2004 Cavalier 2.2 OHC (EcoTec) Alternator

[Siguric]

This is my 5th Cavalier. On all the other ones (ranged 89-99), the 2.2 OHV alternator was a snap to replace (and i know, because i changed at least 10 of them); 3 bolts (13mm, 15mm) and a couple electrical plugs, take it out, put it in, done deal...

well, not so much with this one. the alternator is shoved underneath a few different things, and i'm wondering how to get it out. i have disconnected the bolts and the connectors and all that... the alternator is now completely free to move as it will.

however, i cannot get it out of where chevy decided to wedge it in the engine compartment. There is no room to remove it either through the top or through the bottom.

anyone have this problem? what do i need to remove to get it out? (without completely dismantling the engine)

Thanks in advance.

[Classicrocjunkie]

Its gotta come out the bottom. No room up top due to rad hoses, and intake manifold.

[Siguric]

Would you have to take off the fuel pump (which is what i'm gussing is right below it) because there's even less room below then there is up top.

[Classicrocjunkie]

Originally Posted by Siguric

Would you have to take off the fuel pump (which is what i'm gussing is right below it) because there's even less room below then there is up top.

Fuel pump is in your fuel tank. A/c Compressor is right schmack below it. Thus all the lines running to your condenser, evaporator, and through your firewall.

Try taking it out up top, don't be afraid to move thing outta the way to sneak it by.

[spudracer73]

you could unbolt the motor mount and drop the engine down a little bit and that should buy you just enough room to get it out. i have had to do that a couple times when fixing pullys on my cav. it only takes a couple minutes out of your repair.

[Siguric]

Before I had even posted this thread, I had taken the radiator hoses off (the one that feeds directly to the block, and the one running from the overflow tank). however, unlike the photo that classic posted, the dipstick is located directly in front of the alternator (whereas in the picture, it is positioned to the "back" (driver side) of the motor). That was where my major snafu was. There just wasn't enough room between the block and the dipstick to maneuver it out. And with the airbox (not exactly sure what it is... but it's connected to the air filter housing) directly over the top of it also, it made my life a living hell for a few hours.

Sidenote: I noticed after i posted this, while i was under the car, that it was the ac compressor and not the fuel pump. i apologize for my idiocy.

Finally I just did what spud recommended, took out a mount, rotated the motor, and pushed, pulled, pounded it out, then did the same to get the new one in...

IMHO, chevy really F'd up a good thing with these ecotecs..... i for one will never change the alternator myself on this motor again if i can help it. it's too much hassle for what should be a "quick fix".

[Aario]

I just removed my alternator through the top. I released the bracket holding the dipstick, removed the top radiator hose and was able to squeeze it from the top. It was simple and came out without a fuss.