Volkswagen Workshop Service and Repair Manuals

Removing and installing alternator, 1.4 l TSI   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- Removing: –  Disconnect battery → Chapter.

–  Release vacuum hose -arrow- and pull it off. –  Pull off engine cover upwards from its rubber mountings -1- and remove it forwards in direction of -arrow-.

–  Pull activated charcoal filter -1- upwards out of fasteners -arrows-. –  Place activated charcoal filter -1- with connected hoses to one side. –  Remove poly V-belt → Power unit; Rep. gr.13. –  Unscrew securing bolts -arrows- and remove the upper belt tensioner from the vehicle.

–  Remove securing bolts of air conditioner compressor -arrows-.

–  Release and disconnect connector -1-. –  Unscrew third securing bolt -arrow- and remove air conditioner compressor from bracket.   Note

t  When removing the air conditioner compressor, ensure that both centring sleeves → Item remain in the threaded holes (one on top of the other) of the bracket. 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 under the vehicle until it is ready to be reinstalled. t  Ensure that the hoses -2- are not stretched or kinked when doing this.

–  Release and disconnect DF wire connector -1-. –  Lever off protective cap -2-.

–  Remove securing nut -1- and remove the battery positive wire, located beneath, from the connector thread of the alternator. –  Unscrew securing nut -3- and remove wiring retainer -2- from the alternator. –  Relieve tension on upper tensioning roller again.

–  Unscrew the three securing bolts -arrows- and remove upper tensioning roller -1- from vehicle.

–  Remove securing bolts of alternator -arrows-. –  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 assemblies (alternator, air conditioner compressor, vane pump) are installed correctly. t  When fitting belt, ensure that poly V-belt seats correctly in pulleys!

–  Drive threaded sleeves -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.   Note Before installing the air conditioner compressor, ensure that both centring sleeves → Item are inserted in the threaded holes (one above the other) of the bracket. –  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.