The 1974 Volkswagen Beetle was equipped with a four-cylinder, 1.6-liter engine. Mounted to the engine was a 50-amp alternator driven by a single belt. Although the battery supplies the necessary power to start the engine, it is the alternator which then takes over and powers the vehicle. Due to the unusual design of the Volkswagen's engine, replacing the alternator requires steps not normally associated with most engines. However, replacing the alternator is still relatively straightforward and typically takes about one hour.
Tools Used: Wrench, Socket wrench
Change an Alternator
Removing the Alternator
Remove the battery cables to prevent an inadvertent electrical shock. Remove the air cleaner housing's retaining bolt with a wrench, then lift the assembly off the carburetor.
Remove the carburetor's retaining bolts with a wrench, then lift the carburetor off the engine.
Record the location of each of the wires which attach to the alternator, then pull each wire off the alternator.
Remove the large nut on the face of the alternator's pulley with a socket wrench to expose the shims.
Slide each metal shim off the face of the alternator pulley, then pull the pulley off the alternator to release the alternator belt.
Remove the bolts that secure the bottom of the fan shroud housing to the top of the engine with a wrench.
Remove the bolt securing the alternator's metal mounting strap against the alternator with a wrench, then pull the strap off the alternator. The bolt is located on the passenger's side of the strap.
Remove the four bolts that surround the metal plate attached to the back of the alternator. Note that the two bolts at the bottom of the plate can only be accessed by lifting upward on the fan shroud housing.
Slide the alternator away from the engine until the fan blades at the back of the alternator clear the fan shroud.
Installing the Alternator
Slide the fan blades at the back of the alternator into the front of the fan shroud assembly until the alternator rests on top of its pedestal.
Install and tighten the four bolts that surround the metal plate attached to the back of the alternator, using a wrench.
Position the alternator's metal mounting strap around the alternator, then tighten the strap's securing bolt with a wrench.
Install and tighten the bolts that secure the bottom of the fan shroud housing to the top of the engine, using a wrench.
Insert the alternator's belt into the groove within the alternator's pulley, then position the pulley onto the front of the alternator.
Position the metal shims onto the face of the pulley, then tighten the pulley's single mounting nut with a socket wrench.
Plug each of the alternator's wires into their respective positions on the alternator.
Position the carburetor onto the engine, then install and tighten each of the carburetor's retaining bolts with a wrench.
Position the air cleaner housing onto the top of the carburetor, then install and tighten the housing's retaining bolt with a wrench. Attach the battery cables to the battery.
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