Introduction - Replacing the Alternator
GM really made a mess of this task. First, the voltage regulator is not easily replacable.
This just blows my mind. In all previous SAABs when the alternator stopped producing voltage, the regulator could be replaced in about 15-30 minutes.
On these 9-5s, the voltage regulator is hidden deep in the alternator and cannot be replaced easily on the car.
Second, the alternator cannot be removed from the car easily. Everyone has heard the stories about this job and it is definitely not the easiest task.
However, with some patients and good instructions, you can probably do it in one day and save yourself some money.
You can replace your 130 Amp alternator with a newer 140 amp version.
I did this to my car, but beware there are some small modifications that might need to be done to get it to fit 100%.
I will detail these modifications in step 2.
There are two ways to remove the alternator. From the top and from below. Either way is a tight fit.
I found it easier to go from the top and I could more easily pry the engine forward and lift the alternator out.
(I was sitting on top of the engine!)
You should have a good selection of tools for this job and experience with surprises.
You might run into some "whoops" or "OH SHIT" type of issues.
For example, breaking off a stud in the turbo when trying to drop the turbo downpipe could be an OH SHIT problem.
In addition you might have to make some custom tools to fit in the tight spaces.
If you want a challenge and want to win the war, then this is the job for you.
Be sure to have at least one ice cold six pack. You'll need it!!!