* 13 mm wrench
* 16 mm socket and wrench
* 17 mm wrench
* Long 5 mm hex key
* Pliers
* Screwdriver
* Jack and jack stands
Instructions
NOTE: Although Volkswagen alternators are technically not rebuildable, rebuild kits with various internal parts are available. Be sure to replace brushes, a common failure item.
1. Disconnect the negative battery terminal.
2. Remove the air cleaner. Disconnect the accelerator linkage rod at the carburetor throttle lever by removing the cotter pin and separating the rod ends. Unhook the air cleaner hose at the carburetor. Remove the air cleaner bracket-to-carburetor nuts and lift off the air cleaner assembly.
3. Remove the front fan shroud retaining clips and remove the shroud from the car.
4. Disconnect the alternator/generator lead from the terminal lug on the back of the alternator. It’s held in place with a 13 mm nut.
5. Disconnect the other wire from the alternator that goes to the voltage regulator.
6. Remove the rear bearing housing-to-engine retaining nuts with a 16 mm wrench.
7. Using the 16 mm wrench and a long 5 mm hex key, loosen and remove the four through-bolts that mount the alternator/generator to the case half. This can be a little frustrating as you’re working sort of upside-down.
8. Remove the alternator from the car by rocking and twisting it around the crankshaft.
9. If you’re rebuilding the alternator, take it apart and replace its brushes, armature, rectifier and voltage regulator.
10. If you’re installing a rebuilt or a new alternator, it might be a good idea to replace the rear bearing at the same time. To remove the rear bearing, first take out the 13 mm cap bolt from the middle. Then the bearing can be driven out with a punch.
11. To install a new bearing, first grease it liberally with grease. Then either drive it into the housing with a hammer or use a press to gently install the bearing.
12. Re-install the alternator by carefully angling the alternator into the case half and then installing the through-bolts. Tighten the through-bolts.
13. Reinstall the rear bearing housing-to-engine retaining nuts and tighten them.
14. Reconnect the alternator/generator lead to the terminal lug on the back of the alternator. Reconnect the other alternator lead to the voltage regulator.
15. Reconnect the accelerator linkage rod at the carburetor throttle lever. Ensure the cotter pin is reinstalled through the rod ends and throttle lever.
16. Re-install the air cleaner assembly. Secure it with the bracket nuts.
17. Reinstall the fan shroud.
18. Re-connect the negative battery terminal.
