Alternator options

[Deep Blue]

Driving late today and aircon suddenly went off, then looked at the instrument cluster - red battery symbol - so strongly suspected the original alternator had gone (likely carbon brushes have given up by now - 158,000km0; VW 2009 Passat CC 2.0 TDI (CBBB engine). Anyway, RACV confirmed it was the alternator and the battery was fine.

Now I have to find a mechanic and get it towed there for assessment/replacement - I'm near Richmond. Any suggestions/other options? I did change an alternator (Denso) brushbox on a Land Rover and it only cost me a few dollars for the brushes - I had a little time on my hands that time and had two spare cars!

Not sure with the VW though if it's easy/cheap to do and pick-up a used alternator? Don't know how much it would cost to get a mechanic to put a new alternator in: $900 - $1200 at a guess?

Thing is I need to get this one up and running asap this time around - so might need to go to a mechanic/dealer?

[Deep Blue]

I just noticed I can get a Bosch alternator (Part # 1986A00902) – I believe that's the correct part – from Run Auto Parts (1-2 days delivery). If I don't have to raise the car and it's not too hard and maybe requires special tools to remove the old alternator and replace (the car is out on the street), then maybe I could give it a go?

Any suggestions, or has anyone replaced one of these themselves? I guess the good thing is that I could keep the old one and maybe put new brushes in it and sell it (if that indeed is the problem)?

[MIG]

The voltage regulator module looks to include the brushes. Do you have your current unit's part number?

079 903 803 - BOSCH
07K 903 803 - BOSCH
03L 903 803 D - VALEO

I just checked the service manual; VW has the TDI common rail listed as needing the bumper and crash bar removed in the "service position."

Check out ErWin is you want to download all your service guides.

[Deep Blue]

Haven't taken it out, but based on the VIN it should be a Bosch alternator (Part # 1986A00902) - it's the original. Here's the engine bay with the current alternator:

[Deep Blue]

Was hoping to buy a new unit and changeover myself. The belt looks fine, so I'm thinking it's likely the brushes, or maybe the regulator? Anyway, quicker for me to just remove the alternator and replace, but I don't want to start unless it's relatively straightforward - the VW engines seems to vary a lot, and sometimes the detail is what catches you out! The car is outside and on a slope so want to be able to do it all from above without too much faffing about (prepared to spend an hour or two at the most). The alternator looks a bit buried in there so I'm not sure if it's as easy as some others to replace?

[Deep Blue]

I came across this (Ifixit Guide):

2011- 2017 Volkswagen Jetta Alternator Replacement (2011, 2012, 2013, 2014, 2015, 2016, 2017) - iFixit Repair Guide

It seems to be very close - if it is as simple as this then it's a no-brainer for me, just want to be sure before I start though.

[MIG]

I think your high-pressure fuel pump is in the way; the service book has the TDI as that guide and TDI common rail listed as the long way.
Anyway, give it a try; the service book can be wrong, I just replaced the radiator fan on an up! without needing to get the AC lines recovered, even though the manual said you have to.

[Deep Blue]

Okay, progressed a bit - old, original alternator out (looks in great nick!) - it is VW Part 03G903023 - 14V/180A; I believe the OEM Bosch Part is 0121715003. The car is a 2009 VW Passat CC 2.0TDI (CBBB engine and common-rail diesel) - NOT Stop/Start.

So, that's that bit sorted - I think???

Next thing is availability, price and other options! VW Dealer price for 03G903023 (o/night from Sydney) is $1,334.30. Dealer said the fitted alternator for this car is either Bosch or Valeo and that they are not compatible? The Bosch, as I said before, is available from Sydney, but the Valeo is 3 months back-order from Germany (Valeo also a bit more expensive than the Bosch). (The pulley is an extra $278 from the dealer!)

The VW dealer said that I would also have to swap the old alternator with them (of course I'd take the pulley off!)

I'd prefer new Bosch or an equivalent (if there is one), but would also consider a reco, or even a tested used one.

Any options anyone can suggest - where to buy, etc.?

[Deep Blue]

Yes, common rail!!! Long way!

[Deep Blue]

I got that wrong!!!

It's in fact VW 03G903023 (14V / 180A); Bosch Part # 0121715003!

[Deep Blue]

Thanks so much MIG!

Yes, extracted alternator with pulley - VW 03G903023 (14V / 180A).

I now believe the Bosch Part # is 0121715003.

With a Denso alternator I took out of my Land Rover I was able to buy a new carbon brushbox and it was fine again; you can also buy the regulator/rectifier unit as well.

Not sure how easy it is to repair one of these old VW alternators (once I know what the problem is)??? If the slip-rings are gone or coils, then that is of course way beyond me.

[Deep Blue]

The voltage regulator module looks to include the brushes. Do you have your current unit's part number?

079 903 803 - BOSCH
07K 903 803 - BOSCH
03L 903 803 D - VALEO

I just checked the service manual; VW has the TDI common rail listed as needing the bumper and crash bar removed in the "service position."

Check out ErWin is you want to download all your service guides.

Yes!!! Decided to take it to the mechanic, but he ordered the wrong alternator (ordered before he pulled the old one out - he said it was a real PITA getting it out!).

[Deep Blue]

I came across this (Ifixit Guide):

2011- 2017 Volkswagen Jetta Alternator Replacement (2011, 2012, 2013, 2014, 2015, 2016, 2017) - iFixit Repair Guide

It seems to be very close - if it is as simple as this then it's a no-brainer for me, just want to be sure before I start though.

Yes, not that simple!!! Lol!

[MIG]

The part they are quoting is the 03G903023X then for the refurb and core exchange.

Can you inspect the voltage regulator \ brushes? might be an option to just replace those?

Getting a part from the wreckers is always an option, too; prices look to be the $200 mark.

[Deep Blue]

The part they are quoting is the 03G903023X then for the refurb and core exchange.

Can you inspect the voltage regulator \ brushes? might be an option to just replace those?

Getting a part from the wreckers is always an option, too; prices look to be the $200 mark.

Any wreckers you could recommend? Live close to the city, but willing to travel up to 75km!