1HZ alternator replacement - is it really this hard? (1 Viewer)

[EngineBlockEggs]

Hey folks! I'm replacing the alternator in my HZJ77's 1HZ. I know it's a tight fit, but getting the new alternator back into the mount (where the bottom screw goes) is very difficult. I've been using a rubber mallet to try tapping it into place, but the progress is slow. I've watched videos of other do it, and while they mention it's laborious I don't think they had this much trouble. I was at it for about an hour yesterday. Is this the norm or am I doing it wrong? This is an OEM alternator.

 

[Sundowner]

Question: are the dimensions the same on the new unit, or is it just slightly larger in the exact wrong place?

I've had that happen double-shear situations, before: the new unit (and it could be anything, not just an alternator) is just a tiny bit larger/smaller in one dimension or another and it turns "easy" into "nope, not today." Regardless, I don't like hammering on things like alternators, even with a rubber mallet; I'd rather have it gently slide into place. Full Disclosure: I haven't done a 1HZ, but I'm looking at mine right now and I don't see anything that's particularly odd. It's just hard to reach.

 

[EngineBlockEggs]

Question: are the dimensions the same on the new unit, or is it just slightly larger in the exact wrong place?

I've had that happen double-shear situations, before: the new unit (and it could be anything, not just an alternator) is just a tiny bit larger/smaller in one dimension or another and it turns "easy" into "nope, not today." Regardless, I don't like hammering on things like alternators, even with a rubber mallet; I'd rather have it gently slide into place. Full Disclosure: I haven't done a 1HZ, but I'm looking at mine right now and I don't see anything that's particularly odd. It's just hard to reach.

You might be correct. Unfortunately I don’t have the old one anymore as I did a swap with a refurbishing company. I had some luck sanding off some surface rust from the mount yesterday that got it about 90% in place. I’ll keep working on it, maybe not with a mallet anymore