You will need a FLAT surface to complete
this repair for your safety.
READ ALL OF
THIS PROCEDURE SEVERAL TIMES SO THAT YOU UNDERSTAND IT. DO NOT
PERFORM THE PROCEDURE OUT OF ORDER. THIS WILL RESULT IN DEATH
OR SERIOUS INJURY.
We have available
for download the complete procedure on our
DOWNLOADS page
This
procedure is different from the one listed in the Bentley Manual
TOOLS NEEDED:
10, 13 and
21mm end wrenches
36mm socket 1/2 or
3/4 in drive
1/2 or 3/4 inch
drive ratchet
Straight (slotted or "Prince") screwdriver
Parts needed:
12 Volt Alternator
Alternator Stand
Procedure for removal
Disconnect Negative and
positive Battery terminal connections as shown on Battery Removal page (steps 1 and 2 only).
Use the procedure listed
on Engine Removal page. The Bentley Manual describes how to
remove doghouse and generator with out removing engine.
Once the engine is out
from under the VW then remove 10 mm bolts from the bolting point at
the point in which the Doghouse and the cylinder tin are bolted
together.
Loosen the belt to the
Generator pulley. Remove the belt.
Loosen the Generator
bracket.
Remove the Generator
from the Doghouse.
Once the generator is
removed, then remove the 36mm nut from the squirrel cage cooling
fan..
Remove the generator
stand.
DO
NOT SPIN THE ALTERNATOR UNTIL CONNECTED TO THE BATTERY.
Now for the fun part!
ELECTRICAL Wiring!
The generator is
actually shunted to a fuse on the fuse block.
An alternator should be
connected direct to the battery.
Install the 36mm nut on
the squirrel cage cooling fan. Torque down nut.
Install the alternator
pulley.
Install the alternator
in the Doghouse. Tighten the four Bolts. Torque down
Bolts.
Tighten the
Alternator/Generator bracket. Torque down
Bolts.
Install the 10 mm bolts
to the bolting points at the point in which the Doghouse and the
cylinder tin are bolted together. Torque down
Bolts.
Install the belt.
Tighten the belt to the generator pulley. Torque down nut.
