Audi and VW Passat Alternator R&R – How to Remove
September 11, 2010 12:43 pm DIY, How To Auto Repair, VW
The VW in the image above was getting a new waterpump and timing belt.
© DenLorsTools.com Summary: The telltale battery light staying on means an alternator/generator replacement is needed in most cases. 2000 to 2005 1.8 Liter 5V Turbo engines in VW Passats and Audi A4’s have alternators that look easy to change, however access to the bottom alternator bolt can prove to be very difficult. The book labor time lists 2.8 hours to change this alternator! The most time consuming part of the job has to do with the front bumper removal to get to the fan so the lower alternator bolt can then be removed. The lower alt. bolt interferes with the fan if it is left in place preventing bolt removal. This car repair article is on how to change the alternator easily. DIYers along with some auto technicians that haven’t figured out the short cut (revealed in this repair article) will now be able to reduce the actual labor time by a couple of hours.
The alternator can be seen in this picture behind the fan.
For many jobs done on the 1.8 Turbo engine, the removal of the front bumper is required for easy access. The VW in the two images above was getting a new water pump and timing belt installed. The job was made much easier by getting the front bumper and radiator assembly completely out of the way. Many techs choose to loosen the assembly and use a special tool to hold it (or just longer bumper bolts works just as well). The assembly can then be slid out a couple inches to allow for a little more room for working. The alternator however can be changed without all the extra steps required to remove the bumper/radiator assembly.
Remove the air intake duct and weather stripping to allow more access.
There’s an 8mm Allen head bolt that goes from the backside of the fan assembly (shown just right of center). The two slots in the bracket allows for a tool to be inserted to prevent the pulley assembly from turning while loosening the bolt. A small drift (or substitute a 6 or 7mm Allen wrench) can be used to hold the pulley stationary. The pulley must be turned so the drift can be inserted when it is aligned with the slots, otherwise the pulley will just spin when the 8mm Allen is turned.
A close up of the 8mm bolt being removed – note the drift is NOT in place.
Image shows the bolt backed out and fan lowered.
With the fan assembly bolt removed the fan assembly can be dropped down to allow for access of the lower alternator bolt. This saves a lot of time by NOT requiring the removal of the front bumper assembly to take the fan off from the front-side.
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Bully :
Date: March 4, 2011 @ 8:24 pm
Thank you so much for posting this! Absolutely saved me a TON of time getting this job done recently. I was able to do the switch out in under an hour!
Cjbarnard :
Date: June 16, 2012 @ 5:02 pm
Should now be able to do this job myself on the drive instead of taking it to the garage, probably saving £200. Second hand alternator only £50, will check whether original or replacement has best set of brushes.
Sean :
Date: October 15, 2016 @ 2:48 pm
I removed the bolt for the fan assembly, but it is not falling to allow more access. What could be causing this?