Removing and installing alternator

Caution

When batteries are disconnected and reconnected, the procedure described in the workshop manual must be strictly observed → Chapter.

Special tools and workshop equipment required

Torque wrench -V.A.G 1331-

Locking pin -T10060 A-

Removing:

Carry out the following work:

– Switch off ignition and all electrical loads, and pull out ignition key.

– Disconnect battery → Chapter.

– Loosen poly V-belt →Power unit; Rep. gr.13.

– Remove charge pressure pipes -1- in area of alternator.

– Unscrew bracket of coolant line from engine at top -arrow-.

– Push coolant line -1- to one side and secure to fuel line using a cable tie -2-.

– Unlock and separate connector of DF cable -1-.

– Lever off deflector cap -2-.

– Unscrew securing nut and B+ cable below it from connection thread of alternator.

– Remove both securing bolts -arrows- of alternator.

– Remove alternator from bracket and turn it so rear side is facing upwards.

– Use a long screwdriver to release retaining clip -arrow- of wiring connector from alternator.

– Remove alternator -1- upwards out of engine compartment.

Installing:

Installation is carried out in reverse order of removal. Observe the following when doing this:

Caution

When fitting used poly V-belts observe the direction of rotation marked on removal!

Before installing poly V-belt, ensure that all ancillaries (alternator, air conditioner compressor) are secure.

When fitting belt, ensure that poly V-belt seats correctly in pulleys!

– Drive threaded sleeve -A- about 4 mm in direction of arrow out of alternator housing.

– Tighten threaded connections to specified torque given in assembly overview 20Nm

Caution

When batteries are disconnected and reconnected, the procedure described in the workshop manual must be strictly observed → Chapter.

– Connecting battery → Chapter.

– Start engine and check belt running.

– Stop engine.