Alternator replacement

[Bigebe02]

We have a 2002 Malibu Sunsetter XTI 23’ open bow boat with an Indmar hammerhead 365 HP engine. We have to replace the alternator and belt. Can someone give us a step by step list of what to do. It looks like we will have to disconnect a couple hoses to get the belt on after replacing the alternator.  We just want to do it right and not end up with a bigger problem as we go. Thank you for any guidance!

Erik

[justgary]

I think the biggest chore will be breaking the upper alternator bolt loose (the pivot bolt) and getting the alternator body out.  For some reason that one seems to like to hold on, so be prepared to hit it with your purse, or at lease use a cheater bar on the wrench if you need it.

Since your hoses are no doubt 20 years old, consider just replacing all of them.  I don't see why you would have to remove them to change the alternator, but they are old and are probably tired.  Make sure that you properly seat any hose that you remove so that you don't have any leaks (including air leaks).

I would also consider changing the fuel lines (with marine rated line) and the exhaust hoses as well.

In any event, loosen the bolts on the alternator, swing the alternator in to loosen the belt, remove the belt, remove the bolts and the alternator, replace with new alternator, install bolts finger tight, install belt, pull alternator to tighten belt (maybe use a bar to help), tighten bolts.  If you take a few reference photos before you start, you can easily see how everything goes as you put it back together.