Volkswagen Workshop Service and Repair Manuals

Removing and installing alternator, 1.2 l, 66/77 kW, TSI engine Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331- Removing: –  Disconnect battery → Chapter. –  Remove noise insulation → General body repairs, exterior; Rep. gr.50. –  Remove front right wheel housing liner → General body repairs, exterior; Rep. gr.66. –  Remove poly V-belt → Power unit; Rep. gr.13.   Caution Before removing, mark the top side and direction of rotation of the poly V-belt. When fitting, pay attention to correct direction and installation position. If the belt is installed in the wrong position or against direction of rotation, the belt will be destroyed!

–  Detach connector -1- and remove securing bolts of air-conditioning compressor -arrows-.   Note

t  The hoses of the air conditioner compressor can remain connected. t  Suspend the air conditioner compressor -3- using a piece of wire -1- at a suitable position until it is ready to be reinstalled. t  Ensure that the hoses -2- are not stretched or kinked when doing this. –  Release and disconnect connector -1-.

–  Pull off protective cap -arrow-.

–  Remove securing nut behind it and disconnect battery positive wire from alternator.

–  Remove protective cap -1-.

–  Unscrew bolt -2- and remove idler roller -1-.

–  Remove both securing bolts of alternator -arrows-. –  Lower alternator out of vehicle from below. 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 conditioner compressor) are secure. t  When fitting belt, ensure that poly V-belt seats correctly in pulleys!

–  Drive threaded sleeves -A- roughly 4 mm in direction of -arrow- out of alternator housing. –  Tighten all threaded connections to specified torque → Chapter. –  Reconnect battery → Chapter. –  Start engine and check belt is running correctly.