Alternator Pulley Replacement... | VW Vortex - Volkswagen Forum

Có thể bạn quan tâm

Menu Log in Sign up

Home
Forums
VW Model-Specific Forums
Golf & Jetta (all Gens)
Golf III & Jetta III

Stealth_TDI

Hi, I considered placing this in a technical forum. However, the alternators are common across all A3s (with the exception of 120A spec on a TDI). Therefore, I thought it would get better exposure and attention here. I've been getting some squeaking from the alternator area. I was afraid it was a bad bearing. The problem went away over the winter. Now that it's warm, the problem is back and even worse. Sounding more like a belt, I gave a look and found chunks missing out of the serpentine belt. So I figured that was the problem... a squeaky belt. I replaced the belt and the problem persists. Upon inspection of the alternator pulley, I discovered the pulley is rotating along the shaft. I'm unsure if it can be tightened. BTW, removing an alternator from an A3 TDI is an absolute PITA. I had to remove the right-hand headlight, uncouple an AC bracket, then lift the AC line up about 18" to clear a path for the alternator to come out from behind where the headlight used to be. :shock: ANYWAY, my goal is to figure out how to tighten up this pulley or replace it. I'm certain there is nothing wrong with the alternator. I found a cover that I've removed. However, there are tools needed that I do not have. Check this out:

This photo is looking at the alternator from the pulley side. These splined fittings are inside the pulley area. Surely someone in here has replaced an alternator. Looking at NEW alternators, it appears they are not shipped with pulleys. So this pulley would have to come off whether I'm replacing the pulley or needing to transfer it to a new alternator. That also suggests the pulley can be replaced independently. Does anyone know what I need to do to replace this pulley? With over 200,000-miles on the car, the alternator owes me nothing. Should I just replace it while it's out? My gut says NO. But it would suck to put it back in and have it fail in a few months. :lol: I appreciate your advice... Thanks! Scott #1 · May 19, 2006 Hi, I considered placing this in a technical forum. However, the alternators are common across all A3s (with the exception of 120A spec on a TDI). Therefore, I thought it would get better exposure and attention here. I've been getting some squeaking from the alternator area. I was afraid it was a bad bearing. The problem went away over the winter. Now that it's warm, the problem is back and even worse. Sounding more like a belt, I gave a look and found chunks missing out of the serpentine belt. So I figured that was the problem... a squeaky belt. I replaced the belt and the problem persists. Upon inspection of the alternator pulley, I discovered the pulley is rotating along the shaft. I'm unsure if it can be tightened. BTW, removing an alternator from an A3 TDI is an absolute PITA. I had to remove the right-hand headlight, uncouple an AC bracket, then lift the AC line up about 18" to clear a path for the alternator to come out from behind where the headlight used to be. :shock: ANYWAY, my goal is to figure out how to tighten up this pulley or replace it. I'm certain there is nothing wrong with the alternator. I found a cover that I've removed. However, there are tools needed that I do not have. Check this out:

1 Sort by Oldest first Oldest first Newest first Most reactions #2 · May 19, 2006 Re: Alternator Pulley Replacement... (Stealth_TDI) Wow 120A alt! Hot ticket man! It looks like that pulley is pressed on to the shaft?

3 Jaw puller? I know mine (Non TDI) units have a nut that holds them on (like most std units). #3 · May 21, 2006 Re: Alternator Pulley Replacement... (Dan J Reed) Hi, I've found a few things. First, the pulley can be purchased separately. It's ONLY $114... about half the cost of a reman'd alternator (without a pulley, I'm sure). I've found two places that offer the pulley for under $90. I'll give them a call in the morning. I've also found a tool that will help me remove the pulley:

I ordered it yesterday morning and hope to have it by Wednesday. Since no one spoke up about having seen this fitting, I have to wonder if I'm among the first to have this particular pulley give out? I'll post pics of the broken parts once I receive the tool and remove it. Oh, the spare time has given me the chance to finish up the silicone hose on my intake. While looking at the fit, I found a rare photo opportunity that shows the intake from a different perspective:

You can also just barely see where I had to cut the radiator support to fit my E-codes. Take Care, Scott Take Care, Scott #4 · May 26, 2006 Re: Alternator Pulley Replacement... (Stealth_TDI) Okay. Here are the photos: First, my alternator removal lesson... The AC line is smack in the way of getting the alternator out nice and easy. The only way to move the AC line is to unbolt it and lift it up to slide the alternator under it. The only way to unbolt and lift the AC line is to remove the headlamp. The only way to remove the headlamp is to remove the grill... :roll:

Here you can see the AC bracket I needed to unbolt after removing the grill and headlamp...

Now another lesson... I didn't need to remove the alternator to replace this pulley. In fact, the pulley was on there so tight I HAD to reinstall the alternator so it would be braced well enough for me to hork on the 30-spline pulley nut with a 20" cheater bar. That thing was TIGHT! Here's the old pulley. You can see the center section just sort of let go and the outer section started to slip around the center piece...

It's tough to see; but there are little tiny cracks along the inside of the out piece. You can also see a chip on one part...

The nice, shiny new pulley...

Oh, here's the alternator shaft (I know... I said "shaft"...) :lol:

Apparently, these wacky pulleys made their first appearance in TDIs. They're designed to engage the alternator in only ONE DIRECTION. I guess when you cut off the engine either the sudden stop of the engine or a TINY amount of reverse motion (as the engine comes to rest) causes small voltage spikes that can shorten the life of the alternator. This pulley allows the alternator to spin down separately from the engine. I guess it was an "upgrade" to prolong the life of the alternator. One parts guy told me all the new VWs have these things. But my 2003 Passat w/1.8T does NOT have this pulley. So I'm guessing it's a TDI-only thing. What I don't understand is why a TDI would need this pulley and the other plants do not. :shock: Oh well. It was an interesting lesson. I now have the tool in case I need to swap pulleys again. Now I'll monitor an intermittent N109 Fuel Cutoff Valve fault that MAY have been caused by the pulley. I have a spare part on hand. But the new pulley might have fixed my problem. Time will tell. My VAG-COM has paid for itself over and over again. 8) Take Care, Scott Insert Quotes Post Reply

posts 85M members 1.5M Since 2001 A forum community dedicated to all Volkswagen owners and enthusiasts. Come join the discussion about performance, builds, modifications, classifieds, troubleshooting, maintenance, new releases, and more! Show Less Full Forum Listing Explore Our Forums The Car Lounge Golf IV & Jetta IV Golf III & Jetta III Golf II & Jetta II Golf IV/Jetta IV Parts