How to Change a 2004 VW Jetta Alternator

The 2004 Volkswagen Jetta base model was equipped with a 2.0-liter four-cylinder engine and five-speed manual transmission. The alternator is attached to the alternator bracket, just above the air conditioner compressor on the driver side of the engine. When replacing the alternator, the alternator pulley must be removed and reused on the new alternator. Removing the alternator and alternator pulley will require special tools you may need to purchase from a tool dealer or Volkswagen directly.

Instructions

Removal

1

Lift the vehicle hood and support it with the hood prop rod. Disconnect the negative battery cable with a wrench.

2

Draw the accessory belt routing with the pen and paper. Attach Volkswagen tensioner release tool 3299 to the belt tensioner and rotate the tensioner clockwise to release tension on the belt. Slide the belt from around the alternator pulley and release the tensioner to its resting position.

3

Insert the AST pulley socket H 2592 onto the nut inside the alternator pulley. Attach a box-end wrench to the hex fitting on the top of the pulley socket and insert the T50 torx socket through the wrench and socket into the pulley shaft of the alternator. Attach the ratchet to the T50 torx socket.

4

Hold the pulley in position with the ratchet and torx socket assembly while turning the wrench and pulley socket counterclockwise. Remove the pulley nut. Remove the pulley from the alternator.

5

Unplug the wiring harness from the alternator. Remove the nut at the terminal connector for the battery cable with a wrench and remove the battery cable.

6

Remove the two mounting bolts with the socket and ratchet. Remove the alternator from the alternator bracket.

Installation

7

Set the new alternator onto the alternator bracket and install the mounting bolts. Tighten the mounting bolts to 19 foot-pounds of torque.

8

Plug in the electrical connector and attach the battery cable to the terminal connector. Secure the battery cable with the terminal nut and tighten with the socket and ratchet.

9

Set the alternator pulley over the pulley shaft on the alternator. Thread the pulley nut onto the the pulley shaft. Tighten the nut hand tight with the pulley socket. Insert the AST pulley socket H 2592 onto the nut inside the alternator pulley. Attach a box-end wrench to the hex fitting on the top of the pulley socket and insert the T50 torx socket through the wrench and socket into the pulley shaft of the alternator. Attach the torque wrench to the T50 torx socket.

10

Tighten the pulley nut to 109 foot-pounds of torque by turning the socket and wrench clockwise and holding the torque wrench and torx bit stationary.

11

Inspect the accessory drive belt for any cracks, tears or glazing and replace it if needed. Route the accessory drive belt around all the accessory pulleys and hold the belt tension tight at the belt tensioner.

12

Attach Volkswagen tensioner release tool 3299 to the belt tensioner and rotate the tensioner clockwise. Slide the belt around the tensioner pulley and release the tensioner to apply tension to the belt. Inspect the belt, making sure the belt is properly fitted to all pulleys and there are no twists in the belt.

13

Attach the negative battery cable and tighten with the wrench. Shut the vehicle's hood.