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MK1 1U alternator removal (04 1.9 tdi)

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Hi guys

 

I've another thread for electrical woes but I've got a bit sidetracked and this is more of a mechanical thing. So thought a separate thread was better.

 

Long story short: can't see an easy way to get the alternator out.

 

Through the bottom looks easier. My manual says to take it out through the bottom but the pics are quite different to my engine.

 

Access to the tensioner is really only possible from the bottom. Maybe that's just my giant banana fingers!

 

So there's something below the alternator that I think is the air con compressor. It looks like the one in the manual pics and it's in the same place.

 

So I was thinking tomorrow I'll remove that to get to the alternator. What do you folks think? Is this the right way to go?

  • Author

Ok that idea didn't work out! Don't know why. Removed two long bolts from the sides and one shorter one from the top but the thing wouldn't budge an inch.

 

So reassembled and went in through the top.  Found a guide on here somewhere before so followed it from memory.

 

Engine cover off.

 

Aux belt off.

 

Powersteering pump pulley off. Pump bolts off. Also removed a small bolt down just above the air con compressor that was holding the hard line for the pump in place. Means it'll move easier on the flexible hose section.

 

Aux belt tensioner off.

 

Alternator bolts off.

 

Pried alternator out  a bit to make sure it was free.

 

Previous guide mentioned removing the right side radiator fan. I'll do that tomorrow. Was getting a bit dark by the time I'd done all that other stuff.

 

This is all to put a new voltage regulator in to hopefully cure a parasitic battery drain.

 

So part two of me versus the alternator begins tomorrow after work. Feel like I'm winning now but it might be trying to lull me into a false sense of security.

 

Anyway I thought I'd post all that in case anyone else is looking at there engine and wondering why the process in no way resembles their Haynes manual. Normally I love a Haynes manual. The clymer one I have for my k1100lt is literally a pack of lies!

 

I'll post back my progress anyway.

  • Author

Well that was a mega faff!

 

But the above process did work.

 

Also had to undo all fasteners for the surrounding pipes to get it out. 

 

There's a big thick pipe that runs along the front of the engine bay and into the corner. Think it's to do with the Aircon but not sure. Was a bit of a struggle getting it past that. Had to loosen the fasteners for that too.

 

And to top it all off after two hours messing about in the rain I took the plastic cover off an discovered that eBay had sent me the wrong voltage regulator!

 

Still at least I'm half way there now. New voltage regulator should arrive tomorrow.

 

And if I ever have to replace the power steering pump, the aux belt tensioner, or the right hand radiator fan it'll be a doddle.

 

Hope this helps somebody out there that has the same engine!

 

 

I hope this doesnt upset you but when I was faced with the same removal to replace the regulator/brush pack I managed to do it in situ, a lot of it was working blind but it was not too difficult and removal looked really difficult, you have confirmed that it is.

  • Author

Lol!

 

I absolutely could have done that. It's wasn't too hard to get it pried out and turned on its side.

 

But i just got fixated with getting it out! Couldn't let it go!

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