ALH alternator Pulley replacement

[Cbus27]

Has anybody replaced the alternator pulley in an ‘02 ALH while it’s still in the car. I was thinking if I removed the front engine mount and raised the engine with a jack I could get enough clearance to remove pulley. I’ve seen other posts about how to remove the entire alternator at that point light as well replace the whole alternator. Any help and or threads will help.
Thanks

 

[P2B]

Has anybody replaced the alternator pulley in an ‘02 ALH while it’s still in the car. I was thinking if I removed the front engine mount and raised the engine with a jack I could get enough clearance to remove pulley. I’ve seen other posts about how to remove the entire alternator at that point light as well replace the whole alternator. Any help and or threads will help.
Thanks

VW/Audi Tools - Sockets, Drivers and Bits - Set2 Part MN3400 - Serrated Alternator Pulley Bit SET

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www.metalnerd.com

That's the tool you need to change the pulley in the car.

 

[Cbus27]

Yes I’ve seen that tool, but has anybody actually used it to remove the pulley in this model, year car? I don’t want to buy this tool, new pulley just to not have it work.

 

[P2B]

I own one, it works as advertised on MK4 ALH cars.

 

[Cbus27]

Okay I’ll order form IDparts now. Thanks for the help

 

[Vince Waldon]

You probably already know this, but all of the engine mount hardware other than the three 16mm (two short, one long) bolts that directly attach the mount bracket to the block are single-use only, so if you're planning to remove any of 'em to lift up the engine you'll need to order a bit of hardware.

I've tried it both ways and on an ALH I'd just pull the power steering pump to the side and then lift the alternator up and out... every time I've tried to do a pulley on the car it's fought me and I've ended up pulling it anyways.

 

[snakeye]

Best way to remove the alternator is from underneath by moving the ac compressor and passenger side rad fan out of the way.

Edit: or ^ that way. Never tried, but probably easier than dealing with the compressor.

 

[Vince Waldon]

That'll work too, and it's how the Service Manual recommends as well. Have tried it a couple times and always ended up fighting with the wedged-in mounts on the A/C compressor more than I wanted, when the power steering pump bolts are easy-peasy. Do have to pull the pulley first, so there's that.

 

[Nuje]

I've used the Metalnerd tool with the alternator in car at least half a dozen times; always a challenge to break the pulley free, but if you follow the instructions, add some rust-penetrant and get some heat in there, I've found it the quickest/easiest method.

 

[Mozambiquer]

I always do them out of the car, though generally I'm rebuilding the alternator, when I replace the clutch. I use just the splined tool and an impact wrench and most of the time that'll break it loose nicely.

 

[KrashDH]

Used the Metalnerd tools in the car, haven't move anything. Worked great but it's tight space in there

 

[Vince Waldon]

Doesn't hurt to try it in the car first, tru dat.

Being a belt-and-suspenders kinda guy, I generally reason that if the pulley wore out the brushes and slip rings probably need a look-see too, but that's just me.

 

[P2B]

I change the pulley (in the car) at every timing belt change. The one time I didn't the pulley failed 25k later.

I had one alternator fail at ~200k, the other three are all on their 3rd pulley.