Replacing an alternator pulley without removing the alternator requires skill, the right tools and a cooperative engine bay design. We’ve compiled a list of VW diesels that we work on and listed how difficult it is to replace the pulley with the alternator still installed in the vehicle.
Tools
Getting the right tool is vital to this job. If you have the wrong tool you might not be able to remove the pulley at all, never mind with the alternator still on the car. We recommend the Serrated Alternator Pulley Bit Set from Metalnerd which is a low-clearance design to assist in on-vehicle replacement of the pulley. The Metalnerd tool comes with two inner bits, one for 6 point and one for 8 point alternator shafts.
Volkswagen
- B4 Passat TDI / Mk3 Jetta TDI
- Difficulty: Medium
- Mk4 Jetta/Golf TDI w/ ALH Engine
- Difficulty: Hard, removing alternator recommended.
- New Beetle TDI w/ ALH Engine
- Difficulty: Nearly Impossible, removing alternator required
- Mk4 Jetta/Golf/New Beetle TDI w/ BEW Engine
- Difficulty: Easy, alternator located at top of engine and pulley faces front with no tool interference
- Mk5 Jetta TDI w/ BRM Engine
- Difficulty: Medium, requires removing upper intercooler pipe, very tight working area
- B5.5 Passast TDI w/ BHW Engine
- Difficulty: Medium, alternator located at front of engine and faces front, clearance is tight and cooling fan must be removed
- Mk5/6 Jetta/Golf/Beetle TDI w/ 2.0 CBEA/CJAA Engine
- Difficulty: Hard, alternator not easy to access, very little clearance, removing alternator recommended
- NMS Passat TDI w/ CKRA Engine
- Difficulty: Hard, alternator not easy to access, very little clearance, removing alternator recommended
- EA288 Series TDI – CRUA/CVCA in 2015+ TDIs
- Difficulty: Nearly Impossible, removing alternator required