Volkswagen Workshop Service and Repair Manuals

Removing and installing alternator, 1.6 l TDI 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.

–  Pull engine cover off upwards -arrows-. –  Remove and installing air duct cowling with radiator fan -V7- and, if fitted radiator fan 2 -V177- → Power unit; Rep. gr.19. –  Remove throttle valve control module -J338- → Power unit; Rep. gr.23.   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! –  Remove poly V-belt → Power unit; Rep. gr.13.

–  Release connector -1- and disconnect.

–  Unscrew securing bolts of air conditioner compressor -arrows-.   Note t  The hoses of the air conditioner compressor can remain connected. t  Suspend the air conditioner compressor using a piece of wire at a suitable position until it is ready to be reinstalled. t  Do not pull or kink hoses.

–  Unlock and separate connector of DF cable -1-. –  Lever off deflector cap -2-.

–  Undo nut -1- and detach B+ wire under it from connecting thread of alternator. –  Undo nuts -3- and remove cable retainer -2- from alternator.

–  Unscrew both securing bolts -1- and securing nut -2- of fuel filter -3- and place fuel filter to one side. The fuel hoses can then remain connected.

–  Undo and remove securing bolts -arrows- of alternator. –  Guide alternator towards intake manifold and remove it upwards out of vehicle. 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 sleeve -A- about 4 mm in direction of arrow out of alternator housing.

–  Secure wiring retainer -arrow- on back of alternator in 3 o'clock position. –  Tighten threaded connections to specified torque given in assembly overview → Chapter.   Caution When batteries are disconnected and reconnected, the procedure described in the workshop manual must be strictly observed → Chapter. –  Connecting battery → Chapter. –  Start engine and check belt running. –  Stop engine.