Alternator Pulley Replacement

[damian33]

Hi,

What is the best way to replace the alternator pulley on this Golf model.

I need to raise the alternator around 20mm to be able to insert the spline tool. Initial thoughts were to remove the alternator bolts and try and wiggle it up a bit but can’t quite work out how to access the top bolt on the alternator (not sure if hidden behind the tensioner or just in a deep gap). Bottom bolt is easy enough through the wheel arch.

I’ve heard some suggest jacking the engine up as there is likely to be some tolerance on the mounts but have no knowledge of the best way to do this and any risks to avoid, etc.

Bought a new pulley and belt and keen to get done to deal with the noise from the flapping belt (alternator pulley seems to have lost its ability to freewheel but not bad I guess for 225k miles so far). Ended up with the DMF replaced and advised after this was done that the original symptoms I took it in for were down to the pulley. Pretty sure DMF still had some way to go before any main issues and only had 70k on it.

Many thanks for any advice.

Damian

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[Crasher]

We take them off and do them in the vice with an air gun as often they are VERY tight.

[damian33]

Hi,

Thanks for the info.

Well major schoolboy error as normal - with having a couple of days free, thought I'd have a go at loosening the alternator and get the spline tool on it to see if I could get the pulley off in-situ. No chance, absolutely no room to do anything and now left with the alternator rocking 20mm out of position but can't get it out or back. So I'm in a mess and luckily don't need to use the car tomorrow (but concerned I'm stuck).

Looking at the manual (which I need to read up further), looks like I need to some more things off the front of the car, as well as drop the a/c compressor (although not quite sure why this is necessary if the alternator is coming out of the top). Certainly at the moment it is rocking 10mm or so back and forth but needs some leverage to shift it. Didn't remove the cables at first as limited access Aden though they could be done one the alternator was free of the bracket but now managed to disconnect the 2 leads thinking they may be stopping it moving further (can't get access to any bolt hold the cables to the bottom of the alternator.

If I can't get sorted in next couple of days, I'm a bioty stuffed and will need to get a tow somewhere!!

Section 4.11 of the Repair Manual has the following instructions for Golf Mk6 TDI:

============

– Disconnect the battery. Refer to⇒ “4.1 Battery, Disconnecting and Connecting”, page 20 .
– Pull off engine cover upward in direction of -arrows-.
– Remove the air shroud with Coolant Fan - V7- and, if equipped, Coolant Fan 2 - V177 Refer to ⇒ Engine; Rep. Gr. 19. [I need to read up on this]
– Remove the Throttle Valve Control Module - J338- . Refer to ⇒ Engine; Rep. Gr. 23 ; Removal and Installation . [I need to read up on this]
– Remove the air filter housing. Refer to ⇒ Engine Fuel Mixture Preparation; Rep. Gr. 24 ; Removal and Installation . [I need to read up on this]
– Remove the ribbed belt. Refer to ⇒ Engine Mechanical, Fuel Injection and Glow Plug; Rep. Gr. 13 ; Removal and Installation . [Done]
[A/C Compressor]
– Disconnect the connector -1-.
– Remove A/C compressor screws -arrows-
[Alternator]
– Disconnect the DF lead connector -1-. [Done]
– Pry off cap -2-.[Done]
– Remove nut -1- and B+ wire below from generator connector threads [Done]
– Remove nut -3- and remove wiring bracket -2- from generator.
[Fuel Filter]
– Remove both of the bolts -1- and the nut -2- for the fuel filter -3- and lay them aside. The fuel hoses can remain connected. [Done]
[Alternator]
– Remove both generator mounting bolts -arrows-. [Done]
– Remove the generator upward to the left and out of the vehicle

============

So in summary, I'm up the creek and looking for a paddle!!

Any advice appreciated - feels like I should remove the thing and sort the pulley (or just get a new alternator given age / mileage) but can't get the thing out at the moment.

Many thanks,

Damian

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[Crasher]

That is why we ignore the book of words and do it on the bench.

[damian33]

I think I’m realising that now!!

Given I’m a bit stuck, as doesn’t seem to be going back in and can’t get much purchase on it, to get to the bench, you must have to remove the fans to give some space to bring it out around the air intake area?

For now I will try and get it back in but feel like it needs getting out and cleaning up the fixings to do so!

I will try again to get it back in and then perhaps arrange a trip up to Nottingham (from Coventry).

[damian33]

An update...


Managed to get it out but need to take off a few bits of equipment to create an opening - nightmare.

I've got the old pulley off but just cannot get 85Nm torque on the new one. Don't have a bench vice which doesn't help, just the ability to make a mess of the kitchen floor. Whether my torque wrench is a bit naff or I'm missing some leverage on th 17mm spanner I don't know. I'm just locking the spanner against the floor whilst putting weight on alternator and wrench but just not enough and the pressure is lifting me.

Any ideas on how I can get more torque - is it just physics and I need to find a pipe that I can fit the spanner in??

Many thanks,

Damian

[damian33]

Worked it out - cheapish torque wrench only measures in a clockwise direction, so no good in this situation to get an accurate reading going anti-clockwise. Will assume that as I removed the pulley with the same approach, having exerted more perceived force in fitting the new one, I must be somewhere North of 85Nm and it will be a new alternator should it ever come out again.

Will invest in a better wrench in future.