Alternator replacement on a 2015 Porsche Macan Turbo. Did not see a video covering this job on here, so I tried to document every step along the way. Hopefully it is helpful! These steps can also be used when doing a radiator replacement, serpentine and water pump replacement, replacing broken timing cover bolts, etc.
Tools needed: T-25 and T-30 torx, 10mm ratchet wrench, 13mm socket, E-12 socket, wire cutters, zip ties, push pin pry tool, hose clamp pliers, 7mm socket, long reach pliers
There are a LOT of steps involved in taking the front end off the car, but none of them were difficult.
1. Underbelly Tray: Remove 15 underbelly tray screws using T-25 Torx
2. Under hood cowling:
a. Hood Latch cowling: Remove 4 plastic push pin clips and one retaining clip holding hood release lever on
b. Air box cowling: Remove four plastic push pin clips on each side
3. Air Box:
a. Remove four T25 Torx on top of each airbox
b. remove T30 mounting bolt
c. remove t30 coolant valve mounting bolt (drivers side only)
d. Remove Air box side wall
e. Remove Air filter
f. Slide airbox out of fender well, remove two t30 pins holding air box to turbo inlet pipe
g. Remove air box
4. Inspect Timing cover bolts for damage, replace as necessary
5. Remove headlights
a. Remove headlight trim cowl by removing one push pin
b. Remove two T30/10mm Headlight screws
c. Slide wire harness and breather tube off back of housing
d. Disconnect headlight sprayer from headlight housing, leave attached to car
6. Remove Bumper Cover
a. Remove 8 t-25 bumper an4 4 t30 bolts along top of bumper cover
b. Remove lower splash guard 18xT-25 bolts
c. Disconnect two wire harnesses in passenger side bottom of bumper/wheel well
d. Remove T-25 screws behind fender liner
e. Lift corners of bumper near wheel well up and out
f. Remove bumper cover
g. Remove bumper cover brackets from under headlights t30 bolts x 6
7. Upper core support bar (Silver)
a. Mark location of 6 T-30 and two t25 screws fastening silver piece to black piece, then remove
b. Remove 4 T30 hood latch screws, unclip hood latch wire harness
c. Remove intercooler y pipe 7mm clamps
d. Remove 5 y pipe t25 screws (two are hidden behind movable flaps
e. Remove two small hoses and sensor wire harness
f. Remove y pipe
g. Remove two plastic upper radiator pins
8. Remove upper core support bar (black) 6 T-30 bolts
a. Drilling two access holes makes removal of two of the bolts much easier.
9. Remove front crash bar
a. Swing lower grille inlet wings inwards
b. Remove 4 13mm bolts holding crash bar to frame rails
10. Remove radiator fan assembly
a. Disconnect two wire connectors on bottom passenger side of radiator fan shroud
b. Unclip diverter valve vacuum line from shroud
c. Remove upper front radiator duct by removing wire clips from shroud and unclipping shroud from radiator
d. Unclip AC condenser coil from radiator, move to side
i. Remove three t-30 screws from lower line mount under car
e. Move horn wire harness out of the way
f. Remove front lower bumper support T30 bolts
g. Remove four t30 lower rad bushing retaining bolts
h. Remove upper and lower radiator hoses, drain radiator
i. Slide radiator out towards front of car, turn counter clockwise 90* and set on top of passenger side headlight mount
j. Ziptie top of radiator to hood to prevent falling
11. Remove serpentine belt
a. Loosen tension by using 30mm 12pt socket on the tensioner bracket, turning clockwise
b. Cut ziptie holding hose to bracket near tensioner mount
c. Unclip small plastic hardline
d. Remove belt
12. Remove Alternator
a. Loosen two E-12 bolts roughly two-three turns
b. With socket/extension in place, tap heads of bolts to move the sliding retention nuts on backside of alternator
c. Remove e12 oil cooler coolant line bracket bolt
d. Remove coolant line from oil cooler to make room for alternator
e. Remove two E12 alternator mounting bolts
f. Remove alternator out the front of the vehicle
g. Remove 13mm nut attaching the positive wire to alternator
i. If system Is still energized, be sure to safeguard this wire from shorting out against the engine block!
h. Remove energizer wire plug from alternator
i. Fully remove alternator from vehicle
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