Mondeo Alternator to Disco 200TDi swap Part 1

[weasel_110]

Hi Chaps, I finally got around to doing this yesterday, it took me about 4 hours with a lot of fiddling!

With a 200TDi Disco engine in my '89 110 H/top, the alternator is a right pain to adjust!

Power steering pump and belt first, then tighten the alternator belt...

The first job was to get the old 65 amp unit off, the adjuster bracket was cracked and the tensioning bolt on the alternator was seized solid, an impossible job to undo with it in place!

First, I removed the air filter housing to give better access,then I slackened off the power steering pump tension first, using plenty of Plus Gas as the pump mounting plate was seized to the engine mounting bracket then,I removed the water pump pulley to get the belt off as this is in front of the alternator belt.

Then I undid the alt adjuster bracket mounting bolt and left the bracket on the alternator, then removed the long mounting bolt and undid the alt wires and lifted out the alternator.

My next job was to weld the split in the adjuster bracket.pic

The alternator I got from my local breakers for £20, it is the Bosch 14V 90 amp one which delivers 65amp on idle,90 amp running, and is from a Mondeo 1.8 16 valve, I think the year is 1994 but the part number is 93BB-10300-AE, see pic below

I removed the serpentine pulley using a 24mm ring spanner and a torx bit, the best way I found was to put the bit on a ratchet and clamp it in the vice like so.see pic below

When I put the old pulley on the new alt it rubbed on the body so I used the 4mm thick spacer off the old alt to stop this, I didn't tighten it up at this stage as I didn't know if the belts/pulleys would line up!.

The old alternator has 8mm mounting holes and the Mondeo one has 10mm, so my good mate,Timpo drilled out a piece of 10mm stainless pipe to 8mm ID, which I then cut into 3, 14mm long pieces to sleeve the holes.see pic below

The adjuster sleeve in the new alt had to be pressed out further to fit onto the 200 TDi mounting bracket, I used an 18mm socket and the vice.see pic below

Here is the alt mounted on the engine.see pic below

Heres looking at the pulley alignment below

Seems fair enough but I checked with a straight edge, below

Go to Part 2 as I have run out of pic space!