How do you replace an alternator on a 1999 Saab 9-5?

Answer 1

So I completed the r&r of the alternator on my 4 cyl. In past post about alternator r&r in the forum have been unclear due to people responding on the same issue but talking about both the 4 cyl and the v6. Anyway this is how I believe from experience, is the easiest way to r&r the alternator. It really is a PITA but I think the next time I do it will be easy.

1. Pry tensioner pulley and instert Allen wrench to hold the tensionor in place while you pry it. I think i used a 3mm key. Slip/pry the belt off of the tensioner pulley and the alternator.

2. Remove the tensioner by removing the bolt in the center of the tensioner. I used an 8mm Allen. It is kind of difficult to remove all of the bolts on the front of this motor. It really helped to cut an 8mm Allen wrench with a dremel to the right size. I cut a spare Allen to about 2-2.5 inches. I then was able to remove the belt quicker with my fingers and the Allen. Occasionally I had to use an 8mm wrench directly on the shortened Allen.

3. Next detach the line that runs to the Power Steering pump. This line seemed to be in the way once I had detached the alternator. This would be the best time to do this. the line is attached to the frame with clips. I unbolted two clips. One was below the alternator on the frame and the other was closde to the crank pulley. you might have to disconnect this line ion other places to make it easier to remove the alternator. I am guessing it will differ on different examples.

4. Unbolt the Alternator from the block. The upper bolt will be revealed once you have removed the tensioner. again, once I loosened the bolt it was much easier to use the shortened Allen and my fingers to completely remove the bolt. Next remove the lower bolt theough the wheel well.

5. Remove the back cover on the alternator. Remove the three small scres then pull the cover off by using the release tabs on it. I think there were two tabs that I either had to press or oull to remove the cover. This was easiest when you aim the back of the altermator up and remove the cover from above.

6. Unbolt catalytic exhaust from the motor. I had to do this since it was in the way. It is only three 13mm bolts. Mione werent tight like exhaust bolts usually are. Anyway, after removing the 3 bolts (I did two from above then 1 from below) i was able to pull the cat down a little to get it out of the way. Once unbloted you can drop the cat even further if necessary if you unhook the exhaust hangers behind the cat.

7. Remove bolts from front and side motor mounts. The first mount is on the top front of the motor. The second mount in on the firewall side of the motor and about in the middle of the motor. This mount is down below the top of the motor. I had to use a seires of extensions and a wobble to remove this bolt.

8. Pry motor forward. I used the curved end of a pry bar. I will add pictures to make this clearer. I placed the pry bar on the side of the mount closest to the front and pry the motor towards the front of the car. Once I pulled it as far as I could without the pry bar slipping off, I was able to wedge the right sized deep socket into the mount to hold it in place. Once wedged I replaced the pry bar and pulled the motor even more and insterted a larger socket to hold it in place after I moved it more. You might be able to do this in one pry. It took two for me.

9. Move alternator down to the driveline. At this point you need to either move the alternator from above or below. I had to do a little of each. Onjce it is on the driveline you are ready for the next step.

10. Remove alternator from below. With the power steering line and the cat out of the way you should be able to remove the motor with one last pry. While under the car I was able to put the pry bar between the motor and frame. The best place I found was at the right side of the motor (firewall side) and the frame. I then pulled the motor again towards the front of the car with the pry bar. Once I oulled with one hand I was able to pull the alternator out. Keep pulling it is a tight fit. Oh ya, and don't be laying right under the alternator because it will hurt when you pull the 11 pound beast on to your face. Just a note. When prying below, if you are unsuccessful at your first attempt at pulling out the alternator, you might have to go back above and replace your wedge (socket in my case. you can use whatever fits).

Please contact me if you have any questions. I am happy to help.

DONT USE THESE INSTRUCTIONS FOR THE V6!!!

I will add pics when I am able.