Volkswagen Workshop Service and Repair Manuals

Removing and installing alternator, 2.0 l, 199/188 kW TSI engine Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331-

t  Locking pin -T10060 A-

t  Hose clip pliers -V.A.G 1921- Removing: –  Disconnect battery → Chapter.

–  Remove intake manifold -4-. –  To do this, open retaining clamps -3- of intake manifold and remove intake manifold out of retaining clamps. –  Loosen clamps -1- of intake manifold -4- with hose clip pliers -V.A.G 1921-, pull intake manifold from intake connecting pipe and take intake pipe out of engine compartment. –  Remove engine cover -2- → Booklet25.1.

–  Loosen clamp -5- with hose clip pliers -V.A.G 1921- and remove connecting hose -6- from activated charcoal filter -4-. –  Remove pressure retention valve together with connecting hose -2- from activated charcoal filter -4-. –  Release catch -1- and pull activated charcoal filter -4- upwards out of bracket. –  Remove bolt -3- and put pipework slightly up. –  Remove poly V-belt → Engine; Rep. gr.13.

–  Unscrew bolts -1- and -2- for air conditioner lines.

–  Unscrew bolts -2- of alternator -3- about 5 turns. –  Drive back threaded bush of alternator with light hammer blows on bolts -2- to ease removal of alternator -3-. –  Remove bolts -2-. –  Remove alternator -3- from bracket -1-.

–  Unscrew securing nut -1- and remove wiring retainer from alternator. –  Lever cap -2- off. Unscrew securing nut located beneath and remove battery positive wire from connector thread of alternator. –  Release and disconnect DF wire connector -1-.

–  Swivel alternator -1- in direction of -arrow- to the right out of vehicle. To do this, push loose air conditioner lines -2- slightly to side. 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  When fitting poly V-belt, ensure it is seated correctly in belt pulley! –  Tighten threaded connections to torques specified in assembly overview → Chapter. –  Reconnect battery → Chapter. –  Start engine and check belt is running correctly. –  Switch off engine.