Volkswagen Workshop Service and Repair Manuals

Removing and installing alternator, 2.5 l injection 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-

t	Spring-type clip pliers -VAS 5024 A-

Removing: –  Disconnect battery → Chapter.

–  Release and detach connectors -1- and -2-. –  Unfasten spring-type clip -3- and remove air hose. –  Remove both securing bolts -arrows-.

–  Lift engine cover with air filter up -arrows- and remove from vehicle. –  Remove noise insulation → General body repairs, exterior; Rep. gr.50 .   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! –  Remove poly V-belt → 5-cylinder injection engine (2.5 l engine, 4-valve); Rep. gr.13.

–  Release and disconnect connector -1- and remove securing bolt for -2- air conditioner compressor.

–  Unscrew both remaining securing bolts -arrows- and remove air conditioner compressor from ancillary bracket.   Note t  Ensure that both centring sleeves are not lost.

t  The hoses of the air conditioner compressor can remain connected. t  Suspend the air conditioner compressor -2- using a piece of wire -1- at a suitable position under the vehicle until it is ready to be reinstalled. t  Ensure that the connected hoses are not stretched or kinked when doing this.

–  Unscrew both securing bolts -arrow- and remove lower idler roller -1- from ancillary bracket.

–  Unscrew the three securing bolts -arrows- and remove the upper idler roller -1- from ancillary bracket.

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

–  Unscrew B+ (battery positive) wire -arrow- from alternator.   Note To achieve easier access to the upper securing bolt on the alternator, remove the locking pin -T10060 A- and release tension on the upper tensioning roller for poly V-belt of alternator and coolant pump → Anchor.

–  Remove upper securing bolt of alternator -arrow-.

–  Remove the lower securing bolt on alternator -arrow- and remove alternator from ancillary bracket, taking connected wiring length into account.

–  Unbolt cable retainer from alternator -arrow-. –  Remove alternator from vehicle downwards. Installing: Install in the reverse order of removal. When doing this, note the following:   Caution t  When installing used poly V-belts observe the direction of rotation marked on removal! t  Before installing poly V-belt, ensure that all ancillaries (alternator, air conditioning compressor) are secure. t  When fitting belt, ensure that poly V-belt seats correctly in pulleys!   Note Before installing the air conditioner compressor, ensure that both centring sleeves are inserted in the threaded holes of the ancillary bracket.

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

–  Tighten cable retainer -arrow- to rear of alternator in 9 o'clock position. –  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.