Question about 2003 Volkswagen Golf

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VW alternator won't fit on brackets on engine

I installed an alternator on my car about a year ago (first time doing so) and everything went smooth. It worked for about a year and now I'm in the same situation having to replace it. Ok...fine, it should go even SMOOTHER now that I know what I'm doing. Well, I went to put the new alternator on the housing/brackets that it bolts to and it won't fit. It looks like there are round metal pieces on one side that the screw/bolt threads into and that piece is too think and the alternator won't slide onto the brackets it's supposed to be screwed onto. Is there a way to squash these things down, or file them or should I just take it back and tell the store that it won't fit??

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You need to widen the gap between the tabs. This will allow the alternator to slip over the bracket much easier. Get a socket big enough to allow the threaded insert to be driven inside it. (18/19mm) Then thread the bolt in a few threads and give the bolt a few taps with a hammer until the threaded insert moves about 1/8" or so. This will allow the alternator to fit easily in the bracket and the insert will be pulled back in as the bolt is tightened.

Posted on Feb 28, 2009

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You need to take it back and get the proper one, DO NOT FILE OR GRIND ON IT! This will void your warranty and you will be stuck with an alternator that don't fit and unusable.

Posted on Aug 29, 2008

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  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Drain the cooling system.
  3. Remove or disconnect the following:
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About alternator replacement for 2001 vw beetle gls...I've removed the upper and lower bolts... What am I missing? Alternator still won't budge. Any assistance would be appreciated. Thanks.


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Changing alternator



REMOVAL & INSTALLATION 2.2L Engines
CHRYSLER ALTERNATOR

  1. Disconnect the negative battery cable.
  2. Label and disconnect the wiring (for easy installation).
  3. Remove the air conditioning compressor drive belt, if equipped.
  4. Loosen the alternator adjusting bracket bolt and adjusting bolt. Remove the alternator belt.
  5. Remove the bracket and mounting bolts.
  6. Remove the pivot bolt and nut.
  7. Lift the alternator from the vehicle.

When lifting the alternator out of the vehicle on some years with A/C, clearance may be restricted by the condenser cooling fan assembly or the A/C compressor and mounting bracket assembly, if so, removal of one of these items will be necessary.
To install:
  1. Position the alternator against the engine.
  2. Install the pivot bolt and nut.
  3. Install the mounting bracket bolts, and adjusting bolt.
  4. Install drive belts and adjust to specification.
  5. Tighten all the mounting bolts and nuts.
  6. Connect all alternator terminals.
  7. Connect the negative battery cable.

BOSCH ALTERNATOR
  1. Disconnect the negative battery cable.
  2. Disconnect the wiring and label for easy installation.
  3. Remove the air conditioning compressor drive belt.
  4. Loosen the alternator adjusting bracket locknut and adjusting screw. Remove the alternator belt.
  5. Remove the bracket locknut and mounting bolt.
  6. Remove the pivot bolt and nut.
  7. Remove the alternator from the engine.

To install:
  1. Position the alternator against the engine.
  2. Install pivot bolt and nut.
  3. Set the mounting bracket in place and install the bracket mounting bolt and locknut.
  4. Install the drive belts and adjust to specification.
  5. Tighten all the mounting bolts and nuts.
  6. Connect all alternator terminals.
  7. Connect the negative battery cable.

Jan 02, 2011 | 1994 Plymouth Voyager

2 Answers

How do you install the alternator


1990-93 Accord
  1. With the ignition OFF, disconnect the negative battery cable.
  2. Remove the power steering pump. Refer to Section 8 for the complete procedure.
  3. Remove the cruise control actuator but do not disconnect the actuator cable; simply move the unit out of the way with the cable attached.
  4. Unplug the multi-pin electrical connector.
  5. Remove the terminal nut and remove the wire from the terminal.
  6. Loosen the adjusting bolt; remove the alternator nut. Fig. 3: Alternator mounting on 1990-93 Accords 86803003.gif

  7. Remove the belt from the alternator pulley.
  8. Remove the adjusting bolt, the lower through-bolt and the small support stay.
  9. Support the alternator. Remove the upper through-bolt and remove the alternator.
  10. If desired, remove the alternator mounting brackets. To install:
  11. If the alternator brackets were removed, reinstall them. Coat the bolts with a thread sealer or liquid thread lock. Install the bracket bolts and tighten them to 36 ft. lbs. (50 Nm).
  12. Fit the alternator into place. Install the upper through-bolt and tighten it to 33 ft. lbs. (45 Nm).
  13. Install the small stay, the lower through-bolt and the adjusting bolt. Make certain the adjusting bolt is properly installed.
  14. Install the belt. Install the alternator nut. Adjust the belt tension. Tighten the alternator nut to 19 ft. lbs. (26 Nm).
  15. Connect the wire to the terminal and tighten the nut.
  16. Engage the multi-pin connector to the alternator.
  17. Install the cruise control actuator.
  18. Install the power steering pump.
  19. Connect the negative battery cable.

Oct 18, 2010 | 1992 Honda Accord

1 Answer

Went to change my alternator took off bolt attached to belt pullt bracket and can't seem to get the bracket back on .....HELP


Most cars have a spring loaded belt tensioner - look for a smooth pulley that the back of the belt goes around. If you removed the alternator mount without removing the belt first the tensioner spring will have taken up the slack and now you will not have enough latitude to refit the bracket. Make a sketch of the pulleys and the path the belt takes around them. Remove the belt. Refit the alternator bracket. Now focus your attention on the tensioner pulley. IN the middle of the pulley there will appear to be a bolt head, could be a torx. Fit the appropriate socket and with e wrench pull the nut and the pulley against the spring. It will take some effort but it will move. Once you have familiarised yourself with how the pulley moves it is now time to refit the belt. Using your earlier sketch as reference feed the belt over all the pulleys leaving the smallest until last, at which point the belt can be fitted over this by putting pressure against the tensioner pulley to provide the necessary slack. Easy when you know how

Aug 17, 2010 | 1999 Toyota RAV4

1 Answer

Changing alternator


REMOVAL & INSTALLATION
2.2L Engines
CHRYSLER ALTERNATOR
  1. Disconnect the negative battery cable.
  2. Label and disconnect the wiring (for easy installation).
  3. Remove the air conditioning compressor drive belt, if equipped.
  4. Loosen the alternator adjusting bracket bolt and adjusting bolt. Remove the alternator belt.
  5. Remove the bracket and mounting bolts.
  6. Remove the pivot bolt and nut.
  7. Lift the alternator from the vehicle.
When lifting the alternator out of the vehicle on some years with A/C, clearance may be restricted by the condenser cooling fan assembly or the A/C compressor and mounting bracket assembly, if so, removal of one of these items will be necessary.

To install:

  1. Position the alternator against the engine.
  2. Install the pivot bolt and nut.
  3. Install the mounting bracket bolts, and adjusting bolt.
  4. Install drive belts and adjust to specification.
  5. Tighten all the mounting bolts and nuts.
  6. Connect all alternator terminals.
  7. Connect the negative battery cable.

BOSCH ALTERNATOR

  1. Disconnect the negative battery cable.
  2. Disconnect the wiring and label for easy installation.
  3. Remove the air conditioning compressor drive belt.
  4. Loosen the alternator adjusting bracket locknut and adjusting screw. Remove the alternator belt.
  5. Remove the bracket locknut and mounting bolt.
  6. Remove the pivot bolt and nut.
  7. Remove the alternator from the engine.
To install:
  1. Position the alternator against the engine.
  2. Install pivot bolt and nut.
  3. Set the mounting bracket in place and install the bracket mounting bolt and locknut.
  4. Install the drive belts and adjust to specification.
  5. Tighten all the mounting bolts and nuts.
  6. Connect all alternator terminals.
  7. Connect the negative battery cable.

2.5L Engines
2.5L engines were equipped with either Chrysler or Bosch alternators.

  1. Disconnect the negative battery cable.
  2. Remove the drive belts.
  3. Remove the adjusting bracket-to-engine mounting bolt.
  4. Remove the adjusting locking bolt and nut, then remove the mounting bracket.
  5. Position the alternator to gain access to the wiring.
  6. Disconnect the wiring and label for easy installation.
  7. Remove the pivot bolt, nut, and washers.
  8. Remove the alternator assembly from the engine.
To install:
  1. Position the alternator assembly against the engine.
  2. Loosely install the pivot bolt, washers, and nut.
  3. Attach all wiring connectors to the alternator.
  4. Position the mounting bracket in place, then install engine mounting bolt.
  5. Loosely install the adjusting locking bolt and nut.
  6. Install the drive belts, and adjust to specification.
  7. Tighten all mounting bolts and nuts.
  8. Connect the negative battery cable.

2.6L Engines
2.6L engines were equipped with Mitsubishi alternators.
  1. Disconnect the negative battery cable.
  2. Disconnect the wiring and label for easy installation.
  3. Remove the adjusting strap mounting bolt.
  4. Remove the drive belts.
  5. Remove the support mounting bolt and nut.
  6. Remove the alternator assembly.
To install:
  1. Position the alternator assembly against the engine, then install the support bolt.
  2. Install the adjusting strap mounting bolt.
  3. Install the alternator belts and adjust to specification.
  4. Tighten all the support bolts and nuts.
  5. Connect all of the wiring terminals to the alternator.
  6. Connect the negative battery cable.

3.0L Engines
The 3.0L engines were equipped with either the Nippondenso or Bosch alternators.
  1. Disconnect the negative battery cable.
  2. Install a 1 / 2 in. breaker bar in the tensioner slot. Rotate counterclockwise to release belt tension and remove poly-V belt.
  3. Remove the alternator mounting bolts (2).
  4. Remove the wiring and remove alternator.
To install:
  1. Position the alternator onto the engine, then install the wiring.
  2. Set the alternator against the mounting bracket and install the mounting bolts.
  3. Rotate the tensioner counterclockwise and install poly-V belt.
  4. Connect the negative battery cable.

3.3L and 3.8L Engines
The 3.3L and 3.8L engines were equipped with the Nippondenso alternators.
  1. Disconnect the negative battery cable.
  2. Remove the alternator drive belt, by relieving the tension on the dynamic tensioner.
  3. Loosen the nut on the support bracket at the exhaust manifold, do not remove it.
  4. Remove the alternator tensioner/power steering bracket bolt.
  5. Remove the tensioner stud nut and remove the tensioner.
  6. Remove the alternator mounting bolts.
  7. Remove the power steering reservoir from the mounting bracket, do not disconnect the hoses, and position it out of the way.
  8. Remove the alternator support bracket bolts. Remove the intake plenum to alternator bracket bolt and remove the alternator support bracket from the engine.
  9. Remove the alternator from the engine and disconnect the electrical leads.
To install:
  1. Install the alternator in position on the engine and connect the electrical leads.
  2. Install the alternator support bracket, tighten the retaining bolts to 40 ft. lbs. (54 Nm).
  3. Install the power steering reservoir on the mounting bracket.
  4. Install the alternator mounting bolts, tighten the bolts to 40 ft. lbs. (54 Nm).
  5. Install the tensioner and tensioner mounting stud. Install the retaining nut on the exhaust manifold.
  6. Install the alternator belt, insert a 1 / 2 in. extension into the square hole in the tensioner and turn the tensioner. Tighten the tensioner bolt.
  7. Connect the negative battery cable.

Hope this help (remember comment and rated this).

Apr 01, 2010 | 1994 Dodge Caravan

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