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MK2 1.8 Alternator Replacement and bolt modification

The Captain
Turbo Charged
Posts: 2383
Joined: Wed Dec 07, 2011 8:53 pm

MK2 1.8 Alternator Replacement and bolt modification

Postby The Captain » Mon Mar 04, 2013 8:21 pm

The alternator on 1.8 engined cars is bolted in from the rear of the car which makes adjustment and removal a pretty long winded operation, so when changing a popular modification is to replace the factory fitted bolt with a nut AND bolt from an alternator from a 1.6 engined car.

Below I have shown the steps I took to modify the fitting of the alternator and the replacement of it, and I hope this will be helpful to other owners.


First of all using a 10mm drill bit drill out the thread on the alternator bracket.

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Now prepare to remove the existing alternator:

Disconnect the battery and safely keep the lead away from the terminal
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Chock the rear wheels
Loosen the front wheel nuts
Jack the front of the car
Support the vehicle using axle stands
Remove the front wheels
Remove the clips holding the front part of the wheel arch liners
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Remove the under tray
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Now remove the plug and unbolt the cable attached to the alternator

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Remove the support brace that is bolted to the engine block that supports the throttle body, 2 bolts at the top and one at the bottom

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You can now access the bolt holding the alternator in at the rear of the alternator.


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Now remove the bolt holding the alternator in at the top, slip off the belt and remove.

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You can now fit the replacement alternator from above, making it slightly easier, using the nut AND bolt insert the bolt from the front.

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Tighten the nut and bolt, slip the belt back over, tighten the top bolts.

Replace the support

Adjust and tighten the alternator

Replace the plug and the power cable, make sure the plug is pushed fully home

Replace the under tray and wheel arch liners

Re-attach the battery clamps to the battery and you are good to go.

Next time you need to do an aux belt change, it will be so much easier and quicker.

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