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Thread: Alternator Removal/Replacement DIY?

  1. 09-20-2012 10:13 PM #1
    Hi there,

    I'm looking for an alternator removal/replacement DIY for a 2001 New Beetle, 2.0L - does anyone know where I can find one?

    I did use the Search function but could not find one.

    Thanks!!

  2. Member VWBugman00's Avatar
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    09-21-2012 12:52 PM #2
    Quote Originally Posted by USAFVR6 View Post
    Hi there,

    I'm looking for an alternator removal/replacement DIY for a 2001 New Beetle, 2.0L - does anyone know where I can find one?

    I did use the Search function but could not find one.

    Thanks!!
    So, I've not done an DYI on this, but I have done the work. It's actually pretty easy.

    1. Disconnect the negative wire on the battery.
    2. Remove the power supply, and connector from back of alternator.
    3. Put wrench on belt tensioner, and remove the belt. Take a note, or a picture of it's path.
    4. Remove 2 bolts that hold alternator in place.
    5. Get big pry bar, pry alternator out.
    6. Installation is reverse of removal. I think the bolts are torqued to 22 ft/lbs.

    Keep in mind, the alternator is a very tight fit (as is the space you'll be working in), and will take some wiggling to get into place, and probably the pry bar to get it into place. You may have to remove the pulley of the power steering pump to get to the lower bolt of the alternator. Be careful of the thermostat housing behind the alternator when you're removing the power wire on the alternator.

    You may have to remove a little more to get it out, but this should assist. Let me know if you've got any questions, I can always refer to my Bentley.
    Last edited by VWBugman00; 09-21-2012 at 12:55 PM.
    '00 Beetle, 1.8t T3S60, Brute Rods, Supertech Valve train (stock cam shafts for now), port and polished small port head, custom FMIC (pain in the a** on a Bug!), Bosch 440cc injectors, 3.5FPR, Catch Can, 2.0 Coils with Iridiums, Wilwood BBK, too much other stuff to list, too much $$ spent.

  3. 09-24-2012 10:00 AM #3
    Quote Originally Posted by VWBugman00 View Post
    So, I've not done an DYI on this, but I have done the work. It's actually pretty easy.

    1. Disconnect the negative wire on the battery.
    2. Remove the power supply, and connector from back of alternator.
    3. Put wrench on belt tensioner, and remove the belt. Take a note, or a picture of it's path.
    4. Remove 2 bolts that hold alternator in place.
    5. Get big pry bar, pry alternator out.
    6. Installation is reverse of removal. I think the bolts are torqued to 22 ft/lbs.

    Keep in mind, the alternator is a very tight fit (as is the space you'll be working in), and will take some wiggling to get into place, and probably the pry bar to get it into place. You may have to remove the pulley of the power steering pump to get to the lower bolt of the alternator. Be careful of the thermostat housing behind the alternator when you're removing the power wire on the alternator.

    You may have to remove a little more to get it out, but this should assist. Let me know if you've got any questions, I can always refer to my Bentley.


    That's really great, thank you!

    Do you have any photos or scans or any such thing, that would serve as a diagram?

  4. Member VWBugman00's Avatar
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    09-24-2012 05:35 PM #4
    Quote Originally Posted by USAFVR6 View Post
    That's really great, thank you!

    Do you have any photos or scans or any such thing, that would serve as a diagram?
    Sorry, I don't. When you look at it though, it'll be pretty self explanatory. Even in the bentley, there really isn't too many words there, just a picture. I'm sure you know what an alternator looks like, so just follow the belt up to the top, and you'll see the tensioner. Just release the tension and pull the belt off. Then you can access the bolts for the alternator.
    '00 Beetle, 1.8t T3S60, Brute Rods, Supertech Valve train (stock cam shafts for now), port and polished small port head, custom FMIC (pain in the a** on a Bug!), Bosch 440cc injectors, 3.5FPR, Catch Can, 2.0 Coils with Iridiums, Wilwood BBK, too much other stuff to list, too much $$ spent.

  5. 09-25-2012 05:10 PM #5
    Quote Originally Posted by VWBugman00 View Post
    Sorry, I don't. When you look at it though, it'll be pretty self explanatory. Even in the bentley, there really isn't too many words there, just a picture. I'm sure you know what an alternator looks like, so just follow the belt up to the top, and you'll see the tensioner. Just release the tension and pull the belt off. Then you can access the bolts for the alternator.
    Yes Sir, you were correct: very easy.

    Thanks very much for the help!!!

  6. Member VWBugman00's Avatar
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    09-26-2012 05:28 PM #6
    Quote Originally Posted by USAFVR6 View Post
    Yes Sir, you were correct: very easy.

    Thanks very much for the help!!!
    Not a problem, glad I could help
    '00 Beetle, 1.8t T3S60, Brute Rods, Supertech Valve train (stock cam shafts for now), port and polished small port head, custom FMIC (pain in the a** on a Bug!), Bosch 440cc injectors, 3.5FPR, Catch Can, 2.0 Coils with Iridiums, Wilwood BBK, too much other stuff to list, too much $$ spent.

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