2002 GT TDI 150 Alternator

[Jay]

oh you can get the pulley's from Audi and Seat, probably Skoda and some say Ford do stock them (the Galaxy's use the 1.9TDI).

I think EPC and GSF also do them, but you best check.

[Gozza]

Top man thanks for all the info, will give that a try. Out of interest rather than disconnecting the battery etc wouldn't it be easier just using a none conductive material like a wooden chopstick or similar to spin the alternator blades 

A how to guide on changind the alternator pulley bearing would be superb

[Gozza]

Update,

Cant find on euro car parts or GSF, whats EPC ?

My local garage want £200 odd to change it and sound like they are fishing for more work. Could be power steering pump etc so I think I will change it myself. So will be buying the relevant tool and the bearing asap, wont be using the car anymore as if you leave it then it ruins the tensioner and can ruin the belt too 

[Jay]

If it's only just started happening, don't worry about it too much and just change it soon.

The Laser tool is £10-£15
Pulley is £50+vat ish (receipt is in the car)
Belt was £30+vat ish

You only need the Laser 3307 tool, a 19mm spanner (ratchet spanner would be best imo), and a wrench to hold the Laser tool and about 15-30mins to change the belt and pulley.

I can get an image of the belt layout over the various pulleys if you want for when you refit the belt.

[MarkyMark1983]

Stolen from the Shalaxy Forum: http://www.fordgalaxy.org.uk/ford/index.php?showtopic=11428&st=0&p=95499&#entry95499

1. Disconnect the battery (we don't want any thermal incidents from shorting the alternator).

2. View the alternator from above.

3. Identify the pulley end and look through the ribs of the body of the alternator.

4. Identify the alternator fan blades which can be seen through the ribs.

5. Insert a small electrical type screwdriver in between the ribs and try to turn the fan clockwise and anticlockwise.

6. If the fan turns freely in one direction and tries to move the pulley in the other it is OK.

7. If the fan tries to turn the pulley in both directions it is faulty and is causing this issue.

N.B. The fan does not require much effort to freewheel.




When stationary or at low speeds, and turning the steering wheel does it make a chirpping/squeal?

I just bought the pulley & belt from VW today £89 inc vat for BOTH, but if you have a new belt you probably won't need one now, especially if it's only started happening.

The tool is £15~ Laser 3307 is the name:
http://www.toolsheduk.com/Q/478/2/4/Alternator-Tool-M10-Spline-1-2inchD.html


Remove belt
Clear space in engine bay if needed (which side is the intake on the MK4?)
put tool in position.
Get someone to hold the socket wrench still while you undo the 19mm nut (it's going to require a strong arm and brute force!)
Fitting is reversal of removal as they say.

I'm going to do mine either tomorrow or the weekend, I'm going to take pics and make a pictoral.

i get the noise which you discribe at low speeds but mine has supposingly had a new aux belt and tensioner about 6k ago. Surely its not knackered already.

[Jay]

The item we're talking about replacing is the pulley on the alternator, the other two only need to be replaced if they are worn down.
A knackered alternator pulley will wear down the belt and tensioner quicker than what they would usually wear down, if your noise has only started then don't replace the other 2.

Of course it's possible the tensioner is also knackered or is causing the noise, but I doubt it if it's been changed fairly recently.

[Tucker82]

Im planning on replacing the tensioner, belt and pulley in the next 2 weeks. At first I was getting a slight knocking noise from the tensioner, then the pulley started making a loud tapping noise too when you turned the lights on. This week I noticed that the steering squeek has started! So my car does sound like a rickety bus at the moment.

Im guessing instead of locking the tensioner in place with a bolt, once the belt is off you should be able to gently let it go so there is no resistance at all?

Does anybody know how to replace the tensioner?

+1 for the guide on the pulley change! Will be very helpful....

[Jay]

From a quick look at it, it's 3 or so bolts to remove the tensioner but not 100% sure on that.

[Tucker82]

Yeah looks like it. Im guessing wrench the tension off and pin it back, remove belt. Replace tensioner and pin it back to fit new belt in the meantime change the pulley.

Is there a cover on the alternator pulley as it just looks like a small disc?

[Tucker82]

OH and if this is a common prob on the TDi's maybe someone can make it a sticky in the maint section!?