Problems trying to remove alternator

[bugdriver]

I have been trying to remove the alternator from my Mexi beetle and have run into a problem trying to lift the fan housing high enough to enable access to the bottom two bolts on the alternator plate. It appears that the throttle body and intake manifold will block the access to the blots and the removal of the alternator plate. Plus, I can't even lift the fan housing more than a cm right now, something seems to be stopping it and I can't find it.
Any tricks to this or is it just a miserable job where I have to disassemble the whole topside of the back of the engine?

[gramey lad]

Hi there bug driver!
Usually to do this job you would remove the engine to change the alternator. I have changed the alternator on my own mexi, it is a bit of a struggle though, but it can be done!
After you have undone the bolts on the side of the fanhousing (the small 10mm headed ones), undone the throttle cable and the cables going to the alternator, undo the alternator strap, unclip the wiring harness from the back of the fanhousing. You will have to remove the engine lid and the engine lid supports attached to the body - this will then give you enough room to lift up the fanhousing and allow you to get to the bottom alternator plate bolts, then simply wiggle the alternator and fan assembly out of the hole. Job done!
Re-assembly is a reversal of the above. Like I said, not easy, but it can be done by one person, but is easier with a friend to help.
Hope this helps

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2003 mexibeetle (engine no ACD451023)

[bugdriver]

I got all that done except the engine lid, but as i tried to lift the fan housing something seemed to be holding it back. Any idea what that might be? Do i have to pull the throttle cable thru after undoing it or will it be okay? I'll have to take the lid off and try again, but that will be another day, as i am running outa daylight and i half to work all week so the bug will have to wait! Thanks for the tips.

[gramey lad]

Hi,
You don't have to pull the trottle cable all the way through - just enough to allow you to lift up the fan housing.
Check and make sure that you have unclipped the wiring from the back of the fan housing.
Also check that on the back of the fan housing there is a piece of tinware that comes from the oil cooler that goes through the rubber seal - make sure that this isn't jammed.
Not sure if your fan housing has the directional flaps inside, if so these will be connected to a thermostat underneath the engine, in which case this will also need disconnecting. Make sure that you take the brackets off the engine lid that are connected to the body, otherwise you won't get enough clearance.

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2003 mexibeetle (engine no ACD451023)

[bugdriver]

Ok, thanks for that, I'll look for those things when I go at it again. Thanks for the tips!

[phade]

Hiya Bugdriver,

I used to remove the engine lid to change my alternators (and my orange beetle's dynamo). I had recently found out that there's an easier method of changing the alternator.

To remove the alternator do the following:-

- Disconnect the battery earth

- Disconnect all electrical connections from the alternator

- Use a screwdriver to jam the alternator's pulley

- Now get inside the fan housing and remove the large fan nut. Be careful not to lose any shims.

- Now undo the top pulley and remove the alternator belt

- Undo the alternator's securing strap

- Undo and remove all four mounting bolts on the fan housing

- Now pull the alternator backwards (be careful not to lose the woodruff key !!!). This will separate the alternator from the fan.

- The alternator should now be easily removable


To re-install the alternator, do the following:-

- Put the alternator with the mounting plate loosely onto the fan housing and alternator stand

- Now push the fan back onto the alternator's shaft

- Lightly grease the fan nut's shims. This will make them stay in place when they are on the alternator's shaft.

- Loosely put the fan nut back onto the alternator's shaft

- Tighten the alternator's four mounting bolts on the fan housing

- Tighten the alternator's securing clamp

- Re-install the fan belt and top pulley. Lock the top pulley into place with a flat blade screwdriver.

- Tighten the top pulley nut to 43 lb/ft or 58 Nm

- Tighten the fan nut to 43 lb/ft or 58 Nm

- Reconnect the alternator's electrical connections

- Check the fan belt's deflection. The correct deflection is the following:-

- - Using a mechanical ruler: 11mm to 14mm

- - Using VW 210: 17.5 to 18.5 (old)
17 to 18 (new)

I hope this will make changing the alternator a lot easier

Cheers,

Phil

[bugdriver]

Hi Phil
Okay that sounds easy except....
How do I get into the fan housing?
Even if I could, the bottom two bolts on the fan plate are hidden behind the fuel injection throttle body and intake manifold, so I have to lift the fan housing to get at them, or remove the all the intake and F.I. stuff on the engine( I considered that but it just makes it sound easier to drop the engine!)
Are you talking about an ACD engine?
BD

[phade]

Hiya Bugdriver,

You really don't need to remove the engine (I am talking about the ACD fuel injection engine).

What I forgot to mention was to slacken the two bolts which hold the fan housing into place (one on each side) and lift up the fan housing. To access these bolts you will need a short 10 mm ring spanner.

I also forgot to mention that the throttle body will need to be removed. You do not need to remove the inlet manifold centre piece.

You should then be able to lift up the fan housing to access the two lower bolts. After these have been undone, you should then be able to remove the alternator.

Note: You may need to quickly pull the alternator rearwards to detach the fan from the alternator's shaft (providing you have undone the fan nut first !!). Make sure that the woodruff key is in the upright position.

Good luck with your car,

Phil