Instructions for Alternator Removal?

possible alternator bearing failure which is causing regulator brushes to create abnormal contact and wear .Remove belt turn alternator pulley by hand this should determine noisy bearing or unstable rotor shaft.

Go to youtube, you will find it there.

http://www.myturbodiesel.com/wiki/alternator-pulley-removal-and-fan-clutch-bearing-removal-b5-passat-tdi/

CHECK OUT THIS SITE SHOULD BE ALL THE INFO YOU NEED!!!!

Inspect/Test/Service/Replace Follow service manual procedures given by the manufacturer for the generator you are working on for disassembling, inspecting, testing, and rebuilding AC generators. Remember, improper connections to an AC generator can destroy it.
AC generator removal varies according to the engine size, engine placement, and vehicle accessories (such as power steering and air conditioning). The following is the typical procedure for removal and replacement of the AC generator.

• Place fender covers over the fenders
• Disconnect the battery ground cable

CAUTION
Never attempt to remove the alternator or disconnect any wires to the alternator without first disconnecting the battery negative cable.It's a good practice to wrap the cable with tape or insert the cable inside a rubber hose to prevent accidental contact with the battery terminal.Always wear safety glasses when working around the battery.

• Disconnect and label the wiring harness connections to the alternator (Painters Masking tape works very well for labeling Automotive wiring).
• Loosen the alternator pivot bolt.
• Remove the bolt that attaches the alternator to the adjustment arm.
• Rotate the alternator to loosen the drive belt and disengage the belt from the pulley. Be careful that any spacers that are used in mounting are kept with their original bolts. This will make correct reinstallation much easier.
• While supporting the alternator remove the pivot bolt.
• Remove the alternator from the vehicle.

To reinstall the alternator, reverse the removal procedure.
To adjust the belt tension, leave the pivot and adjusting arms loose. Look up the belt tension specification for the vehicle you are working on. Using a belt tension gauge on the belt apply pressure to the alternator until the correct belt tension registers on the gauge and tighten the mounting and adjustment bolts to the specified torque specification.

CAUTION
Over tightening of the alternator drive belt will cause the unit to whine and premature failure of the alternator drive end bearing, the water pump or the engine crankshaft

Inspect/Test/Service/Replace Follow service manual procedures given by the manufacturer for the generator you are working on for disassembling, inspecting, testing, and rebuilding AC generators. Remember, improper connections to an AC generator can destroy it.
AC generator removal varies according to the engine size, engine placement, and vehicle accessories (such as power steering and air conditioning). The following is the typical procedure for removal and replacement of the AC generator.

• Place fender covers over the fenders
• Disconnect the battery ground cable

CAUTION
Never attempt to remove the alternator or disconnect any wires to the alternator without first disconnecting the battery negative cable.It's a good practice to wrap the cable with tape or insert the cable inside a rubber hose to prevent accidental contact with the battery terminal.Always wear safety glasses when working around the battery.

• Disconnect and label the wiring harness connections to the alternator (Painters Masking tape works very well for labeling Automotive wiring).
• Loosen the alternator pivot bolt.
• Remove the bolt that attaches the alternator to the adjustment arm.
• Rotate the alternator to loosen the drive belt and disengage the belt from the pulley. Be careful that any spacers that are used in mounting are kept with their original bolts. This will make correct reinstallation much easier.
• While supporting the alternator remove the pivot bolt.
• Remove the alternator from the vehicle.

To reinstall the alternator, reverse the removal procedure.
To adjust the belt tension, leave the pivot and adjusting arms loose. Look up the belt tension specification for the vehicle you are working on. Using a belt tension gauge on the belt apply pressure to the alternator until the correct belt tension registers on the gauge and tighten the mounting and adjustment bolts to the specified torque specification.

CAUTION
Over tightening of the alternator drive belt will cause the unit to whine and premature failure of the alternator drive end bearing, the water pump or the engine crankshaft

The thermostat on this vehicle's In-line 6 cylinder engine is on the driver's side of the engine, below & behind the alternator. You have to remove the alternator to gain access to the thermostat housing. You also need to disconnect the battery before you remove the alternator to avoid sparks and shorts.

Most directions outline removal of the alternator to gain easy access to the hose clamps, bolts and housing of the thermostat. I have located a site that after free registration, has detailed instructions on how to do this job, and the link below that describes an easier method with photos. Check out:

http://forums.trailvoy.com/showthread.php?t=54225&highlight=replace+thermostat

2005 Ford Mustang 4.0L SFI SOHC 6cyl
Ford Mustang 1999-2005
Alternator - Removal & Installation

3.8L And 4.0L Engines

1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
2. Disconnect the negative battery cable.
3. Remove the accessory drive belt.
4. Disconnect the alternator electrical connectors.
5. Remove the alternator shield (4.0L engine).
6. Remove the alternator mounting bolts.
7. Remove the alternator from the vehicle.
8. Installation is the reverse of the removal procedure.

To install:

1. Position the alternator onto engine. Tighten the lower bolt to 35 ft. lbs. (47 Nm) and the upper bolt to 18 ft. lbs. (25 Nm).
2. Install the alternator shield (4.0L engine).
3. Connect the alternator electrical connectors.
4. Install the accessory drive belt.
5. Connect the negative battery cable.

4.6L Engines (Non-Supercharged)

1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
2. Disconnect the negative battery cable.
3. Remove the air intake scoop bracket, if equipped.
4. Remove the accessory drive belt.
5. Remove the upper alternator bracket.
6. Disconnect the alternator electrical connectors.
7. Remove the alternator bolts.
8. Remove the alternator from the vehicle.
9. Installation is the reverse of the removal procedure.

To install:

1. Position the alternator onto engine. Tighten the mounting bolts to 18 ft. lbs. (25 Nm).
2. Connect the alternator electrical connectors.
3. Install the upper alternator bracket. Tighten the bolts to 89 inch lbs. (10 Nm).
4. Install the accessory drive belt.
5. Install the air intake scoop bracket, if equipped.
6. Connect the negative battery cable.

4.6L Engines (Supercharged)

1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
2. Disconnect the negative battery cable.
3. Remove the accessory drive belt.
4. Raise the vehicle.
5. Disconnect the alternator electrical connectors.
6. Remove the alternator bolts.
7. Remove the alternator from the vehicle.
8. Installation is the reverse of the removal procedure.

To install:

1. Position the alternator onto engine. Tighten the lower bolt to 18 ft. lbs. (25 Nm) and the upper bolt to 37 ft. lbs. (50 Nm).
2. Connect the alternator electrical connectors.
3. Lower the vehicle.
4. Install the accessory drive belt.
5. Connect the negative battery cable.
6. Installation is the reverse of the removal procedure.

More details about this model in Autozone.com (free register).

I hope help you with this (remember rated this help). Good luck.

if you go to your local auto parts store you can buy a chiltons manual for the vehicle for around $15-25 and this will tell you how to do it. hope this helps you out. and please rate my solution
thank you

chb725: If you go to mybunkey solutions and see the heading " "Starter, battery and alternator ok", you will find that I have given instructions for the removal and installation of a starter for a 1995 Nissan Maxima, in great detail.
The instructions include the tools needed, proceedures in a sequence more detailed (which you will not find in any book) and precautions to be taken during the removal and installation of the starter.
I hope this will provide the answer you are looking for. If not, I will await a more detailed request from you.