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Discussion Starter · #1 · (Edited)
Ok, I'm doing an Alternator upgrade and am literally stuck at the last hurdle of physically removing the alternator.

Check the pic's below for my set-up (1.6SE BCB '03)

My questions are:

1: I have not put in the 'maintenance position' yet but is the direction of alternator removal TOWARDS the bumper & NOT left or right? Or is it up/down?

2: I have removed on the alternator the two long bolts, the positive to alternator & 8mm small nut to rear of alternator so is there ANY other things holding this on?

3: If I need to pry it out where to put the crow/pry-bar? See pic for idea of to the rear of alternator near the engine?

4: Just how the flip do I get this out as when I pull left/right/up/down the whole engine moves!!!

I have followed my Haynes (not very helpful for last stage) and read several forum posts on this so this is testing my manhood/want to replace the alternator so let me know what works before I give up / contemplate paying the stealership £200 just to remove the heavy little frigger! :mad:


 

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i bet he'll be back for reinstall... lol

i sanded the slightest bit of the brackets off with a metal file so the alt. was still very snug. it just made it easier to reinstall.
 

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Discussion Starter · #6 · (Edited)
No vwGLI I ain't back for the re-install but a bit more on the removal...

After a long time I came back to this problem for a second go, got my pry-bar out and managed to move in 1/2 an inch or so and am now faced with this problem...

It looks like from the pictures that the Power Steering thin metal pipe is just in the way so my question is; can I undo the nut at the top (see Pic) of the Power Steering and move the bar out the way?

Is this pipe under pressure i.e. do I need to de-pressurise elsewhere or just catch the fluid that may come out?

Other forums are talking about removing the air con compressed below the alternator so is this the better route?

2003 1.6 BCB (important info as most pics in Haynes manuals look like pre 2002)


 

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For your next project do yourself a favor and ditch the Haynes manual for a Bentley one. It'll basically turn into your bible haha
 

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when all else fails get a bigger hammer and a bigger prybar and do her right

but in all seriousness the 1.6 is from across the pond i personally have never worked on one but from the pics i can tell you, you need to take that p/s hard line out and move it to the side take all the bolts completely out of the alternator that hold it to the bracket spray some penetrating lubricant like wd-40 or what i always use is pb blaster. after you have it soaked up nice and well take your pry bar and seat it right on the hard part where the bolt slides trough on the casing of the alternator (not one of the fins or slots they break very easily and then you ruined your core) and give it a nice whack with your hammer on the end of your pry bar and it should unseat it. if that fails sometimes ive had to take the entire bracket out with the alternator (ive done this when a bolt snapped on me had to get a bolt out from behind the alt idk how i did it but i got it out and the whole thing literally dropped out) and get it out that way. best of luck to you and also from the looks of it in the picture you have to take out the condesner fan for it to come out and clear the radiator on its way to the ground lol.

happy wrenching :K:
 

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Discussion Starter · #9 ·
Thanks 05GTI1.8T, very helpful reply

Just to clarify few points you put;

In "taking the P/S Line out the way" is that unbolting that top nut (see my previous pic) and/or removing the P/S Pump? If former only, is it under pressure or can I just undo nut, pop out hard line pipe and so give myself a bit more of room?

For the "taking out the condenser fan" are you talking about the fan behind the radiator or the A/C Compressor below the alternator?

Thanks
 

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Thanks 05GTI1.8T, very helpful reply

Just to clarify few points you put;

In "taking the P/S Line out the way" is that unbolting that top nut (see my previous pic) and/or removing the P/S Pump? If former only, is it under pressure or can I just undo nut, pop out hard line pipe and so give myself a bit more of room?
the power steering is only under pressure when the engine is running the serpentine belt. you will however lose fluid and possibly introduce air into the system requiring a bleed to flush it before you drive again.
 

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Discussion Starter · #11 ·
8 Year Bump & Second Major Go; now help needed with one particular bolt removal:

Said was gonna run it until the wheels came off (nearly did but that is another storey!) so now the alternator has died so am in process of removal to replace. Read extensively and not going for putting in Service position but most say to take X/Y/Z out first then get to the Alternator which is where I'm now stuck at a very interesting unique nut & bolt so gonna need bit of help ESPECIALLY if you have done on the exact same model as this throws up something I've never had to deal with in my experience...

Ok, way to alternator is basically Air Con Compressor shift from its position (not removal as would need to de-gas the air con) then via bit of wobbling it about for access to alternator out, new one in.

From pics below; a/c compressor held in with 2 long bolts; lower LHS is simple 16mm, upper is "Double Stud with Hexagon Drive : M10x115 / M8x15" VAG part №: N90633802. The second smaller nut that is on top of this bolt is the M8x15mm BUT is listed as "Shouldered Hex Nut, Self Locking" VAG part №: N02300313 and as you can see it becoming burred in my attempts to remove.

So, million dollar question; no, aint going in other way and need to remove as a/c compressor is faulty so will be replacing at some future point. Researched extensively 'stuck nuts' & 'removing self-locking nuts' but at the moment nothing obvious. As far as can tell, this isn't a nylon self lock nut so can't burn the plastic out but think it's a tight end threaded lock nut which self locks when initially tightened.

Have put some SeaFoam Deep Creep nut releasing spray on BUT think what am really dealing with is a LOCKED locking nut which will need to replace when putting it all back together. Haynes is no help and nothing in Bentleys on this specific type nut+bolt removal. These types of bolt are getting rarer so just cutting it off is not a viable solution but just how the FRIG do I get this off?!!!

Single word answers or saying why bother / sell the car please keep to yerself - honest answers / advice and if yer done it with this specific nut then let me know as attacking with a long extended wrench think is only going to fracture the nut/bolt/frame.

BTW can't get to the 16mm headed nut below this due to this top nut restricting access and the thing it holds (Power-steering line metal frame has to come off otherwise the 16mm bolt won't be able to be undone!

Hive VW Mk4 Mind your help is needed...🙏

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