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PostPosted: Fri Dec 30, 2016 9:01 pm 
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I sheared my alternator (generator) adjusting/fixing bolt on my 81 LUV diesel while trying to adjust for the larger-than-stock fan belt that the Guatemalan guy I bought it from said was an upgrade.

So I'm removing my alternator and will try to heat or drill the sheared bolt out.

I followed the simple instructions in the LUV diesel shop manual and it still won't come out. I could use some help.

Manual says:
-remove intake silencer (not sure what that is but I think I removed it)
-disconnect generator wiring (done)
-disconnect vacuum hose (done - in fact I disconnected a big and a little one)
-remove the fan belt (done)
-I also disconnected a little electric line bolted to the back.

Am I missing anything? There's a long bolt visible toward the bottom back of the alternator - do I need to remove that?

Thanks for any help.

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PostPosted: Sat Dec 31, 2016 9:16 am 
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I'm guessing your shop manual isn't a genuine Chevy or Isuzu manual. You didn't mention the oil line, which must be disconnected (replace it, because it's going to leak).

Other than that, check the replies you got on the Isuzu P'up forum.

Jack

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PostPosted: Sat Dec 31, 2016 10:19 am 
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Thanks for the tip on the oil line Jack. Know anything about the benefits or risks of using a larger fan belt? The guy I bought it from really seemed like he knew what he was talking about.

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PostPosted: Sat Dec 31, 2016 11:01 am 
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LUVFishin wrote:
Thanks for the tip on the oil line Jack. Know anything about the benefits or risks of using a larger fan belt? The guy I bought it from really seemed like he knew what he was talking about.

Never heard of that. Larger as in width? I really don't know.

As for the oil line, I need to elaborate. I was replying from my phone before, so I was brief. The vacuum pump (on the back of the alternator) won't work without a constant oil bath. So that oil line supplies a generous flow of oil from the block to the vacuum pump under strong pressure. Another line runs back to the oil pan, but it doesn't have the pressure that the supply line has (kinda like our household plumbing lines). The high-pressure supply line has an outer cover that's fabric, and you can't see the condition of the actual inner rubber line. It gets brittle over time. It may go for years without a problem, but if you disturb it (such as by removing the alternator) you break the inner tubing. I can tell you from experience, you will lose your engine oil in a hurry--and that can destroy your engine. Fortunately, I caught mine in time to shut down before damage was done. But I had oil spatters all over my tailgate! So change it, please. There's a guy on the P'up site who may be the ONLY source for those lines (factory/new). They were about $35 last time I bought one.

Jack

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PostPosted: Sat Dec 31, 2016 11:05 am 
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Good info, I'm on it. I am told the fellow's name is Jerry in the Pup site. Thanks.

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PostPosted: Sat Dec 31, 2016 11:06 am 
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LUVFishin wrote:
Good info, I'm on it. I am told the fellow's name is Jerry in the Pup site. Thanks.

Correct. He goes by "JLEMOND".

Jack

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PostPosted: Sun Jan 29, 2017 9:26 pm 
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I got the alternator off then back in! The LUV fired right up! Then my oil line off the back of the alternator vacuum pump blew.

And just like you mentioned it spray oil all over the place. I will redouble my efforts to fine one. Any reason I couldn't make one? Looks easily enough.

The hardest part with the alternator was getting the long bottom alternator bolt past the fan shroud but I followed the advice of unscrewing the shroud and eventually got it out of the way.

The larger belt that I mentioned may just be stock - it's a TR22410 and O-Reilly Auto Parts says its compatible with the 2.2 diesel.

Thanks for the help everyone. If anyone has a extra oil line for sale let me know!

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PostPosted: Mon Jan 30, 2017 7:11 pm 
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I have oil lines on the way FYI.

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PostPosted: Mon Jan 30, 2017 7:13 pm 
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LUVFishin wrote:
I have oil lines on the way FYI.

That's great news. I came SO close to toasting my engine when mine blew out.

Jack

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PostPosted: Sun Feb 19, 2017 10:26 pm 
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I ask this not because I am incompetent but merely to have it on record for everyone else's sake.

I finally have my alternator and my vacuum pump oil lines back in and am ready to refill with oil.

Is the oil filler cap is just a plug that I pull out? Mine isn't coming out so easy and turning it does nothing and I don't want to yank on it and break it and have to find a new one from who knows where.

Thanks.

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PostPosted: Sun Feb 19, 2017 10:59 pm 
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LUVFishin wrote:
I ask this not because I am incompetent but merely to have it on record for everyone else's sake.

I finally have my alternator and my vacuum pump oil lines back in and am ready to refill with oil.

Is the oil filler cap is just a plug that I pull out? Mine isn't coming out so easy and turning it does nothing and I don't want to yank on it and break it and have to find a new one from who knows where.

Thanks.

Yes, on the diesel it just pulls out.

Jack

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