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Changing an alternator on a Peugeot 205 TU engine

Written By: a_bosc2000 (and one other contributor)
  • Comments: 2
  • Favorites: 0
  • Completions: 1

Difficulty

Moderate

Steps

13

Time Required

01:00:00

Sections

1

Flags

1

Ce tutoriel a été créé par la communauté

Ce tutoriel a été créé par la communauté

User contributed

Introduction

The alternator contains a whole bunch of moving parts that wear out over time. Regulator carbons, slip rings, bearings... It is often easier and more economical to replace the alternator rather than repair it.

On this car the lights and headlights would flicker when turned on and the battery light would flash occasionally.

I removed the right front wheel, the mudguard, the radiator hose bracket and the exhaust manifold sheet metal for the sole purpose of having clearer photos for this tutorial. This operation can very well be done without disassembling all of this by going through the top and bottom under the car.

  1. the alternator is located on the distribution side below, under the exhaust manifold

    • the alternator is located on the distribution side

    • below, under the exhaust manifold

    Edit

  2. locate the negative terminal of the battery unplug it and put her aside

    • locate the negative terminal of the battery

    • unplug it

    • and put her aside

    Edit

  3. remove the alternator regulator plug remove the protective cap from the red wire (this is the + battery) unscrew the nut of the red wire using the 10mm socket wrench and disconnect it

    • remove the alternator regulator plug

    • remove the protective cap from the red wire (this is the + battery)

    • unscrew the nut of the red wire using the 10mm socket wrench and disconnect it

    Edit

  4. The alternator has 2 mounting points. unlock the top screw, 16mm key

    • The alternator has 2 mounting points.

    • unlock the top screw, 16mm key

    • unlock the bottom screw, 13mm key

    Edit

  5. Unscrew the tensioner screw completely (without removing it), 10mm wrench and remove the belt

    • Unscrew the tensioner screw completely (without removing it), 10mm wrench

    • and remove the belt

    Edit

  6. remove the bottom screw, 13mm wrench then the top screw, 16mm key remove the alternator from below

    • remove the bottom screw, 13mm wrench

    • then the top screw, 16mm key

    • remove the alternator from below

    Edit

  7. We will do a fairly quick visual check; we will have ensured compatibility before dismantling (call a professional if in doubt). check that the attachment points and connectors are identical as well as the values

    • We will do a fairly quick visual check; we will have ensured compatibility before dismantling (call a professional if in doubt).

    • check that the attachment points and connectors are identical

    • as well as the values

    Edit

  8. present the alternator from below put the top screw in place and advance it using the 16mm key (do not screw it in all the way) put the tensioner screw in place and advance it using the 13mm key (do not screw it in all the way)

    • present the alternator from below

    • put the top screw in place and advance it using the 16mm key (do not screw it in all the way)

    • put the tensioner screw in place and advance it using the 13mm key (do not screw it in all the way)

    Edit

  9. put the belt on I reused the belt because I changed it very recently.

    • put the belt on

    • I reused the belt because I changed it very recently.

    • act on the tensioner screw to tighten the belt

    Edit

  10. There is a procedure for tensioning the belt It requires a blood pressure monitor, a device that is quite expensive. but the TUs are very solid engines and not as sharp as modern mechanics, we can do the tension by guesswork: not too tight but still enough, we try to have a little more than 1cm of deflection on the belt

    • There is a procedure for tensioning the belt

    • It requires a blood pressure monitor, a device that is quite expensive.

    • but the TUs are very solid engines and not as sharp as modern mechanics, we can do the tension by guesswork: not too tight but still enough, we try to have a little more than 1cm of deflection on the belt

    Edit

  11. lock the tensioner screw using the 13mm key and the top screw using the 16mm key check the belt tension again

    • lock the tensioner screw using the 13mm key

    • and the top screw using the 16mm key

    • check the belt tension again

    • A belt that is too tight will stress the alternator and wear out its bearings. A belt that is not tight enough may skip or fail to drive the alternator properly.

    Edit

  12. reconnect the regulator plug reconnect the red wire and screw the nut, 10mm wrench replace the protective cap

    • reconnect the regulator plug

    • reconnect the red wire and screw the nut, 10mm wrench

    • replace the protective cap

    Edit

  13. reconnect the battery start the car and check that everything works, you can test with a multimeter (when running, you should have more than 14 volts on the battery)

    • reconnect the battery

    • start the car and check that everything works, you can test with a multimeter (when running, you should have more than 14 volts on the battery)

    • The belt tension will be checked again after a few kilometers to make sure everything is ok.

    Edit
Finish Line

One other person completed this guide.

Author

with 1 other contributor

a_bosc2000

Member since: 11/3/19

28,481 Reputation

147 Guides authored

2 Comments

Thanks for the introduction

rg-a - Resolved on Release Reply

Hello, thank you for your effort I have a question if you allow me on the length of the belt and how many teeth.

Said -

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