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My alternator just took a crap yesterday so today I went over to AutoZone and got a rebuilt one. I took the old alternator out with no problems at all, but installing the new one has proved to be a lot of trouble. I'm not a mechanic so bear with me. I put the long bolt through the alternator so that it can pivot and allow you to take on and off the belt. That was easy. Then, I put the belt back on and proceeded to try and put the other bolt in that holds the alternator in place. It's the one attached to the little slider. The friggin thing just doesn't want to go into the alternator!! I tried taking off the belt and trying - no use. I tried raising the alternator up and bolting it in - it went in but crooked, so no use. I even tried putting a friggin toothpick in the housing of the alternator to see where it came out and then pushing the toothpick in and guiding the bolt in - no use. I'm getting very very pissed off and very very greasy from this. Can anyone offer a little advice as to how I should be installing this - step by step?
 

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=)

I had the same problem with mine. Someone (ahem,...) put the wrong thread bolt into the old alternator when they installed it (basicly cut new threads into the aluminum)

So, when I went to put the new one in its place, the adjustment bolt wouldnt fit the new alternator. I just went to my spare bolt box and pulled out a generic Toyota bolt, and it fit perfect =) Couldnt tell you what size or pitch the threads were though.

My advise is to take the alternator to a bolt supply place, or a hardware store and find a bolt that threads in properly. It shouldnt go in crooked or bind up. It should go in smooth and tighten evenly.

Oh, dont force the wrong bolt in, or you may loose your ability to adjust the belt next time you have to because of stripped threads.

Hope this helps =)

Aaron
 

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Yup! That was the problem. I tried another bolt I had from pulling various parts from MK2's in the junkyard and it worked. Thanks! Unfortunately, the problem isn't over yet. The rebuilt alternator is installed without flaw, but the car still won't stay running. When I start the car, it turns over as usual and then immediately stalls. If I hold my foot slightly on the gas pedal, the car will stay running. It's only when I take my foot off the gas that the car stalls. The battery is brand new and "maintenance free" so I know it's not the battery (Deka). I suppose the rebuilt alternator could possibly be bad, but I'm doubting it. I can't find any other logical reason that the car would not hold charge except maybe a bad ground somewhere. I noticed a few weeks ago the car started making a weird noise. It was like a clanking noise that happened as soon as the car started. It seemed to be coming from the starter or in that area. Somewhere towards the bottom of the engine. The starter isn't shot obviously because the car starts fine and never takes more than 2 seconds to turn over. Any clues as to what the problem could be?
 

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Now I mean, honestly, draggin it up here, but isnt that the point of searching?
My car is making that same Clanking noise upon startup when cold, but runs like a scalded dog and quietens down after 12 seconds post cold start.
I have spun rod bearings due to lack of oil on a 5m 'cry like a lil girl', this is not it?
 

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It might be the starter sticking at startup.(need a new bendix spring) or like you said it could be bearings,lifters.
 

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Check your fuses??

Yup! That was the problem. I tried another bolt I had from pulling various parts from MK2's in the junkyard and it worked. Thanks! Unfortunately, the problem isn't over yet. The rebuilt alternator is installed without flaw, but the car still won't stay running. When I start the car, it turns over as usual and then immediately stalls. If I hold my foot slightly on the gas pedal, the car will stay running. It's only when I take my foot off the gas that the car stalls. The battery is brand new and "maintenance free" so I know it's not the battery (Deka). I suppose the rebuilt alternator could possibly be bad, but I'm doubting it. I can't find any other logical reason that the car would not hold charge except maybe a bad ground somewhere. I noticed a few weeks ago the car started making a weird noise. It was like a clanking noise that happened as soon as the car started. It seemed to be coming from the starter or in that area. Somewhere towards the bottom of the engine. The starter isn't shot obviously because the car starts fine and never takes more than 2 seconds to turn over. Any clues as to what the problem could be?
 
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