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  1. #1
    Join Date
    Apr 2005

    Default Remove alternator without removing intake manifold?

    Had the "loose screw" issue on the alternator pulley on my wife's 2009 XC90 3.2 and dutifully replaced the overrun pulley, which involved removing the intake manifold, etc. Two weeks later and I had to check something else and noticed a nice red grease spray around the pulley area, and I think I know what happened. When I opened the new pulley box, I expected to see a new cap along with the pulley, but it didn't come with one, so I re-used the old one, which I warped slightly removing from the old pulley (it's a rubber-coated flex-steel cap). It seemed to fit snug, so I reinstalled everything and didn't think of it until I saw the spray.

    I'm assuming that the overrun pulley isn't 'sealed' and this is likely internal grease that is normally held in by the cap spinning though the cap seal. I assumed the cap was more to protect from dust and water - not to hold grease in! Regardless, the warped cap isn't sealing and I'll have to order a new one.

    My question: when I removed the alternator, I noticed that the bolts don't thread into the block all that far - maybe 1/2 - 3/4 of an inch. I can see the top two bolts and 'feel' the bottom two bolts - has anyone removed the alternator bolts and 'backed-off' the alternator without removing the intake manifold? There's likely enough room to slide it to the left enough that I can re-pack the overrun pulley and install a new cap, but I'm not sure if I have enough room to loosen the mounting bolts.

    If I have to remove the manifold again, then I might as well order a new overrun pulley and cap, but just trying to save another day under the hood.

    Last edited by amonti; 03-22-2022 at 07:52 AM.

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