Volkswagen Workshop Service and Repair Manuals

Removing and installing alternator, 1.4 l, 118 kW TSI 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- 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 → Engine; Rep. gr.13. –  Relieve tension on upper tensioning roller again.

–  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.

–  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) have been mounted 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.