Volkswagen Workshop Service and Repair Manuals

Removing and installing alternator, 1.4 l, 90 kW TSI engine Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331-

t  Locking pin -T10060 A- Removing: –  Disconnect battery → Chapter.

–  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.

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

–  Unscrew wiring retainer -2- and pull off protective cap -1-.

–  Disconnect DF connector -1- and unscrew battery positive wire -2- from alternator.

–  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  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.

–  Remove lower alternator securing bolt -arrow-. –  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. –  Tighten threaded connections to torques specified in assembly overview → Chapter. –  Start engine and check belt is running correctly.