Friday, 21 November 2008
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Mechanic: "I own a Volkswagen and don't trust others to make car repairs so that pretty much makes me a mechanic."

The daily pleasure of driving the people's car is often interrupted by a visit to the people's garage.

Job that broke the mechanic's back
Saturday, 07 June 2008

If there was one then surely it was the task of removing, ordering and replacing the alternator of a '99 VW Passat V6. After ordering the wrong voltage regulator online, having the AutoZone guy order the wrong remanufactured alternator once and then finally getting the correct unit I'm proud to announce that the Passat is once again roadworthy.

Earlier I wrote that removing the alternator was like delivering a baby. Well if that's the case then reinstalling it was like trying to put the baby back from whence it came. No easy task on machine nor beast. The problem is that on this particular V6 the alternator is mounted to the bottom of the engine but above the 6 1/2 quart oil pan, which flanges out unlike a traditional oil pan.

To access the alternator you have to first put the car in the "service lock position" which means: Remove the front bumper cover; remove the headlights and turn signal lights; remove the bumper reinforcement bar; remove bumper reinforcement bar mounting strut; pull entire radiator / condenser assembly approximately six inches forward. You may now be able to fit a crescent wrench or socket wrench into the void and remove either the metric headed bolts or torx/star headed bolts. Mind you that each is of a varying and specific size and length. You may have to use an entire chest of tools but at least you won't mix them up.

Needless to say after a double 2 1/2 hour stint in my 98+ degree garage I managed to fully reassemble the car a scant two weeks after I took it apart. Surprisingly there were no left over mystery bolts or unaccounted for fasteners. The car runs and only makes a slight belt noise from the new alternator pulley. I expect that noise will go away as the pulley breaks in.

After this experience I realize that the problem with VWs isn't that something always breaks or that they need constant maintenance. The problem is that you always need specialty tools or replacement parts that no one either carries or knows jack squat about. On the other hand this car, compared to the wife's American vehicle, is an efficient driving machine a pure joy to ride around in. What can I say, I guess you can't have the best of both worlds unless you have a full time mechanic or lease your vehicles.

 
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