Alternator removal help

[Ozzie]

Ok, so im in the process of removing a bad alternator. I looked up how to remove it on vfaq, and everything was going alright until i got to the part where you have to push the bottom bolt of the alternator out through the other side. heres a picture from v### of what im talking about.

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there isnt enough room to pull it out all the way. It hits the side of my wheel well or something and wont come out all the way. I tried searching on the forums to find another thread on this but I didnt get any good results back. Thanks in advance.

 

[luvmygst]

On my 2g it hits the frame rail you have to take the motor mount loose and let the motor drop a little bit. When you put it back together put the bolt in the other way to avoid this in the future. Good luck

 

[sc2_ct]

If I remember correctly, you have to jack the engine up without lifting the car (use a block of wood under the oil pan and jack from there to get some more clearance.

 

[phillabaum03]

On my 2g that side panel comes off. Ive done 2 alternators without jacking the motor up or removing mounts?

 

[DROOPY209]

Remove the drivers side splash guard. It is held on by (3) 12mm bolts, and 2 plastic screws.

Installation is going to be trickey as you have to fumble around aligning the alternator holes with the mounting holes.

DON'T install the bolt backwards, it is meant to be installed the way it comes out so the nut & bolt don't break loose.

The drivers side of the alternator has a little "notch" so the bolt stops there, then you tighten the nut on the right side of the alternator.

 

[vaboys2ndgen]

yea yea old thread w/e



is there a method to installing this damn alternator back into its rightful spot? i've been trying for the last hour and it doesnt just slide right in . it was a pain in the azz taking it out and is worst puttin it in without another set of hands.


thanks in advance

 

[90CherryTSI]

What makes it 100% easier is removing the splash guards and the fan. With the fan out it is only a 10 minute job for the whole thing. I've done it twice now, first time it was an hour, second time I yanked the fan and had it done in right around 10 minutes. Other than the fan and the splash guards you just loosen a couple bolts and pull it right out.

 

[vaboys2ndgen]

What makes it 100% easier is removing the splash guards and the fan. With the fan out it is only a 10 minute job for the whole thing. I've done it twice now, first time it was an hour, second time I yanked the fan and had it done in right around 10 minutes. Other than the fan and the splash guards you just loosen a couple bolts and pull it right out.

yea thanks but its already out.. soo that doesnt help much.

 

[SinaiTSi]

Yeah, it sucks putting it back in. I assume you're talking about getting it to "slide" back into it's pivot point, which it doesn't really slide that well. It took me a while but I just pushed and wiggled it back and forth enough to where I could see the two holes (where the bolt slides into) on the side closer to the driver's fender start to line up. Then I put a large screwdriver in there and tried to sorta pry/wiggle the holes so they're line up even better. Even after all that, the bolt wouldn't just slide in, I had to lightly tap it in with a hammer. Just be extra careful that you don't jam the bolt in there so hard that you booger then end of the threads. I hope that helped, kind of a bad explanation.

 

[vaboys2ndgen]

Yeah, it sucks putting it back in. I assume you're talking about getting it to "slide" back into it's pivot point, which it doesn't really slide that well. It took me a while but I just pushed and wiggled it back and forth enough to where I could see the two holes (where the bolt slides into) on the side closer to the driver's fender start to line up. Then I put a large screwdriver in there and tried to sorta pry/wiggle the holes so they're line up even better. Even after all that, the bolt wouldn't just slide in, I had to lightly tap it in with a hammer. Just be extra careful that you don't jam the bolt in there so hard that you booger then end of the threads. I hope that helped, kind of a bad explanation.

finally got it back on tonite.. with the help of a friend who had a rubber mallet. so basically yeah samething you had said. it still seems to be smokin lightly? wtf is that all about any1 care to share?

 

[merqury]

So the alternator can be taken out from the top, without jacking it up or going under the car?

 

[luv2rallye]

So the alternator can be taken out from the top, without jacking it up or going under the car?

On your car yes it can but power steering pump and bracket has to be removed first.

2g turbo alternator (alt) removal steps:

All nuts/bolts are 12mm so get a 12mm socket w/rachet, a 2" and 12" extension, and 12mm box end wrench. Disconnect one battery terminal. Remove inner splash shield from under car next to alt and oil filter cooler (so there is room to pull bottom alt mounting bolt out). Remove fan in front of alt to give more clearance for it’s removal. Pull out alt electrical connector while pressing locking tab (wiggle and press and pull hard). Undo nut that holds large electrical cable onto alt and remove cable (this is hot so tape wire up so it will not touch anything and don't let wrench touch metal - in case battery gets reconnected before its back on). Remove upper adjustor locking bolt that holds alt to brace and loosen tensioner screw (see pic below). If you can now push alt back enough to remove belt off it’s pulley, do so. Remove alt bottom mounting bolt nut (just above oil filter - remove filter if need to). Drive out lower alt mounting bolt (that you just took nut off). Remove alt drive belt off pulley if haven't yet. Remove alt by wriggling it back and forth a lot while pulling hard. Bring alt out bottom (Note: Can bring alt out top but power steering pump and bracket has to be removed first). Pic below shows alt with tensioner (power steering pump and it's bracket have been removed).

http://www.dsmtuners.com/forums/attachment.php?attachmentid=144444&d=1346305878

 

[merqury]

Thanks luv2rallye. Is the process same for a 95 Talon Tsi?

Also, I'm wondering if there is any way I can screw up when removing or putting the belt back on the alt pulley for eg. timing etc.

 

[luv2rallye]

Yes the process is the same for all 2g turbos (which your 95 is). The timing belt (TB) is inside the cover and is independent of the alt, PS, or A/C belts so you can't screw it up. The only problem I've seen is not tensioning the alt belt properly or using the correct belt. Some people remove the water pump pulley (which is actually 2 halves) to replace the TB or water pump and then put the pulley back on backwards which causes the alt and PS belts to have a slight left to right offset (lined up with the other pulleys) which destroys the belt.

 

[jumpfroggy]

I just replaced mine, had a hard time getting it out. I also had to remove the power-steering pump and bracket (tried without either, wouldn't fit).