles, so I thought I would post some helpful tips and tricks for anyone else doing this on their own. All in all it was a pretty involved (but not terribly difficult) DIY project, and I got plenty dirty doing it. However, (and this is the important part) my total cost was around $325 and that also included new belts (I figured since I had to take one off, I might as well replace both).

I consider myself to be very handy and I have some automotive knowledge and a really good set of tools. If you have that, and the RAVE manual, do not fear attempting this project. I went REALLY slow, worked mostly alone, looked at the directions often, and the removal took me about 3.5 hours (a lot of that time is spent waiting for coolant to drain). Putting everything back together (including changing the A/C belt) took about 1.5 hours. If you do not have the instructions from the RAVE CD/Manual (provided below), I would NOT attempt this job.

Source your parts:
The hardest part for me was finding the proper wrench to remove the fan bolt (32mm). I tried Napa and Autozone (they rent kits to remove fans), but their kits don't have the right size wrench. I went to Sears and bought a nice 32mm open end for $26.00. If you have the time, they have the actual LR equivalent on e-bay, but none were local to me.

Next, the alternator - I called the dealer and was shocked by their price, and I found a guy on e-bay who is local to me and rebuilds these alternators on an exchange basis. He was even kind enough to bring it over for me. He charges $250 plus shipping. He sells under the name stonegateauto on e-bay, ( link here: http://myworld.ebay.com/ebaymotors/stonegateauto/ ) He was really friendly and seemed to know what he was talking about and they offer a one year warranty. Company name is UCP Manufacturing in Riverside, CA. His office number is (951) 353-0407. I would recommend.

The reman. alternator does not come with the rubber seal on the back. I would ABSOLUTELY recommend changing that to a new one before refitting (dealer item). I compared the old seal and the new one and the old one had stretched a bit and I did not trust it. I think it was $27. While at the dealer, I would pick up a couple of the little black alligator clips that hold the fan shroud to the radiator. I broke one of the 3, so pick up at least one if not 2 for $1.75 each.

Other than that, get a big tray from Autozone to catch your (very expensive) coolant, and a nice sized funnel. I had to buy another gallon of coolant to make up for some that was lost on the ground and by bleeding the system, but it was *only* $21 at the BMW dealer compared to $41 at my local RR dealer.

Besides that, read and follow the instructions in the RAVE CAREFULLY. The steps for the alternator are 14 easy steps. The steps that have to come before you can get to those 14 steps are the real work. Basically you remove the coolant from the block and the radiator (make sure it's not hot and that you remove the coolant cap), remove the top radiator hoses, remove fan and cowel, remove the belt and tensioner and THEN you are ready to start on the alternator.

Usually you find extra stuff that can be eliminated using the RAVE manuals. I did NOT find anything that could be changed to make the process easier or provide a shortcut. You are not gonna get the alternator out from the bottom or without removing the fan, I assure you. Just take your time, do all the steps, and do it right.

Disclaimer - this is how I did it. It is intended to help you, but not a guarantee of how yours may or may not compare. I am not a mechanic, so take my tips and instructions as those of a novice. If you have anything to add, I am sure any additional advice would be appreciated for those attempting this down the line.

Here are the pages from the RAVE Manual: