Volkswagen Workshop Service and Repair Manuals

Removing and installing alternator, 2.0 l SDI engine   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

t  Torque wrench -V.A.G 1331-

t  Locking pin -T10060 A- Removing: –  Disconnect battery → Chapter.

–  Pull engine cover upwards -arrows A- and forwards -arrow B-.

–  Disconnect DF wire connector -1- and pull off protective cap -2-.

–  Unscrew B+ (battery positive) wire -arrow- from alternator. –  Pull fuel filter out of bracket and place to one side. When doing this, the fuel hoses can remain connected.   Caution Before removing, mark the top side and direction of rotation of the poly V-belt. When installing, ensure correct fitting position and direction of rotation. If the belt is installed in the wrong position or against direction of rotation, the belt will be destroyed! –  Mark direction of rotation of poly V-belt.

–  Release tension of poly V-belt by swivelling tensioning element in direction of -arrow- using a 16 mm open-jaw spanner.

–  Lock tensioning element using locking pin -T10060 A-. –  Remove poly V-belt.

–  Remove securing bolts of alternator -arrows-.

–  Unscrew wiring retainer -arrow- from alternator. –  Remove alternator. Installing: Install in the reverse order of removal. When doing this, note the following:

–  Drive threaded sleeves -A- about 4 mm in direction of -arrow- out of alternator housing.   Caution t  In order to avoid damage to cylinder block and ancillaries bracket, adhere strictly to the tightening sequence for the ancillaries bracket → Chapter. t  When installing used poly V-belts observe the direction of rotation marked on removal! t  Before installing poly V-belt, ensure that all assemblies (alternator, air conditioner compressor, vane pump) are installed correctly. t  When fitting belt, ensure that poly V-belt seats correctly in pulleys! –  Tighten threaded connections to torques specified in assembly overview → Chapter.   Caution Observe notes for battery terminal clamp bolt → Chapter. –  Reconnect battery → Chapter. –  Start engine and check belt is running correctly. –  Switch off engine.