[Vwdiesel] Today's Work, notes: Alternator and Starter

[Dave Cook]

Today was possibly one of the last nice afternoons I'll have for a long time, so I utilized it to get some pre-winter stuff done.

First, I replaced the starter in the '02 Golf.  It has always cranked a little slower than I wanted, and last week on a cold morning, would only click and not crank, until I tapped it with the tire iron, and rolled the car and bumped it a bit by trying to roll start it.  (As it turns out, the driveway isn't long enough for me to get enough momentum by myself.)  

So I figured I should replace it so it won't be a problem on upcoming mornings.  See below for how that turned out...

Second, I replaced the alternator in my friend's 01 Jetta.  Because someone was asking about this recently, here's how:
*Disconnect battery
*Use a 16mm wrench to turn the tensioner and remove the serp belt.
*There are two hoses that run through a bracket at the bottom corner of the fan shroud.  Loosen the clips and pull the hoses free so they can be pushed out of the way.
*Unplug the AC clutch wires, and use a 16mm socket to remove the bolts.  I had enough flexibility in the hose to let it sit upright on the ground.
*Remove the 3 screws and drop the passenger side fan down, and "hang" out of the way. (The wires were long enough to let it sit on the ground too.)
*Use a 13mm deep socket to remove the three bolts holding on the serp belt tensioner, remove it.
*Unplug the alternator exciter wires, and the main wire.  Also remove the wire holder that is mounted on a stud on the alternator.
*Use the 13mm socket to remove the alternator bolts.

*Use a pry bar, screwdriver, etc to carefully pry the alternator loose from the bracket.  For me, it came out by pushing it towards the front of the car a bit, then out the back of the bracket.  I had to shove some hoses and wires out of the way.

To Install:
As they say, installation is reverse of removal! Ha ha.

To make it easier, use a C-Clamp and a large socket to press the threaded sliding bushings that the mounting bolts thread into to loosen them a bit.  This way the alternator and compressor can easily be mounted on the brackets.

Third, I changed the oil (was draining while working on the Jetta) and filter, a burned out glow plug, and fuel filter on the Golf.  The mileage has been steadily declining since about August, so I'm hoping the fuel filter might help that a little.

Fourth, I changed the alternator in my 4Runner.  Not super relevant to the lists, but I did also do it today.

As For the Golf Starter: The stupid thing is messed up!  Twice today after installing it, it didn't start the car, but was whirring even with the key off.  Essentially the starter gear was spinning, but the solenoid hadn't pushed it out to engage the flywheel.  But it didn't stop spinning when I turned the key off.  The first time this happened, it did stop after a few seconds.  (Ironically, it was in the part store's lot after returning the core and getting the oil change stuff, but I thought it was an anomoly.) The second time, it wouldn't stop spinning until I tapped it with the tire iron.  Must be some sort of internal short or something.  Ugh

 
Dave Cook