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.

This answer covers:
2005 Chrysler 300 6cyl VIN "G" 3.5L SFI HO (72% of 2005 300's)
2005 Chrysler 300 6cyl VIN "R" 2.7L MFI DOHC (28% of 2005 300's)
2005 Dodge Magnum 5.7L engine

Alternator

Removal & Installation


WARNING - Precautions Section:
Disconnect negative cable from battery before removing battery output wire (b+ wire) from alternator. Failure to do so can result in injury or damage to electrical system.

2.7L Engine

1. Before servicing the vehicle, refer to the Precautions section.
2. Disconnect negative battery cable.
3. Remove alternator drive belt.
4. Disconnect alternator field circuit plug.
5. Remove B+ terminal nut and wire.
6. Remove 2 lower mounting bolts.
7. Remove alternator.

To install:

1. Install alternator.
2. Install upper bolt mounting bolt.
3. Install 2 lower mounting bolts.
4. Tighten bolts to 48 ft. lbs. (65 Nm).
5. Install B+ terminal nut and wire. Tighten nut to 115 inch lbs. (13 Nm).
6. Connect alternator field circuit plug.
7. Install alternator drive belt.
8. Connect negative battery cable.

3.5L Engines

1. Before servicing the vehicle, refer to the Precautions section.
2. Disconnect negative battery cable.
3. Remove alternator drive belt.
4. Remove bracket bolts.
5. Remove upper mounting bolt.
6. Raise and support vehicle.
7. Remove middle splash pan.
8. Disconnect alternator field circuit plug.
9. Remove B+ terminal nut and wire.
10. Remove lower mounting bolts.
11. Remove alternator.

To install:

1. Install alternator.
2. Install lower mounting bolts. Loosen install the upper mounting bolt.
3. Tighten lower mounting bolts to 48 ft. lbs. (65 Nm).
4. Connect alternator field circuit plug.
5. Install B+ terminal nut and wire. Tighten nut to 115 inch lbs. (13 Nm).
6. Install middle splash pan.
7. Lower vehicle.
8. Remove loose installed upper bolt.
9. Install bracket and bracket bolt.
10. Install upper mounting bolt and bracket.
11. Tighten upper mounting bolt to 48 ft. lbs. (65 Nm).
12. Tighten the bracket bolt to 40 ft. lbs. (54 Nm).
13. Install alternator drive belt.
14. Connect negative battery cable.

5.7L Engines

1. Before servicing the vehicle, refer to the Precautions section.
2. Disconnect negative battery cable at battery.
3. Remove alternator drive belt.
4. Raise and support vehicle.
5. Unsnap plastic insulator cap from B+ output terminal.
6. Remove B+ terminal mounting nut at rear of alternator. Disconnect terminal from alternator.
7. Disconnect field wire connector at rear of alternator by pushing on connector tab.
8. Remove alternator support bracket nut and bolt. Remove support bracket. See Figure 1.
9. Remove 2 alternator mounting bolts. See Figure 2.
10. Remove alternator from vehicle.

Fig. 1 Alternator Support Bracket - 5.7L engine



Fig. 2 Alternator Mounting Bolts - 5.7L engine

Hello! Ignore my request regarding the engine size, The thermostat is well hidden..Standard labor to replace is 2.0 hours...Thermostat is part # 06B-121-111-G....
Step 1: Drain coolant...

Remove bottom belly pan... Remove coolant reservior tank cap... Remove plastic clip holding coolant sensor in place at lower radiator hose/pipe... With bucket/catch pan underneath, remove sensor and let coolant drain...


Step 2: Remove upper radiator hose...

Remove the small hose connecting the coolant reservoir to the upper radiator hose... Then remove the larger hose from the hard pipe running along the intake and from the radiator... You'll need to pop up (but not off) the metal clip holding the hose to the radiator, then firmly pull back..

Step 3: Remove intake hose (throttle body to inter-cooler)...

Remove driver's side headlight (not necessary but makes it a lot easier). Loosen clamp at each end and remove hose...

Step 4: Remove throttle body...

Remove electrical connector and 4 hex bolts (5mm)...

Step 5: Loosen serpentine belt and slip off of alternator...

Use a box-end or adjustable wrench on tensioner, pull to the right... Carefully slip belt off alternator (towards front of car). Allow to hang loose below...

Step 6: Remove alternator bolts...

Remove 4 bolts holding alternator to bracket...

Step 8: Remove vertical support piece from intake manifold to block...

Remove the two bolts holding the support piece (6mm hex)...

Step 9: Remove bolt from metal hose on thermostat; remove bolt from top of oil cooler...

This will allow you to move the hard pipe away from thermostat... Then wiggle it free from the pipe afterwards...

Bolt holding the hard pipe on the right, two bolts holding the thermostat to the block on the left...

Step 10: Remove upper and lower hoses from t-stat. Remove electrical connector on back side...

Step 11: Remove 2 bolts holding thermostat to block, and remove thermostat...See photo below...Guru...Saailer









I’m happy to help further over the phone at https://www.6ya.com/expert/david_6df67de3b14de867

Here's an illustration: Disconnect negative battery cable. remove radiator fan (next to alternator). Loosen upper alternator tension bolts & tilt/move toward engine to give slack to the drive belt. Remove drive belt & then remove lower alt mounting bolt & top tension/mounting bracket bolt. Disconnect alternator wiring/connections. Lift alternator out. Assembly is in reverse order of removal.

3.5L Engines

1. Before servicing the vehicle, refer to the Precautions Section.
   
2. Remove or disconnect the following:
   
   • Negative battery cable
     
   • Right side engine undercover and side inspection cover
     
   • Radiator on Maxima
     
   • Radiator fan on 350Z
     
   • Drive belt
     
   • Alternator and A/C compressor harness connectors
     
   • Upper and lower alternator bolts
     
   • Alternator
     

Install or connect the following:

• Alternator
  
• Upper and lower alternator bolts. On Maxima tighten the upper bolt to 12-15 ft. lbs. (16 -20 Nm) and the lower bolt to 32-38 ft. lbs. (44-52 Nm). On 350Z, tighten the upper bolt to 48 ft. lbs. (65 Nm) and the lower bolts to 21 ft. lbs. (28 Nm).
  
• Alternator and A/C compressor harness connectors
  
• Drive belt
  
• Radiator on Maxima
  
• Radiator fan on 350Z
  
• Right side engine undercover and side inspection cover
  
• Negative battery cable
  

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Removal and Installation L4-2.5L (QR25DE) Engines To Remove:

1. Before servicing the vehicle refer to the precautions at the beginning of this section.
2. Remove or disconnect the following:
   • Negative battery cable
   • Engine cover
   • Front/right-side engine undercover
   • Drive belt
   • Alternator harness connector
   • Engine ground wire from top mount
   • Alternator upper and lower mounting bolts
3. Set the alternator aside and remove the top mount.
4. Remove the alternator.

To Install:

1. Slide alternator in place.
2. Install or connect the following:
   • Alternator top mount
   • Alternator upper and lower mounting bolts
   • Engine ground wire from top mount
   • Alternator harness connector
   • Drive belt
   • Front/right-side engine undercover
   • Engine cover
   • Negative battery cable

V6-3.5L (VQ35) To Remove:

1. Before servicing the vehicle refer to the precautions at the beginning of this section.
2. Disconnect the negative battery cable.
3. Drain coolant from the radiator into a suitable container.
4. Remove or disconnect the following:
   • Radiator
   • Front/right-side engine under cover
   • Drive belt
   • Idler pulley
   • Alternator adjustable top mount
   • Alternator lower mount bolt and nuts
   • Alternator lower front bracket bolt
   • Alternator harness connectors
   • Alternator

To Install:

1. Install or connect the following:
   • Alternator in place
   • Alternator harness connectors
   • Alternator lower front bracket bolt
   • Alternator lower mount bolt and nuts
   • Alternator adjustable top mount
   • Idler pulley
   • Drive belt
   • Front/right-side engine under cover
   • Radiator
2. Replace the engine coolant.
3. Connect the negative battery cable.
4. Start the engine and check for leaks.
5. Recheck coolant level and top off as needed.

2001 Chevrolet Metro 1.3L MFI SOHC 4cyl

Alternator - Removal & Installation

1. Before servicing the vehicle, refer to the precautions section.
2. Remove or disconnect the following:
   Negative battery cable Air cleaner assembly Alternator electrical connectors Accessory drive belt Upper and lower mounting bolts Alternator
   

To install:

1. Install or connect the following:
   Alternator and the bolts, do not tighten the bolts at this time
   
2. Install the alternator belt and adjust the tension until a deflection of 0.24-0.31 inch (6-8mm) deflection with 22 lbs. (10 kg) of pressure exerted when installing a used belt. On a new belt the belt deflection should be 0.20-0.27 inch (5-7mm) with 22 lbs. (10 kg) of pressure exerted.
   Alternator electrical connectors, then torque the alternator bolts to 17 ft. lbs. (23 Nm) Air cleaner assembly Negative battery cable
   

1. Before servicing the vehicle, refer to the precautions section.
2. Remove or disconnect the following:
   Negative battery cable Accessory drive belt Alternator electrical connectors Alternator
   

To install:

1. Install the alternator and hand-tighten the bolts.
2. Install the alternator belt and adjust the tension until a deflection of 0.24-0.31 inch (6-8mm) deflection with 22 lbs. (10 kg) of pressure exerted when installing a used belt. On a new belt the belt deflection should be 0.20-0.27 inch (5-7mm) with 22 lbs. (10 kg) of pressure exerted.
3. Install or connect the following: Upper alternator bolt to 18 ft. lbs. (25 Nm) Lower alternator bolt to 40 ft. lbs. (54 Nm) Alternator electrical connectors Accessory drive belt Negative battery cable
   
   
   Fig. Exploded view of the alternator-Metro and Prizm models
   

Hope thats help (remember rated this).

We have a 2000 Beetle. You have to remove 4 allan head bolts and remove the throttle body . Remove it from the large hose. This allows you to get to the alternator . Undo 3 bolts on the belt tensioner and remove that. Undo the electrical connections on the alternator. Undo 2 bolts holding the alternator on to the bracket and pry out. Here's where I just about had a meltdown, the alternator won't fit out past the body work. However remove the passenger side headlight. There is a plastic lever you slide all the way up and slide the headlight out. Remove the 3 torx head screws to remove the headlight cup and the alternator will come out no problem through the headlight hole.

What type of Car is it And year?

under the steering column.

Disconnect negative battery cable
Raise car
Disconnect the wire harness from the electrical connections
Loosen the lower mounting bolts. Working from top loosen the upper adjustment lockbolt, back off the adjustment bolt swivel alternator toward the engine and then release the drivebelt from the pulley
Unscrew and remove the upper and lower mounting bolts and washers then remove alternator from its mounting bracket

2.7L Engine

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following:
   
   Negative battery cable from the shock tower Accessory belt splash shield and loosen the belt Alternator electrical connectors A/C pressure switch and clutch electrical connectors Engine oil dipstick Alternator
   

To install:

1. Install or connect the following:
   
   Alternator and torque the bolts to 40 ft. lbs. (54 Nm) Engine oil dipstick tube A/C pressure switch and clutch electrical connectors Alternator electrical connectors Drive belt and splash shield Negative battery cable
   

1. Before servicing the vehicle, refer to the Precautions section.
2. Raise vehicle and support.
3. Remove the accessory drive belt splash shield.
4. Loosen the accessory drive belt.
5. Remove the lower mounting bolt.
6. Lower the vehicle.
7. Remove the electrical connections from the alternator.
8. Disconnect the electrical connector to the A/C pressure switch and A/C clutch.
9. Remove the engine oil dip stick.
10. Remove the 2 upper mounting bolts.
11. Remove the alternator.

To install:

1. Install the alternator.
2. Install the 2 upper bolts, but do not tighten.
3. Install the engine dip stick tube.
4. Connect the A/C pressure switch and A/C clutch electrical connectors.
5. Connect the electrical connections to the alternator.
6. Raise vehicle and support.
7. Install the lower bolt. Tighten bolt to 40 ft. lbs. (54 Nm).
8. Install the accessory drive belt.
9. Install the accessory drive belt splash shield.
10. Lower the vehicle.
11. Install the 2 upper mounting bolts. Tighten bolts to 40 ft. lbs. (54 Nm).
12. Connect the negative battery cable.

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