Nippon Denso Alternator

This task breaks down into two phases:

1. Gaining access to the alternator attachment bolts, wiring, etc.

2. Unbolting & moving the loose alternator down and out.

Phase 1

This requires working first from above and then (with the car on jackstands) from below. When you attempt to see the adjustment bolt on the alternator pivot arm from above remember it must also be completely
removed and later replaced. So to get room, remove the power steering fluid container's sheet metal mount and push it away to the rear. Also, remove the power steering hose from the top of power steering pump and push it back to the rear ( I drained the container, but the fluid tends to drip out of the hose anyway). [You can probably get creative and stop the drips by strategically placing a pen cap or such in the end of the open hose to cork it up--Doug]

To get access to the top of pump, take out engine dipstick and remove oxygen sensor. You will need a variety of tools -mostly metric. Now, you should be able to loosen and remove the adjustment bolt and just loosen-only the top pivot strap bolt. The alternator is still held up by the bottom bracket and belt.

Loosen right side front wheel bolts, jack up, support, remove wheel (do not turn steering wheel from straight ahead position).

Phase II

From below, remove oil filter in order to get at the alternator connector and also the single wire with its terminal, the connector needs to be squeezed at the plastic locking tab in order to disconnect it. First, disconnect battery before alternator connections.

OK, now for the tricky part, because it doesn't seem possible for the alternator to be removed! It comes through the opening between half-shaft and frame, and remove the hose clamps from the pipe along the frame opening at the bottom to get more room. Then locate and unbolt the right most bolt from the alternator bottom bracket (from the engine), then loosen the remaining left most bolt and tilt the bracket-alternator combination down to the right in order to separate the alternator via the *long* pivot bolt. There is just enough room to remove this *long* bolt. No need to remove the bracket from the engine, however.

Now, you should pry up and the alternator is in your hand and it is heavy - be careful as you reverse the alternator end-for-end and slip it down through the opening connector end first and up. This is not easy and requires some fishing around until it falls through. [Make sure the kids aren't around to hear all the swearing--Doug]

My rebuilder charged about $115, and please check that the pulley bolt is tight before reinstallation (just reverse all the previous moves!).

write-up by Loren

the ref wrote:I did mine last year what a to do. I had to take out the drive shaft If you have small hands you MAY be able to do the job with out takeing the shaft out.

Trigger wrote:

the ref wrote:I did mine last year what a to do. I had to take out the drive shaft If you have small hands you MAY be able to do the job with out takeing the shaft out.

Yea the guy who did mine said he had to remove the driveshaft aswell ... also noticed that the one that came off was a Denso replacement part rather than the original Lotus part. Mind you it makes more sense as you can afford to buy 4 or 5 of the Denso ones for the price of a Lotus original one lol.

tashuka wrote:

Trigger wrote:

the ref wrote:I did mine last year what a to do. I had to take out the drive shaft If you have small hands you MAY be able to do the job with out takeing the shaft out.

Yea the guy who did mine said he had to remove the driveshaft aswell ... also noticed that the one that came off was a Denso replacement part rather than the original Lotus part. Mind you it makes more sense as you can afford to buy 4 or 5 of the Denso ones for the price of a Lotus original one lol.

but diod u not say a lotus one would last better?

jackdaniel wrote:Have you got the part number for that Denso alternator, please.
Impossible to source in Oz, and I want a bigger output Bosch alternator on. don't mind doing a custom adjustment bracket, but sizing and mountings need to be close enough.

Denso Europe wrote:DENSO Starters and Alternators are represented by the following distributor in Europe:

United Kingdom
DENSO Sales UK Ltd
Building 1, Eden Road, Walsgrave Triangle
Coventry CV2 2TB
United Kingdom
T: +44 24 76843416
F: +44 24 76842521
E: J.Woodward@denso-sales.co.uk

Finland
Atoy Oy
Lauttasaarentie 54
00200 Helsinki
Finnland
T: +358 (0)9-68271
F: +358 (0)9-6827201
E: atoy@atoy.fi
W: www.atoy.fi