Volkswagen Workshop Service and Repair Manuals

Removing and installing alternator, 1.6 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- Removing: –  Disconnect battery → Chapter.

–  Pull engine cover panel upwards -arrows-.

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

–  Unscrew B+ (battery positive) wire -arrow- from alternator.

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

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

–  Unclip coolant hose from hose bracket -1- and unscrew securing nut -2-.

–  Remove securing bolts -arrows-. –  Remove holder together with clamping element from vehicle.

–  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:   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!

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

–  Tighten cable retainer -arrow- to rear of alternator in 3 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.