Volkswagen Workshop Service and Repair Manuals

Removing and installing alternator, 3.2 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- Removing: –  Disconnect battery → Chapter. –  Place lock carrier in service position → General body repairs, exterior; Rep. gr.50. –  Remove radiator fan → 6-cylinder injection engine; Rep. gr.19

–  Pull activated charcoal filter -1- upwards out of fasteners -arrows-. –  Place activated charcoal filter -1- with connected hoses to one side.

–  Separate connector -1-, remove wire from cable holder -2- and pull off deflector cap -3-.   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.

–  Relieve tension in poly V-belt by swinging tensioning element in -direction of arrow- and holding it in place with the locking pin -T10060 A-. –  Remove poly V-belt. –  Remove locking device of tensioning element.

–  Remove securing bolt of alternator -arrow-. –  Remove noise insulation → General body repairs, exterior; Rep. gr.50.

–  Remove lower idler wheel securing bolt -arrow- and remove idler wheel.

–  Remove lower alternator securing bolt -arrow-. –  Remove alternator from vehicle. 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. –  Tighten threaded connections to torques specified in assembly overview → Chapter.   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 ancillaries (alternator, air conditioning compressor) are secure. t  When fitting belt, ensure that poly V-belt seats correctly in pulleys!   Caution Observe notes for battery terminal clamp bolt → Chapter. –  Reconnect battery → Chapter. –  Start engine and check belt is running correctly. –  Switch off engine.