Need Help ! Alternator Replace 2006 2.5L Gas Beetle

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1998-2011 New Beetle
2.5 Liter Gas

Gitmobeetle G Sorry for re-post...just noticed this was in the 2012 + section. ------------------- Hi, seems to me that I brought this issue up as a reply on another thread, but now it does not show up. Sorry if this is duplicative. Helping my son with alternator replacement in a 2006 2.5L gas beetle. I have not found any videos that address this job. The closest thing I found is a gentleman on Youtube that approaches the job by removing the A/C compressor, then the belt idler pulley, and then has ample room to pull the alternator from the bottom. His car is a 2011 2.5L that apparently has much more room on top and from the bottom than ours. I attempted the same thing, and found that the A/C hoses are tangled so the compressor cannot hang down far enough(Probably a factory mess-up). The only way I can see being able to use this strategy is to also remove a shiny Aluminum bracket on which attaches both the A/C compressor, as well and the idler pulley. It looks do-able, but I worry that I don't see that approach written up anywhere. The poor E-book manual that I have is cryptic, and tells me to remove the front of the car ?...does not say anything about the radiator, fans etc... but all of those would have to be removed in order to pull the alternator out the front...curiously enough, this procedure then tells you to remove the A/C compressor, and also says that the alternator can then be removed downwards, which makes me wonder why remove the front in the first place? Anyone that has done this job on a 2006 through 2010, please give a shout on how you approached this job. Once I complete the job I will do my best to post the details with pictures to make it easier for the next poor soul that has to disassemble the car in order to get the alternator out. Many thanks in advance for your inputs. #1 · Sep 24, 2017 Sorry for re-post...just noticed this was in the 2012 + section. ------------------- Hi, seems to me that I brought this issue up as a reply on another thread, but now it does not show up. Sorry if this is duplicative. Helping my son with alternator replacement in a 2006 2.5L gas beetle. I have not found any videos that address this job. The closest thing I found is a gentleman on Youtube that approaches the job by removing the A/C compressor, then the belt idler pulley, and then has ample room to pull the alternator from the bottom. His car is a 2011 2.5L that apparently has much more room on top and from the bottom than ours. I attempted the same thing, and found that the A/C hoses are tangled so the compressor cannot hang down far enough(Probably a factory mess-up). The only way I can see being able to use this strategy is to also remove a shiny Aluminum bracket on which attaches both the A/C compressor, as well and the idler pulley. It looks do-able, but I worry that I don't see that approach written up anywhere. The poor E-book manual that I have is cryptic, and tells me to remove the front of the car ?...does not say anything about the radiator, fans etc... but all of those would have to be removed in order to pull the alternator out the front...curiously enough, this procedure then tells you to remove the A/C compressor, and also says that the alternator can then be removed downwards, which makes me wonder why remove the front in the first place? Anyone that has done this job on a 2006 through 2010, please give a shout on how you approached this job. Once I complete the job I will do my best to post the details with pictures to make it easier for the next poor soul that has to disassemble the car in order to get the alternator out. Many thanks in advance for your inputs. See less See more Sort by Oldest first Oldest first Newest first Most reactions #2 · Sep 25, 2017 Some pictures Alternator replace Feels a bit lonely, so I'll break my own ice and start replying ! I pulled down the a/c compressor again, (pict 1) and for sure, there is not enough room to pull the alternator as it sits. The bracket to which the A/C compressor and the idler pulley connect, also holds the alternator itself, so I cannot pull this thing until the alternator comes out, thus defeating the purpose of pulling it. Pic 5 shows the bracket in front of the alternator. The four holes are the attachment for the idler pulley that I already pulled off. The other avenue will have to be to get rid of the power steering pump line that VW conveniently wrapped around the alternator (Pic 4). I'm pretty sure this is the return line for the P.S. pump (pic 2), it is a black solid steel pipe all the way from the pump to the front middle of the car, past the A/C compressor, where it becomes a flexible hose...too late to do me any good in getting it out of the way of the alternator. I tried to loosen a nut that attaches it to the bracket (Pic 3), but it barely gained me 1 cm of play ( way not enough !) If I can't get any good feedback from the forum, then my option will be to pull the return line (pic 2) off the power steering pump. Hate to do this for 3 reasons: 1- it will make a mess with a lot of fluid spilling all over the place 2- I'll probably have to get into a lengthy process of bleeding the P.S system 3- I have found not a peep about pulling this line from anyone on the net , and I am now sufficiently gun-shy about VW engineering, that I am afraid I will screw something up by pulling it. Appreciate any feedback...did I say it feels lonely on this thread ?

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#3 · Sep 25, 2017 Correction to Post 2 Correction to previous post. The line that I may have to take off the power steering pump is the high pressure line, not the return line. The high pressure line is metal starting from the pump, coiling around the alternator (really !), and continuing past the a/c compressor and towards the front middle of the car where it finally becomes a flex hose. #4 · Sep 26, 2017 Alternator replace update. Anyone out there !!! Pipe in if you have good inputs...all ideas will be considered ! Given that I did not receive any inputs I went ahead and pulled the power steering pressure line off, and the mess was less than I would have expected, but still considerable leaking all over the place, as there is no room to slide even a plastic bag to catch the dripping. Loosening the pressure line did give me a considerable amount of play around the alternator (pic 2) , and made me feel that I was winning this fight. A dark cloud came up once I realized that a hose in the background around where the alternator would pivot, was actually... !another black pipe !. We decided to push ahead and try to remove the alternator anyway to see if we could wiggle it through. Taking the two bolts off was totally easy (an ominous sign), and then reality sank in. The alternator was not moving even with the two bolts completely removed and sitting on the floor. Turns out that the Bosch engineers in their wisdom put in bushings on the alternator that rust badly. Not one trace of rust on the whole car except on the alternator bushings. There is no room for a pry bar, and trying it had zero effect. Ten minutes after spraying with Blaster PB50 anti-rust, picked up a piece of 2x2 wood, and whacked it with a hammer about ten times and now I have the alternator loose from the lower bushing, (Pic 1) but the top one remains firm. Will look for some small opening where I can whack it from the top (with a smaller piece of wood. After all this work and trying crazy ideas, I feel like I am on the verge of discovering nuclear fusion, but it is only the removal of a frikking alternator from a little car I am beginning to seriously dislike. Hope someone comes up with pearls of wisdom...I need some right about now.

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#5 · Sep 26, 2017 Tiny victory After a bit more well directed PB Blaster right on the top bushing, waited 10 min, and used a piece of 1x1 to whack alternator downwards, with the only effect being that it came to rest in the original position (both upper and lower bushings correctly lined up for bolt insertion) I again went back to the bottom and gave it about 8 whacks again, and again got the lower bushing off the bracket. At this point I grabbed the alternator hard with a shop towel, and finally managed to rotate it back and forth about 1/2 " on the upper bushing. Not coming out mind you, but showing glimmers that it might someday ! I can't take this much winning, and it's late, so I am quitting for the night while I am slightly ahead. Don't forget to send in your cards and letters offering suggestions. The winning suggestion will receive honorable mention! #6 · Sep 26, 2017 Another setback. This morning I got a bit of time, so I went to the car and again, alternator rotates, but won't come out of top bushing. I inserted a big flat blade screwdriver between bottom bushing and bracket, to prevent alternator from going back into its normal position for bolt insertion, and then had my son give it about ten whacks from the top with a 2x1. There was some movement, but not enough to pull it out from the bracket. It is incredible that VW opted for such close tolerances, in an alternator where there is barely any room to do anything. The fact that Bosch then used cheap material for the alternator bushings (only rust spot) makes this an almost impossible situation. Again, if anyone can offer suggestions, please pipe in...I can use all the help I can get right now...coming close to throwing in the towel. I can't believe I am saying this. I have changed 30 to 40 alternators in many years of tinkering with cars. I never had a case even remotely as insane as this one.

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#7 · Sep 26, 2017

Gitmobeetle said: This morning I got a bit of time, so I went to the car and again, alternator rotates, but won't come out of top bushing. I inserted a big flat blade screwdriver between bottom bushing and bracket, to prevent alternator from going back into its normal position for bolt insertion, and then had my son give it about ten whacks from the top with a 2x1. There was some movement, but not enough to pull it out from the bracket. It is incredible that VW opted for such close tolerances, in an alternator where there is barely any room to do anything. The fact that Bosch then used cheap material for the alternator bushings (only rust spot) makes this an almost impossible situation. Again, if anyone can offer suggestions, please pipe in...I can use all the help I can get right now...coming close to throwing in the towel. I can't believe I am saying this. I have changed 30 to 40 alternators in many years of tinkering with cars. I never had a case even remotely as insane as this one. Click to expand...

Hey Gitmobeetle sorry I can't be of help but try calling this number (818) 896-5666 and talk to Tony he's experienced with vw/Audi maybe he can offer some help. Here's a link to his page: http://www.youraudivwwarehouse.com 1 Reply #8 · Sep 27, 2017 Thank you LittleRed Hey LittleRed, many thanks for clueing me onto Tony. He is a truly nice guy, and took the time to go through some ideas with me and texted me a couple of pictures. Tony thinks that the way to do this is to drop it through the bottom as I have attempted to do. I think he is thinking of a 2011 to 2013 Beetle where they made a lot more room and change some thing that make it a total piece of cake to just drop the compressor out the way, and the alternator just comes straight out the bottom. In any case, Tony should be a resource to everyone on this site. Used parts and friendly help...can't beat that ! Again, many thanks for your input...you have given me some more hope. #9 · Sep 27, 2017 Maybe a 40 yard gain tonight Tried a bunch of ideas tonight to loosen alternator from its rusty top bushing. Whacking was not doing it, so screwed in a bolt and then whacked the lower one to see if I could drive the bushing back in a bit, but too rusty for that to happen. Also tried to screw in a bolt halfway into bushing, and then another bolt going the other way, with the idea of forcing the bolts against each other and thus force the bushing back in...also no go. all the while giving the top bushing a spray of PB blaster. Finally decided to try rocking it back and forth on the bushing and apply a twisting motion to alternator, and after about 15 minutes of this I finally felt it start giving way and traveling downward slightly until it cleared the upper bushing and came free (Pict 1). Too tired to continue, so tied the alternator down with some wire , and tomorrow I will remove the connectors and try to wiggle it completely out of the car. Putting the new one in should be a lot easier, because the bushings on the new one are outside of the channel (Pict 2) , rather than inside the channel in the original one. My guess is that the bushing moves in as the mounting bolts are being torqued. Will update tomorrow if I get time to work on it.

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#10 · Sep 27, 2017 I'm glad you got some ideas from Tony he was immense help when I started my journey with my beetle. And I'm also glad you finally got the damn thing out! Keep us updated! #11 · Sep 29, 2017 Just reverse the steps to replace Removing the rusted bushing alternator was the worst and most challenging job I have done in a car in a very long time, maybe ever, so now replacing should have been a piece of cake without the rust problem...well not quite! Let's not forget about the high pressure power steering pipe removed in post 3. This thing that VW stupidly made a rigid pipe, and then even more stupidly, wrapped it around the alternator, now becomes a huge factor when you want to put the alternator back in. You can put the alternator in, and then try to put the high pressure pipe back in place...impossible, there is no room as there is zero flexibility in this pipe. Then you try the other way...you loosely put the pipe right near where it belongs, and now there is no room to put in the alternator. At this point my son and I have taken a break in frustration and sweat. The only way that we can possibly see putting both items back in will be if we put then back in at the same time. This means we wrap the pipe around the alternator near the ground and start inserting them both at the same time, and hope that they can together make the turns necessary, as there is no way for the alternator to go straight back up. I doubt this will work, but it is the last thing we can possibly try before we totally and radically change strategy. Tomorrow I may try to go by a VW dealer and try to sneak a talk with one of the mechanics to see if they can offer any options except "tow it in, and we'll take care of it". All of this B.S. could have been avoided if VW permitted the swap of the voltage regulator which is the only thing wrong with the alternator, but they will not allow that either, as I could not locate a regulator I could feel would work, after a couple of hours of looking. Earlier this morning I saw that one of the VW executives was indicted for the emissions cheating scandal...I thought to myself that maybe this guy was the one who decided on these great engineering ideas that I have been describing...If so, I hope the prosecutor turns out to be a steel toothed pit-bull. #12 · Sep 30, 2017 Accepting defeat...changing srtrategy. Apparently the only way we will get this alternator re-installed, will be to follow the cryptic procedure that calls for removing the front end. This will work because this procedure also involves putting the "lock carrier" into the "service" position, which means that you move the whole front end with radiator, fans, and hoses attached, forward 4 to 8 inches, which would be more than enough to make the alternator go straight in. Today I went by two of the local VW dealers. The parts people played dumb when I asked them about the lock carrier, service position,and the special bolts to make the lock carrier slide forward (as if they did not exist) . In one dealer I talked to a mechanic that played dumb about ever having worked on a New Beetle. At the other, the mechanic would not answer direct questions about whether they use the special tools, whether you need to extend the lock carrier to get the alternator out, and finally told me " Sir, why don't you ask these questions from Amazon.com, and try to have a nice day". Very obvious that these guys see DIY as some sort of threat to their livelihood, and they are not sharing even a bit of information. As it turns out, my local library has access to a database that contains all the Chilton manuals, so hopefully I will be able to get the details about these procedures and the special tools there. Again, since I have not seen anyone explain how to use the lock carrier on this web site, once we have completed this job, we will possibly create a new thread with pics that covers this end to end. I may also end up having to make two of the special bolts for the lock carrier, and if so, I will explain what I did on those as well. Wish me luck ! #16 · Dec 12, 2017

Gitmobeetle said: Today I went by two of the local VW dealers. The parts people played dumb when I asked them about the lock carrier, service position,and the special bolts to make the lock carrier slide forward (as if they did not exist) . In one dealer I talked to a mechanic that played dumb about ever having worked on a New Beetle. At the other, the mechanic would not answer direct questions about whether they use the special tools, whether you need to extend the lock carrier to get the alternator out, and finally told me " Sir, why don't you ask these questions from Amazon.com, and try to have a nice day". Very obvious that these guys see DIY as some sort of threat to their livelihood, and they are not sharing even a bit of information. Click to expand...

Wow. deutsche bags. 0 Reply #13 · Oct 2, 2017 Re:Alternator This is probally a job to put car in front clip service postion...The front clip of bug slids foward just a bit to do job...... #14 · Oct 7, 2017 Success...Finally !! After having to totally change my strategy, I ended up having to remove the front bumper which comes out as an assembly along with the left and right front fenders, and then manufacturing my own bolts to extend the lock carrier into the service position. With that I was able to extend the front end (radiator, fans, and other doodads )about three inches from the frame, which was enough to put the new alternator in place. For anyone attempting this job, many portions of it will be a two person job, so make sure that you have a friend lined up for certain sections. Also, make sure that you download files from the internet with the 100 worst curses in both Spanish and German. This will come in handy to relieve the frustration you will encounter with the idiotic German engineering, and the extremely crappy Mexican materials and manufacture. The car is still up on jack stands, but the new alternator, A/C compressor, and the Power Steering High Pressure line are bolted tight on the car, and after testing, the alternator measured a healthy 13.78 v, which should be perfect as the battery was a bit weak when we fired up the car. I have taken lots of pictures and as time allows, will put together a tutorial for whatever poor soul is cursed with this job down the road. If one of the moderators can PM and let me know how I could upload a five to six page tutorial with pictures, I will hopefully before the end of the year upload the tutorial. My thanks to LittleRedflea and all who helped. #15 · Oct 11, 2017 Thank you for making this post. We just bought our daughter an 07" 2.5 Beetle and on the way home we found out the hard way that the alternator is bad. I'm starting the same project tonight hopefully. I need to know if you would have done anything different with the removal had you put the car in the "service position" first. Would the alternator still had to be taken out though the bottom? Would you still needed to remove the power steering line? Thank you for sharing your challenges with us. BeetlerepairDAD #17 · Jan 11, 2019 Wish I had seen this a few days ago I am working on replacing the alternator on my girlfriend's 2006 Beetle and have run into some of the same problems you did. I had a heck of a time removing the top mounting bolt from the alternator, because of the lack of space. I ended up removing the power steering fluid reservoir and cracking it in the process. :-( After that, and after trying various combinations of ratchet and extension, I got it out. I am now at the point where the alternator is hanging on the lower bushing. The upper bushing did not cause a problem. Anyway, does anyone know whether Gitmobeetle posted his tutorial and photos anywhere? #18 · Apr 30, 2019 (Edited) I found this thread, as well as a video shared to me by John Reid on the facebook group. Using these tools, I have documented my process for doing this alternator swap. Hopefully I show in pictures the way I *relatively* easily performed this aggravating procedure. Good luck with your own alternator swaps everyone! How-To: Alternator Swap 2.5L (2005-2009) Video: https://youtu.be/9w2oDTFAUwg?fbclid=IwAR18mHGUYslwY1Chji2oBxEItMitVHBQgomVH3y5WPp6UeP6mIAv_OVVrCI #20 · Sep 28, 2024

Froggy said: I found this thread, as well as a video shared to me by John Reid on the facebook group. Using these tools, I have documented my process for doing this alternator swap. Hopefully I show in pictures the way I relatively easily performed this aggravating procedure. Good luck with your own alternator swaps everyone! How-To: Alternator Swap 2.5L (2005-2009) Video: Click to expand...

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