Remove & Replace Passat B5.5 2.0 Liter TDI Alternator In 22 Minutes ...

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SgtArms S After seeing many somewhat tedious and altogether time consuming recommendations to replace my alternator on my 2005 B5.5 2.0 liter TDI -- including one to remove the entire front end (What?!?) I documented my steps below. I changed my alternator in 22 minutes flat from hood-up to hood-down. If you want to save yourself HOURS of wasted time...read on. Tools you'll need... - 19mm open-end wrench (for belt tensioner pulley bolt) - 13mm short socket (for alternator mount bolts, 2 each) - 8mm allen wrench (for rear fan pulley bolt, 1 each) - small rubber strap wrench (for fan clutch pulley) Instructions... 1. Remove upper engine cover (3 x 10mm nuts) 2. Looking down behind the radiator follow the alternator belt down and find the 19mm tensioner pulley nut (just to the passenger side of the fan clutch) 3. Rotate the tensioner pulley bolt COUNTER-CLOCKWISE to reduce belt tension and work the belt off the alternator pulley 4. Using the short end of the 8mm Allen wrench, locate the REAR of the fan clutch bolt (it runs forward) and place the Allen wrench into the bolt 5. Using a small rubber strap wrench (tip: clean rubber strap with alcohol first making sure any grease/residue is removed) install rubber strap wrench around fan clutch pulley. 6. Slowly rotate the fan clutch pulley until the 8mm Allen wrench comes into contact with alternator bracket (make sure Allen wrench is fully seated). 7. Hold Allen wrench in place and tighten rubber strap wrench and rotate fan pulley COUNTER-CLOCKWISE until fan bolt loosens 8. TIP: The idea is to remove the PULLEY from the bolt--not the BOLT from the pulley. (The pulley bolt is NOT reverse threaded.) 9. Once loosened, the fan clutch pulley will easily spin off by hand and drop free from the bolt. 10. Now you have LOTS of room to remove the two 13mm alternator mount bolts. 11. Process to install new alternator is the reverse of the above. 12. DON'T FORGET TO REVERSE YOUR RUBBER STRAP WRENCH BEFORE INSTALLING THE FAN CLUTCH PULLEY. 13. Whole process should take less than a half hour to complete and absolutely NO NEED to remove the radiator, complete front-end or any of that other nonsense. 14. Enjoy! #1 · Jan 30, 2017 After seeing many somewhat tedious and altogether time consuming recommendations to replace my alternator on my 2005 B5.5 2.0 liter TDI -- including one to remove the entire front end (What?!?) I documented my steps below. I changed my alternator in 22 minutes flat from hood-up to hood-down. If you want to save yourself HOURS of wasted time...read on. Tools you'll need... - 19mm open-end wrench (for belt tensioner pulley bolt) - 13mm short socket (for alternator mount bolts, 2 each) - 8mm allen wrench (for rear fan pulley bolt, 1 each) - small rubber strap wrench (for fan clutch pulley) Instructions... 1. Remove upper engine cover (3 x 10mm nuts) 2. Looking down behind the radiator follow the alternator belt down and find the 19mm tensioner pulley nut (just to the passenger side of the fan clutch) 3. Rotate the tensioner pulley bolt COUNTER-CLOCKWISE to reduce belt tension and work the belt off the alternator pulley 4. Using the short end of the 8mm Allen wrench, locate the REAR of the fan clutch bolt (it runs forward) and place the Allen wrench into the bolt 5. Using a small rubber strap wrench (tip: clean rubber strap with alcohol first making sure any grease/residue is removed) install rubber strap wrench around fan clutch pulley. 6. Slowly rotate the fan clutch pulley until the 8mm Allen wrench comes into contact with alternator bracket (make sure Allen wrench is fully seated). 7. Hold Allen wrench in place and tighten rubber strap wrench and rotate fan pulley COUNTER-CLOCKWISE until fan bolt loosens 8. TIP: The idea is to remove the PULLEY from the bolt--not the BOLT from the pulley. (The pulley bolt is NOT reverse threaded.) 9. Once loosened, the fan clutch pulley will easily spin off by hand and drop free from the bolt. 10. Now you have LOTS of room to remove the two 13mm alternator mount bolts. 11. Process to install new alternator is the reverse of the above. 12. DON'T FORGET TO REVERSE YOUR RUBBER STRAP WRENCH BEFORE INSTALLING THE FAN CLUTCH PULLEY. 13. Whole process should take less than a half hour to complete and absolutely NO NEED to remove the radiator, complete front-end or any of that other nonsense. 14. Enjoy! See less See more Sort by Oldest first Oldest first Newest first Most reactions #2 · Feb 18, 2017 I might need it in the future, thank you very much for taking the time to post this here. It sounds easy! Insert Quotes Post Reply

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