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Repairing the Alternator by Replacing the Pulley

Model: Volkswagen Passat 3BG, B5 - Years 1996-2005
Part: Alternator

Disconnect the negative terminal of the battery and move the cable away. Lift the vehicle on a ramp, open the bonnet, and unscrew the retaining screws of the bumper. Lower the vehicle and remove the grille, bumper, and lighting assembly, placing them in a 'maintenance' position. Remove the upper engine cover. Loosen the bolt on the alternator tensioner and remove the belt. Loosen the second tensioner and remove the auxiliary drive belt. Remove the plastic cover on the alternator pulley and take off the pulley using a impact wrench. Fit the new pulley using the specific tool. Replace the plastic cover, adjust the tensioner, and install the new belt. Check that the belt is correctly fitted by running the engine for two revolutions. Adjust the second tensioner and fit the new belt. Set the correct tension.

Updated on 2 February 2026 by ScegliAuto

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