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Go Back   TDIClub Forums > TDI Model Specific Discussions Areas > VW B5 Passat TDIs

VW B5 Passat TDIs This is a general discussion about B5 Passat(>98 (2004-2005 in North America)). Non TDI related postings will be moved or removed.

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Old January 6th, 2008, 14:41   #1
MOGolf
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Default How To: R/R B5.5 BHW Alternator Pulley

Tools:

13mm socket
13mm deep socket
10mm socket or wrench
17mm box wrench
19mm open end wrench (long length preferred)
8mm hex bit - 3/8 inch drive
3 inch extension for 3/8 inch drive
3/8 inch drive ratchet wrench
3/8 inch drive torque wrench
1/2 inch drive ratch wrench or breaker bar
1/2 inch drive torque wrench
3212 pin wrench
19mm socket
Metalnerd Part MN3400SET - Serrated Alternator Pulley Bit Set


1 - open the bonnet (hood) and remove the engine cover. Note: This is not documented with pictures. If you can't do this without pictures you should stop now and let someone else do the job.

2 - slide the battery cover to the right side of the and lift off. See note of step 1.

3 - Loosen the nut on the negative terminal and pull off the cable


4 - Place a rag over the terminal to prevent accidental contact


5 - Remove the black cap from the large cable retaining nut on the back of the alternator. Remove the nut and take the cable off of the post, then put the nut back on so you don't lose it. Disconnect the connector for the smaller wires as shown in the upper right of this picture. Note the small tab on the wire tie type of retainer below that connector. You can push that small tab towards the long loose end of the retainer and slip that long loose end back through the retainer then remove the cable from the alternator.


6 - Use a 19mm wrench on the ribbed belt tensioner and move the top end (as picture) towards the right side of the car (bottom of this picture) then slip the belt off of the alternator pulley. Note the bolt in the center left of the picture. You will remove this bolt later.


7 - slip the 8mm hex bit on the extension through the access hole in the bracket


8 - counterhold the pulley with the 3212 pin wrench and remove the bolt with the 8mm hex bit.


This is the back of the pulley where you can see the holes for the 3212 pin wrench.


You might be able to use a strap wrench to counterhold the pulley, but I have the 3212 so I didn't try.

9 - Let the fan assembly gently rest as shown. You won't be able to get it out of the car.


10 - Use 13mm short socket and remove the bolt pictured above with the belt tensioner. Then use a 13mm long socket to remove the bolt below the alternator pulley. The long socket allows your ratchet wrench to clear the alternator pulley and makes it easier to remove the bolt.

11 - Use a pry tool gently to pry the alternator loose. Once the top was loose I flipped this pry tool over and used the short end to pry the bottom loose.


12 - remove the alternator from the car in the area shown.
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Old January 6th, 2008, 14:41   #2
MOGolf
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Default How To: R/R B5.5 BHW Alternator Pulley continued

13 - secure the alternator so that you can remove the pulley. I placed it in a vise.

14 - This is the pulley to be replaced with the plastic cover removed. Note the multiple splines.


15 - insert the multispline tool from the Metalnerd kit (or 3400 tool if you have one) into the pulley


16 - slip a 17mm wrench onto the multispline tool, and insert the M10 triple square or T50 6 lobe bit (as appropriate for your alternator) through the multispline tool. Use a 1/2 drive ratchet or breaker bar to turn the bit in a clockwise (typically tightening) direction while counterholding with the 17mm wrench. This pulley was put on to 80 Nm. The pulley will unscrew from the shaft of the alternator.


17 - screw the replacement pulley onto the shaft, assemble the tools as above, and use a torque wrench to tighten the pulley to 80 Nm. Tightening is accomplished by turning the torque wrench counterclockwise (typically loosening) direction. Install the plastic cover.

18 - Place a 19mm socket around the threaded inserts and press them out of the alternator mounting tab a little. The shiny surface on the one pictured here is the side to put the socket on. I sandwiched mine in a vise to press the inserts to the position shown. This will make it easier to remount the alternator on the engine bracket.


Installation is the reverse of removal.
Tighten the 8mm hex bit bolt to 45 Nm.
Tighten the alternator mounting bolts to 25 Nm.
Tighten the 13mm nut on the large cable to 15 Nm.

Last edited by MOGolf; January 6th, 2008 at 14:44.
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Old January 7th, 2008, 09:09   #3
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Thanks for the writeup mogolf, but in all my years I have never had to replace a pulley on an alternator. What was wrong with it that warranted replacement.
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Old January 7th, 2008, 10:06   #4
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http://forums.tdiclub.com/showthread.php?t=181381
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Old January 7th, 2008, 14:19   #5
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Quote:
Originally Posted by dlai
OHHHHHHHH It's not a pulley that needs changing, it's the one-way bearings IN the pulley that act like a clutch which you can only get by buying a new pulley. Why didn't you just say so?
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Old January 7th, 2008, 16:04   #6
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Actually, this was preventive maintenance. The old one is still good.
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Old January 7th, 2008, 17:50   #7
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Please use your significant influence to make this a sticky. I'll never be able to find it again when I need it!

Thanks for a great how-to.
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Old January 7th, 2008, 22:27   #8
Route 66
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MoGolf that is truly impressive
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Old January 8th, 2008, 19:46   #9
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Thank you.

This procedure avoids pulling the front of the car to the "service position". If you did that, then it would be possible to completely remove the fan from the car. That is all extra work that doesn't need to be done to r/r the alternator.

I put a link to this thread in the "How To" sticky thread of TDI 101 .
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Old January 9th, 2008, 15:18   #10
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Isn't there a way to oil that bearing to extend its life?
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Old January 9th, 2008, 16:02   #11
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The pulley does not come apart unless it is broken. "Sealed for life."
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Old January 9th, 2008, 17:06   #12
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Has anyone had this replaced under warranty? Is this a problem that shows up after the 60k warranty limit?
Also, what is the cost of the replacement pulley?
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Last edited by Keyser_Soze; January 9th, 2008 at 17:10.
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Old January 9th, 2008, 21:15   #13
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If the car has a warranty and the part fails, it will be covered. Several have posted in other threads of this.

A quick check shows the part is $115 or more at various suppliers. Prices subject to change.

Last edited by MOGolf; May 18th, 2014 at 02:50.
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Old January 12th, 2008, 16:22   #14
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Man, I wish this writeup had been done before I tackled it a few months ago! it took me forever to figure out where the bolt was for the fan...

Great writeup! Thanks!
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Old January 16th, 2008, 09:12   #15
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Mine was replaced $115.00 is right.
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