1) Good idea.I'll be honest chaps, cleaning it is no issue, but replacing an earth cable sounds a tad beyond me at the moment...
New alternator has arrived. Tensioner moves enough for me to slip a belt on and off (hopefully), so I'm gonna give this a go tomorrow.
I'm assuming the process is something like:
1. Disconnect battery
2. Remove engine cover (Any need to detach the coolant pipe? It just seems in the way...)
3. Release tension and remove belt
4. Remove fixing bolts (how many are there?)
5. Unclip cable connectors
6. Reverse of above to install replacement
Thanks all!
2) Coolant pipe? Do you mean the L-shaped metal air return pipe from the intercooler to the rear of the engine? - this wraps around the front of the Tdi engines. Undo the three fixings and the engine acoustic cover will take off with the intercooler pipe in situ although there is usually a bit of wrangling with the edges as you manoeuvre it under the cabin air intake trumpet. I've taken it off when replacing thermostats and coolant temp sensors however I cannot remember having had to do so when removing alternator as you have access from the side.
3) yes. It may be easier to remove the tensioner completely (three bolts to undo it, M8/13mm from memory). If you aren't replacing the belt removed with a new one, before removal put a piece of tape on it with an arrow indicating which orientation it currently is in so that it can be replaced the same way round - I've read enough times that re-installation in the reverse direction can cause major problems.
4) there are two long bolts that secure the alternator to the bracket. The threaded ends are in the vicinity of the thermostat housing - give these both a good squirt of WD40 or Plusgas / penetrating oil the day before trying to undo them preferably if they haven't been taken out before - one of mine was seized in place (galvanic corrosion over 19 years) and snapped off just below the head when I got some proper leverage onto it.
5) yes
6) yes.
Obviously open to correction. Best of luck!